description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] Reference is made and priority is claimed from U.S. Provisional Patent Application No. 60/700,287 filed Jul. 18, 2005, entitled Spreader Grader Apparatus invented by William Juergen of Splendora, Tex.
STATEMENT REGARDING FEDERALY FUNDED SPONSORED RESEARCH OR DEVELOPEMENT
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] A spreading and grading apparatus (hereinafter, “apparatus”) comprised preferably of a multiplicity of elongated and inverted rigid channel or u-shaped members substantially in a planar and parallel orientation attached to a supporting structure to maintain the orientation of the members and provide a preferable attachment surface for connection to a device to push or pull the apparatus.
[0005] This invention relates to moving and grading materials on a surface. Such materials comprise soil, gravel, sand and mulch. Such materials are more easily graded with the present invention when substantially loose and dry but can be graded when wet or packed. The present invention also relates to disrupting an existing surface by use of a scarifier attached to the apparatus.
[0006] The present invention is preferably configured to be pulled by attachment to a three-point hitch mechanism commonly found on the rear portion of utility tractors. However, the present invention may be configured to be pulled from a drawbar, or any other attachment mechanism. In one such embodiment, in the absence of hydraulic control and leverage, the apparatus could simply be pulled by a small tractor or animal power. In addition, the apparatus could be configured to attach to the front of a tractor, such as the hydraulic lift system commonly employed to attach a bucket or blade at the front portion of the tractor. Further, to increase the grading or scraping action, weight could be added to the apparatus.
[0007] One advantage of a three point hitch mechanism is the ease of attachment, movement and control of the apparatus by using the tractor hitch mechanism and hydraulic controls. In addition, the present invention may be configured to be pushed during spreading or grading without loss of functionality of the invention. Whether the apparatus of the present invention is pushed or pulled is a decision by the user largely dependent upon the equipment available to provide the force, the available attachment mechanism, and the particular circumstances of the location and type of material. Pushing or pulling the apparatus of the present invention does not substantially affect the spreading or grading operation, depending upon the configuration of the apparatus.
[0008] A common use of the present invention would be to spread and grade soil prior to installation of a lawn by seed or sod. Typically, a large tractor, bulldozer or other earth moving machine would first prepare the surface by flattening high spots and spreading any large piles of material thus providing a somewhat rough initial surface. The next step would be to have that rough surface finish-graded prior to installation of the lawn by seed or sod. Similarly, existing lawn areas may be disturbed for a variety of reasons or in poor repair and need maintenance. Or, an area of a golf course or sports field may require grading to a fine finish prior to lawn installation.
[0009] The apparatus of the present invention provides a versatile unit for spreading and/or grading. The preferred embodiment comprises substantial materials but it is not generally suited to move and spread large piles of heavy material more commonly distributed by more powerful machines. The apparatus is not a traditional box configuration so moving large aggregations of material over distance is not efficient. It is specifically designed to have openings between the members to prevent the buildup of material. In addition, the ends of the members are not covered thereby allowing material to flow along the scraper blade out the end. Thus the design of the present invention allows material to move past the scraping surfaces thereby preventing buildup, in contrast to the traditional ‘box scraper’ design that captures and moves that buildup of material.
[0010] 2. Description of Related Art
[0011] The well known ‘box scraper’ has traditionally been employed to spread or grade materials by pulling the unit with animal or tractor power. The use of a box scraper is just as the descriptive name implies. The common configuration is an open-top four-sided metal box mounted to a frame. This frame is designed to accept attachment to a drawbar, three point hitch or similar attachment to a power source. Generally, the side walls also act as skids and the rear “wall” of the box is adapted at the lower edge to have a blade-like function. The front panel may be elevated to prevent it from doing a majority of the scraping, instead allowing material to pass underneath, contact the rear scraper blade and accumulate in the box. In use the apparatus is lowered to the ground and then pulled forward by the tractor. The hydraulic attachment of the three-point hitch raises and lowers the box scraper and thus determines the contact with the material or surface. As the box is pulled forward the rear blade acts as a scraper and material collects within the box. The material within the box may then be transported to another location to be spread, or left in a pile as the box is raised. The box scraper works best to move small amounts of material. Because of the closed configuration, its ability to spread and grade are limited. When used for grading, material tends to continually collect within the box and small piles are usually left behind for working by another machine or by hand to smooth out. In addition, the side walls of the scraper act as skids and leave unsightly tracks or grooves in the newly graded or smoothed surface. It then may be necessary to hand rake these tracks to make them blend in for the final finished surface.
[0012] The more advanced box scraper of U.S. Pat. No. 4,869,326 to Hutchins et al., provides front and rear moveable blades to allow the unit to be pushed or pulled. The blades must be adjusted up or down depending upon whether the unit is being pulled or pushed. However, this is still a box leaving skid marks, and in which material collects whether pushed or pulled.
[0013] The grader of U.S. Pat. No. 5,191,943 to Minor et al. is configured substantially as a pulled box-scraper with vertical sides, also used as skids, to collect and move material. The unit is configured with multiple adjustable blades for finish smoothing. Only the function and location of the blade, or blades, differs substantially from the traditional design. However, the unit will still collect material between the box sides and the sides will leave skid marks in the finished surface.
[0014] The soil leveling apparatus of U.S. Pat. Nos. 5,213,164 and 5,771,980 to Mork is essentially a massive box scraper with the blade in the front and a substantial frame to hold parallel closed-bottom smoothing members. Other attachments enhance the versatility. However, the unit will still collect material between the box sides and the sides will leave skid marks in the finished surface.
[0015] The groomer attachment of U.S. Pat. No. 5,497,569 is adapted to the forks of a forklift, not a three-point hitch mechanism of a tractor. It comprises flexible blades extending from a rigid horizontal member adapted to an attachment for a forklift to be used on a substantially hard flat surface in an industrial area. The preferred embodiment shows a substantially u-shaped structure for the groomer. However, the attachment is limited to use on a forklift in an industrial area. The flexible blades are necessary since it is used on a hard surface, and could be ineffective in a moving and smoothing operation on a lawn, sand or gravel surface. Replacing the flexible blades with hard steel blades would cause them to wear considerably on a hard flat asphalt or concrete surface and spark creating a potentially hazardous use in some industrial areas. The single u-shaped member is designed to move small amounts of material and depends upon the rigidity of the forks to perform as stated.
[0016] The device for dressing a lawn of U.S. Pat. No. 5,191,944 comprises an open grid secured to a frame adapted to a three point hitch. However, the design is basically a low profile box scraper with fixed angular scraping surfaces secured to a open metal box frame. The edge of the grid in contact with the surface to be smoothed is at an angle. Loose material may move through the numerous grid openings and spread out over the upper grid surface but is contained within the box frame. Eventually, the material accumulating above may drop through the grid openings to fill low spots. If not then material may accumulate and clog the opening making the device ineffective.
[0017] The related art as described above discloses a variety of box-type scrapers. However, these inventions generally accumulate material or do not provide a plurality of scraping edges to enhance the spreading and leveling functions. Similarly, the related art allows grading or tire tracks to remain in the finished surface.
[0018] Therefore it can be appreciated that there exists a need, and would be advantageous and convenient to provide, the functions of a box-type scraper and a blade-like material spreader in one apparatus. The present invention substantially fulfills this need.
BRIEF SUMMARY OF THE INVENTION
[0019] The apparatus of the present invention substantially departs from the conventional concepts of the related art by combining the functions of box-type scraper and blade-like material spreader in one device for the consumer.
[0020] This apparatus of the present invention overcomes the limitations of the related art by attachment of multiple inverted u-shaped members to a substantially rigid frame for adaptation to a three point hitch, drawbar, etc. for use by a tractor or other power source capable of traction and use over multiple surface types.
[0021] The present invention is an apparatus for spreading material and/or grading a surface. The apparatus comprises a plurality of substantially horizontal inverted u-shaped grading members secured substantially in parallel to one or more substantially rigid horizontal support members as part of a support frame. The support frame is configured to receive a three point hitch mechanism, or other attachment mechanism for coupling to the source of power. The grading members further comprise a support member preferably having a first edge and a second edge and preferably secured to said edges one or more vertical grading elements or grading element supports. The exposed edge of said grading elements would come in substantial contact with the surface. Said edge could be substantially vertical and straight and would thus act like a scraper.
[0022] In an alternative embodiment, the edges could adjust in either direction and thus act like a scraper or blade.
[0023] In a further alternative embodiment the edges could demonstrate a variable or interrupted edge profile. Such as a substantially shark-tooth or spike-type appearance.
[0024] In a further alternative embodiment, the horizontal members could be reversibly attached to a frame and interposed between the two elements a spring or other shock absorbing type assembly to allow deflecting movement of said members when encountering a rigid obstruction.
[0025] In a further alternative embodiment the edges or grading element supports further comprise a surface to which may be reversibly secured the grading element. This configuration allows replacement of the grading element due to wear without having to replace the entire member, or to provide a variety of patterns for the grading element.
[0026] In a further alternative embodiment, one or more horizontal members have a multiplicity of grading elements attached thereto. These grading elements could have the same or different profiles, as stated above. In order to place the appropriate grading element in grading position, the angle or position of the grading element could be adjusted. To increase convenience, the adjustment could be by rotating the member. Thus, the apparatus could be configured by the operator with relative ease to perform a coarse grading function, and then changed to perform a fine grading or smoothing function by adjustment of one or more horizontal members.
[0027] The horizontal members are spaced at such a distance to allow material to drop between them thereby reducing the incidence or amount of material accumulating on the upper surfaces of the apparatus. The ends of the members are substantially unobstructed thereby allowing material to flow out during use and prevent the accumulation and packing problems reminiscent of the box-type scraper devices.
[0028] In a further alternative embodiment, spaced in front of or before the first horizontal member and comprising part of the frame and attachment for the three point hitch is secured a horizontal surface at an angle substantially acute to the surface. This purpose of this surface is to reduce the possibility of the apparatus gouging the surface during operation. The angular or curved surface could be an exposed length of a round cylinder or a plate secured to a backing member. This element also serves to aid in grading and/or smoothing. Similarly, such an element may be attached at the trailing edge of the apparatus for use when the apparatus is pushed.
[0029] In a further alternative embodiment, an adjustable blade may be secured to the leading edge or the trailing edge of the apparatus. The blade could be adjustable and used to move larger accumulations of material than the apparatus could easily move, and would be more suited to pushing or pulling larger quantities of material over some distance. Thus the operator would have a blade, spreader and grading assembly in one unit that could be pushed or pulled to perform its intended operation.
[0030] In a further alternative embodiment skids or wheels may be attached to the apparatus to use during operation or during transport. The support may be configured such that a substantial amount of the tracking is graded out during operation.
[0031] It is an advantage of the present invention that the plurality of functions in one apparatus enables it be used as a grader and spreader at the same time.
[0032] A further advantage of the present invention is that the three functions of grading, spreading and blade distribution described herein may be utilized together or in a plurality of combinations with a similar conformation of a preferred embodiment designed to attach to a three-point hitch.
[0033] Therefore, it is an object of the present invention to provide a spreading and grading apparatus that can be pushed or pulled comprising a leading edge to reduce the incidence of gouging into the work surface and a multiplicity of static or adjustable or variable grading elements in a spaced and open ended support and frame assembly.
[0034] It is a further object of the present invention to provide a spreading and grading apparatus with grading members attached via a spring or shock absorbing type of mechanism to reduce wear on the grading elements and increase control of the unit and the operation by allowing a member to deflect when encountering resistance.
[0035] It is a further object of the present invention to provide an increased grading capacity by mounting a blade on the leading or trailing edge of the apparatus thereby allowing larger accumulations of material to be pushed or pulled than could easily be handled by the apparatus without the blade.
[0036] It is a further object of the present invention to provide a rough surface preparation capacity by mounting a scarifier on the leading or trailing edge of the apparatus thereby allowing more aggressive disruption of the surface, such as scarring or breaking up a substantially hard or firm surface or breaking or removal of roots, than could easily be handled by the apparatus without the scarifier.
[0037] It is a further object of the present invention to provide a spreading or grading apparatus that does not utilize the lateral skid design in its structure thus eliminating the lines or furrows created during the use of such a design, and thus eliminating the additional step of grading or covering the furrows to provide a finished surface.
[0038] It is a further object of the present invention to provide a new and useful apparatus combining four needs of the consumer for surface preparation functions of scarifying, grading, spreading and blade distribution in a conformation designed to attach to a three-point hitch.
BRIEF DESCRIPTION OF THE FIGURES
[0039] FIG. 1 is a lateral elevation view of a preferred embodiment of the apparatus of the present invention with the blade and scarifier installed and constructed in accord with the principles of the present invention;
[0040] FIG. 2 is the view of the embodiment of FIG. 1 with the blade moved into position for pulling material or grading a surface;
[0041] FIG. 3 is a perspective view of the embodiment of FIG. 1 ;
[0042] FIG. 4 is an exploded perspective view of the embodiment of FIG. 1 ;
[0043] FIG. 5 is an inferior perspective view of FIG. 2 ;
[0044] FIG. 6 is an inferior perspective view of FIG. 3 rotated 180 degrees;
[0045] FIG. 7 is a lateral elevation view of another preferred embodiment of the apparatus of the present invention with the scraping members assembly attached to pivots and the blade and scarifier installed, and constructed in accord with the principles of the present invention;
[0046] FIG. 8 is a superior perspective view of the scraping member assembly of FIG. 7 isolated from the supporting structure and constructed in accord with the principles of the present invention;
[0047] FIG. 9 is an enlarged view of the scraping member assembly of FIG. 8 ;
[0048] FIG. 10 is an inferior perspective view of FIG. 7 ;
[0049] FIG. 11 is an inferior exploded view of FIG. 7 ;
[0050] FIG. 12 is an exploded perspective view of FIG. 7 ;
[0051] FIG. 13 is an alternative exploded perspective view of FIG. 7 ;
[0052] FIGS. 14 and 15 are perspective views of FIG. 7 ;
[0053] FIGS. 16 and 17 are perspective views of FIG. 7 with the scarifier elevated and the blade moved into position for pulling material or grading a surface;
DETAILED DESCRIPTION OF THE INVENTION
[0054] The present invention is described more fully by reference to the preferred embodiments of the drawings. However, the embodiments of the invention may be in different forms and these drawings should not be construed as limiting the scope of the invention as described herein. FIGS. 1 through 17 are illustrious of embodiments of the present invention and constructed in accord therewith.
[0055] Referring to the drawings, FIG. 1 is a lateral elevational view of a preferred embodiment of the grading and spreading apparatus of the present invention, hereinafter the “apparatus” 10 , comprised generally of a support frame 12 further comprising a plurality of horizontal support members 14 having a first end 16 and a second end 18 , aligned substantially parallel in the direction of the force applied, and securedly attached at ends 16 to a first frame member 20 and at ends 18 to a second frame member 22 aligned substantially perpendicular to the direction of force applied through a three point hitch yoke assembly 24 . The three point hitch yoke assembly 24 further comprising a main support member 26 having a fist end 28 and a second end 30 , a first lateral support member 32 having a first end 34 and a second end 36 terminating in a first pin tab 38 with opening 40 , a second lateral support member 42 having a first end 44 and a second end 46 terminating in a second pin tab 48 with opening 50 , a securing pin 52 , a first lateral pin attachment 54 securedly attached to the first lateral support member 32 and a second lateral pin attachment 56 securedly attached to the second lateral support member 42 . The yoke assembly 24 is securedly attached to the first frame member 20 at the first end 28 of the main support member 26 , the first end 34 of the first lateral support member 32 and the first end 44 of the second lateral support member 42 . The yoke assembly 24 is further strengthened by the addition of a diagonal support member 58 securedly attached to the main support member 26 at first end 60 and to a horizontal support member 14 of the support frame 12 at a second end 62 . In use a three point hitch attachment apparatus installed on a tractor is coupled to the yoke assembly 24 of the grading and spreading apparatus 10 by connecting the lateral hitch members to the first lateral pin attachment 54 and the second lateral pin attachment 56 , and the third hitch member to the main support member 26 by insertion of the securing pin 52 . Once attached to the source of power, such as a tractor, the grading and spreading apparatus 10 may be raised or lowered. Once lowered to engage the ground surface it is then pulled or pushed to achieve grading of the surface and spreading of the material.
[0056] The grading and spreading functions are accomplished by employing a plurality of inverted u-shaped grading members 64 secured substantially in parallel beneath the support frame 12 . In FIGS. 1 and 2 , due to the addition of the blade assembly 66 (show in the retracted position in FIG. 1 and the engaged position in FIG. 2 ), a spacer member 70 is incorporated to lower the grading members 64 below the bottom plane of the retracted blade assembly 66 . If the blade assembly 66 is not present, then the grading members 64 may be attached directly to the underside of the support frame 12 .
[0057] A grading member 64 of the present invention further comprises an inverted u-shaped channel 82 defined by a backing portion 72 , a first side portion 74 , and a second side portion 76 . Thus formed, the grading member 64 has a first edge 78 and a second edge 80 respectively associated with the side portions. In the embodiments shown in FIGS. 1, 2 , 5 and 6 the grading members 64 are preferably arranged in substantially parallel configuration to each other and the first 20 and second frame members 22 , are substantially perpendicular to the force applied through the three point hitch yoke assembly 24 , are securedly attached to the underside of the support frame 12 , and extend substantially the width of the support frame 12 . In practice using the preferred embodiment described herein, the grading and spreading apparatus 10 is pulled over a surface, such as firm ground being prepared for lawn installation. The first edge 78 and the second edge 80 of the grading member 64 engage the surface material and scrape the surface. Depending upon the downward force applied and the surface material, the action of scraping accumulates loose material within the channel 82 of the grading member 64 . However, the embodiment of the present invention is not configured as a box scraper and the scraped material flows out the open ends of the grading members 64 to be dispersed by the operator. Depending upon the skill of the operator and the control of the three point hitch, the surface may be graded to a final finish without tire or scraper tracks and ready for lawn installation. In an alternative embodiment, the grading members 64 could be adapted to allow adjustment or variability of one or more grading members 64 to a non-parallel configuration as compared to that described above. In an additional alternative embodiment, the grading members 64 could be adapted in to vary in unison from the perpendicular configuration described above to assume a plurality of angular configurations. Such variable configurations could be favorably employed to provide not only scraping but cutting or slicing action to the surface, and enhance the directing of the spoil to one side or the other of the apparatus 10 . In a further alternative embodiment, an elongated grading element 84 comprised of a substantially rigid material and having a body 86 , a first edge 88 , a second edge 90 , a first end 92 and a second end 94 , may be attached to one or more of the plurality of first 74 and second side portions 76 . The grading element 84 would be attached so edges 88 or 90 would extend below the edges 78 or 80 to preferentially engage the surface. The exposed edges 88 or 90 of the grading elements 84 would come in substantial contact with the surface in place of the edges 78 or 80 . The edges 88 or 90 would preferably be substantially vertical and thus act as the scraping mechanism. An advantage of this embodiment of grading elements 84 is that they may have profiles formed into their edges 88 or 90 to provide a variability to the surface preparation. In addition, the grading elements 84 may be reversibly attached and replaceable to reduce wear on the grading member.
[0058] The preferred embodiment of FIG. 1 was constructed from commonly available materials to minimize cost but the construction and dimensions may be varied to achieve the principle tenets and teachings of the present invention. The grading members 64 are 2 inch by 5 inch channel steel welded to approximately 3 inch box tubing used for the support frame 12 and spaced approximately 5 inches apart to allow an increased flow of the spoil. Closer spacing, such as three inches, may cause the spoil to accumulate and reduce the effectiveness of the scraping or grading operation. In addition, the support frame 12 is not a solid surface or enclosed such as in a box scraper. Thus, the spoil may flow over and through the apparatus 10 during operation preventing buildup which is a major advantage over the box scraper for this type of operation.
[0059] In a further alternative embodiment, a smoothing member 96 further comprising a substantially round surface 98 , a first end 100 and a second end 102 is spaced in front of the first frame member 20 or replaces the member 20 to comprise part of the support frame 12 . The purpose of this surface 98 is to reduce the possibility of the apparatus gouging the surface during operation and to smooth the ground surface if desired. The angular or curved surface 98 could be an exposed length of a round cylinder or an angular plate secured to a backing member. Similarly, such an element may be attached at the trailing edge of the apparatus 10 for use when the apparatus 10 is pushed. In the embodiment of FIG. 1 , the smoothing member 96 is shown attached below the first frame member 20 to be below the plane of the blade assembly 66 .
[0060] In a further alternative embodiment, an adjustable blade assembly 66 may be secured to the support frame 12 at either the leading edge or the trailing edge of the apparatus 10 . The embodiment of FIG. 1 shows the blade assembly 66 attached at the trailing edge of the apparatus 10 . The blade assembly 66 further comprises a blade 104 extending substantially the width of the apparatus 10 , a plurality of retaining tabs 106 attached to the rear of the blade 104 secured in position by a retaining pin or bolt 108 , to a frame retaining tab 107 , a plurality of swivel tabs 110 also attached to the rear of the blade 104 and secured to a frame support tab 112 by use of a swivel pin 114 . To position the blade to pull material as in FIG. 2 the retaining pin 108 is removed and the blade 104 is rotated on the swivel pin 114 and retained in position by a locking pin 116 inserted through the repositioned retaining tab 106 and frame locking tab 118 . It is understood by those familiar with the art that a variety of mechanisms may be employed to retain, assist and position the blade assembly 66 including but not limited to mechanical levers and engagement pins, or hydraulic mechanisms. One advantage of the blade assembly 66 could be move larger accumulations of material than the apparatus 10 could easily move, and would be more suited to pushing or pulling larger quantities of material over some distance. Thus the operator would have the options of employing a blade, spreader and grading assembly in one unit that could be pushed or pulled to perform its intended operation.
[0061] In a further alternative embodiment, an adjustable scarifier assembly 68 may be secured to the support frame 12 at either the leading edge or the trailing edge of the apparatus 10 . The embodiment of FIG. 1 shows the scarifier assembly 68 attached at the leading edge of the apparatus 10 . The scarifier assembly 68 further comprises a plurality of tines 120 extending substantially vertically and having a first end 122 and a second end 124 , securedly attached to a body 128 extending substantially the width of the apparatus 10 . The scarifier assembly 68 is securedly attached to the support frame 12 by bolts 130 . The presence of the scarifier assembly 68 on the leading or trailing edge of the apparatus thereby allows more aggressive disruption of the surface, such as scarring of the surface or breaking up a substantially hard or firm surface or breaking or removal of roots, than could easily be handled by the apparatus without the scarifier. As in FIGS. 17 and 18 , the scarifier may be raised to allow the grading members or the blade to engage the surface.
[0062] In a further alternative embodiment, an adjustable grading member assembly 132 may be secured to the support frame 12 of the apparatus 10 . The embodiment of FIGS. 7, 8 and 9 shows the grading member assembly 132 attached on the underside of the support frame 12 . The advantage of the variable assembly is that the angle of the members may be varied to affect the surface scraping or spreading activity;
[0063] It is understood that the embodiments and descriptions of the invention herein described are merely instruments of the application of the invention and those skilled in the art should realize that changes may be made without departure from the essential elements and contributions to the art made by the teachings of the invention herein.
JUERGEN DRAWINGS & FIGURES—LIST OF NUMBERS
[0064]
10
G & S apparatus
12
Support frame
14
Horizontal support members
16
14 first end
18
14 second end
20
First frame member
22
Second frame member
24
Three point hitch yoke assembly
26
24 main support member
28
26 first end
30
26 second end
32
First lateral support member
34
32 first end
36
32 second end
38
First pin tab
40
38 opening
42
Second lateral support member
44
42 first end
46
42 second end
48
Second pin tab
50
48 opening
52
Securing pin
54
First lateral pin attachment
56
Second lateral pin attachment
58
Diagonal support member
60
58 first end
62
58 second end
64
Grading member
66
Blade assembly
68
Scarifier assembly
70
Spacer member
72
64 backing portion
74
64 first side portion
76
64 second side portion
78
64 first edge
80
64 second edge
82
64 channel
84
Grading element
86
84 body
88
84 first edge
90
84 second edge
92
84 first end
94
84 second end
96
Smoothing member
98
surface
100
96 first end
102
96 second end
104
blade
106
Retaining tab
108
Retaining pin
110
Swivel tab
112
Frame support tab
114
Swivel pin
116
Locking pin
118
Frame locking tab
120
68 tines
122
120 first end
124
120 second end
128
68 body
130
bolts
132
Grading member assembly
134
136
138
140
142
107
Frame retaining tab | A spreading and grading apparatus comprised preferably of a multiplicity of elongated and inverted rigid channel or u-shaped members substantially in a planar and parallel orientation attached to a supporting structure to maintain the orientation of the members and provide a preferable attachment surface for connection to a device to push or pull the apparatus. | 4 |
FIELD OF THE INVENTION
The present invention relates generally to the field of railroad maintenance and particularly to a method and apparatus for reconditioning ballast used as the roadbed for a railroad track. More particularly, the invention relates to reconditioning the ballast at a relatively high rate of speed by separately removing a portion of the ballast which is less susceptible to contamination or deterioration, salvaging reusable ballast from this portion, removing the remainder of the ballast, salvaging reusable ballast from this portion, then combining the salvaged ballast for replacement beneath the track with waste being conveyed along the track for disposal.
BACKGROUND OF THE INVENTION
As is well known the ballast forming the roadbed of a railway track is susceptible to contamination and deterioration caused by the passage of trains over the track. In some areas the ballast must be reconditioned at least annually. There are numerous forms of apparatus which have been developed for this task. Typical apparatus which are used for this type operation include track undercutters to remove the ballast from beneath the tracks, ditcher wheels to remove ballast from areas alongside the tracks and cleaning screens to recover reusable ballast from the ballast removed by the undercutters and ditcher wheels.
It will be appreciated that the rail lines which require the most frequent maintenance are the busiest lines, therefore the time available during which the tracks may be blocked by apparatus reconditioning the ballast is quite limited. Therefore it is imperative that the reconditioning proceed as rapidly as possible. Typical ditcher wheels may remove ballast from alongside the tracks at speeds up to 5,000 feet per hour and typical undercutters may operate at slightly reduced speeds. However when the ballast from the undercutter and ditcher wheels are fed to a cleaning screen, the rate of progress is limited by the capacity of the screen. Typical screen capacity limits the forward rate of travel in such instances to about 1,000 feet per hour. The shortcomings of such machines are well known and are fully discussed in U.S. Pat. No. 4,534,415. U. S. Pat. No. 4,534,415 purports to improve the speed of the operation by providing a further ballast screening installation, mounted on the apparatus frame, which may thus effectively double the capacity of the cleaning system. While such an apparatus seems suitable for its intended purpose, it leaves something to be desired in terms of economy and efficiency in that the apparatus is appreciably more complex than the instant invention.
I have previously addressed this problem in my U.S. Pat. No. 4,705,115, wherein I separated the fouled ballast and cleaned only the portion of the ballast which was most contaminated, to wit, the ballast directly beneath the track. While this was acceptable in certain circumstances, it was not always the best mode for reconditioning the track. Thus there remains a need for an apparatus which will rapidly and completely recondition the ballast.
SUMMARY OF THE INVENTION
It is the object of the present invention to provide a method and apparatus for reconditioning the ballast along a railroad track at a substantially higher rate of speed than heretofore possible while cleaning the ballast from one side of the track to the other.
Yet another object of the invention is to provide a unitized apparatus which can clean the ballast as desired and remove waste ballast forwardly along the track for disposal and receive fresh ballast for replenishing the cleaned ballast from rearwardly along the track.
Still another object of the invention is to provide an articulated system which can negotiate relatively small radius curves in the track without increasing the height of the system.
The above objects are advantageously accomplished in my invention by the use of six frame members which are articulated on seven shared carriages or bogies which travel on the railroad track. The frame members support a plurality of work stations which sequentially remove, clean and retain portions of the ballast bed. In essence, the ballast bed is divided into longitudinally extending regions which are separately removed and cleaned by dedicated mechanisms with the cleaned ballast being recombined for reuse beneath the track. To accomplish this, I use a pair of opposed ditcher wheels which remove ballast from adjacent the track to a ballast cleaner supported on one of the articulated frames. A set of tie end cutters are then used to undercut the ends of the sleeper or cross ties and the ballast outwardly of the track is graded. The ballast cleaner discharges the cleaned ballast adjacent the track, while the spoil or waste is conveyed forwardly along the track for disposal. The deposited cleaned ballast is recovered by a second set of ditcher wheels mounted forwardly of an undercutter which removes all of the ballast remaining beneath the track down to a selected depth. This fouled ballast is removed to a second ballast cleaner which discharges a cleaned portion which is recombined with the ballast recovered by the second set of ditcher wheels and deposited beneath the track rearwardly of the undercutter.
BRIEF DESCRIPTION OF THE DRAWINGS
Apparatus embodying features of my invention are depicted in the accompanying drawings which form a portion of this invention and wherein:
FIG. 1 is a side elevational view of the articulated ballast cleaning system;
FIG. 2 is a side elevational view of the forward section of the articulated ballast cleaning system dedicated to removing ballast alongside the track;
FIG. 3 is a side elevational view of the rearward section of the articulated ballast cleaning system which removes ballast from beneath the track; and
FIGS. 4-12 are sectional views of the track and ballast bed during operation of my apparatus.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings for a clearer understanding of my invention it will be seen in FIGS. 1-3 that my ballast cleaning apparatus 11 is an articulated vehicle having a plurality of carriages 12 or bogies which engage the rails 13 of a railroad track which include the sleepers 14 or crossties and rails 13 and which is supported on a ballast bed 16. The carriages 12 support six frame members 17-19 and 21-23 with each adjacent frame member sharing a bogie 12 such that the vehicle is articulated at the bogies 12. Forward frame member 17 supports a driver's cabin 24 having conventional control connections thereto which are not shown. Also supported on frame members 17 are a pair of ditcher wheels 26 and 27 which remove fouled ballast from adjacent the ends of the crossties 14 as shown in FIG. 5 to associated cross conveyors 28 (only one of which is shown) which carry the fouled ballast to a center conveyor 29 for transport to a screen cleaner 31 supported on frame member 18. A tie end undercutter 32 such as disclosed in my U.S. Pat. No. 4,850,123, which removes ballast from beneath the ends of the crossties 12, as shown in FIG. 6, is also mounted on carriage 17 along with a blade assembly 33 which grades the ballast outwardly of the track removing only accumulated fouled ballast discharged by the tie end cutter 32 as shown in FIG. 7. The ballast cleaner 31 separates the fouled ballast into a cleaned portion and a spoil or waste portion. The cleaned portion is discharged adjacent the track as shown in FIG. 8 and the waste portion is conveyed to a lifting wheel 34, which is simply a vertical conveyor which lifts the spoil from a discharge conveyor 36 to a spoil conveyor system including elevated conveyor 37 supported on frame 18 above the ballast cleaner 31.
Frame member 19 supports a power module 38 which includes diesel engines generating 2000 hp, hydraulic pumps, reservoirs and fuel tanks, all of which are conventional and are not shown in the interest of clarity. Overlying the power module 38 is a spoil conveyor 39 which has its discharge end positioned above elevated conveyor 37.
Frame member 21 supports a second screen ballast cleaner 41 which cleans fouled ballast removed from beneath the track by an undercutter 42 supported on frame member 23. The fouled ballast is transferred to the ballast cleaner 41 by fouled ballast conveyors 43, 44, and 46 which are elevated conveyors cooperatively supported on frame members 21, 22, and 23 respectively. Spoil or waste ballast is discharged from ballast cleaner 41 onto spoil conveyor 47 for delivery to spoil conveyor 39. It thus may be seen that waste ballast removed from beneath and alongside the track is combined on elevated conveyor 37 and carried forwardly along the track to an elevated conveyor 48 supported on frame 17 and hence to a discharge conveyor 49 overlying the operator's cab 24. The waste ballast is discharged into a hopper car 50 forward of the ballast cleaner apparatus 11.
Frame member 22 supports a second pair of ditcher wheels 51 and 52 and their associated cross conveyors 53 (only one of which is shown). The ditcher wheels recover the cleaned ballast deposited by ballast cleaner 31 as indicated in FIG. 9, and the cross conveyor delivers the cleaned ballast to a clean ballast conveyor supported on frame member 22. Thus the undercutter 42 does not have to remove any ballast except that under the center of the track as per FIG. 10 and ballast cleaner 41 has only to clean that portion removed by the undercutter 42. The cleaned ballast from ballast cleaner 41 is transported on the clean ballast conveyor system by intermediate conveyors 56 and 57 to clean ballast conveyor 54. Clean ballast conveyor 54 has a discharge end overlying a receiving conveyor 58 mounted on frame member 23 which delivers the combined cleaned ballast to a discharge conveyor 59 which carries the cleaned ballast past an operator station 61 and the undercutter 42 to a point rearwardly of the undercutter 42. A portion of the cleaned ballast may be deposited beneath the track or sent to a cleaned ballast hopper 62 also on carriage 23. When the cleaned ballast is insufficient to properly reform the ballast bed fresh ballast conveyor 63 delivers fresh ballast from a hopper car 65 located rearwardly of a rear driver's cab 64. Carriage 23 also supports a track lifting attachment 66 which is used in conjunction with the undercutter 42 as is conventionally known.
Although the operation of my device should be relatively clear to those familiar with railroad maintenance equipment, FIGS. 4-12 give a pictorial representation of the track and ballast as my apparatus reconditions the ballast. In FIG. 4 the track and ballast are shown in their undisturbed fouled condition. In FIG. 5, the ballast adjacent the ends of the crossties has been removed by ditcher wheels 26 and 27 for cleaning by screen cleaner 31. In FIG. 6, the tie end cutters 32 have removed fouled ballast from beneath the ends of the sleepers 14 to a position outwardly of the tracks. In FIG. 7, blade assemblies 33 have graded the ballast in preparation for the deposit of cleaned ballast by cleaner 31 as in FIG. 8. FIG. 9 illustrates the cleaned ballast which is to be removed by the ditcher wheels 51 and 52. In FIG. 10 the track supported by track lifting apparatus 66 has been undercut by undercutter 42 and in FIG. 11 cleaned ballast from the two screen cleaners 31 and 41 has been deposited rearwardly of the undercutter 42. In FIG. 12, the ballast bed has been reformed to its original condition using a combination of cleaned and fresh ballast.
From the foregoing, it is clear that my device is a clearly superior unitized track cleaning apparatus, however the actual physical characteristics are even more impressive. The entire apparatus, not including hopper cars for spoil or fresh ballast, is 260 feet in length and has a travel turning radius of 250 feet. The unit can remove, clean, and restore the ballast at a depth of 280 mm below the sleepers at a rate of 480 meters per hour. Further no spoil is left along side the track and with a height of 13 feet the apparatus can be used in virtually any locale.
While I have shown my invention in one form, it will be obvious to those skilled in the art that it is not so limited but is susceptible of various changes and modifications without departing from the spirit thereof. | An articulated ballast cleaning system utilizes a pair of ballast cleaners each dedicated to cleaning only a portion of the ballast bed of a railroad track, such that one cleans the peripheral ballast while the other cleans the center ballast. Spoil or waste ballast is conveyed forwardly along the apparatus for disposal, while cleaned ballast is conveyed rearwardly for replacement aft of an undercutter device. Fresh ballast may be conveyed forwardly along the apparatus to supplement the cleaned ballast. | 4 |
BACKGROUND
[0001] Detectable warnings, a distinctive surface pattern of domes detectable by cane or underfoot, are used to alert people with vision impairments of their approach to streets and hazardous drop-offs. The ADA Accessibility Guidelines (ADAAG) require these warnings on the surface of curb ramps, which remove a tactile cue otherwise provided by curb faces, and at other areas where pedestrian ways blend with vehicular ways. They are also required along the edges of boarding platforms in transit facilities and the perimeter of reflecting pools.
[0002] The technical specifications of the ADA require that detectable warnings on walking surfaces have a specific truncated dome pattern. This unique pattern is intended to provide a consistent and uniform surface that is distinctive from other materials and, therefore, recognizable as a warning to pedestrians that they are approaching a potentially dangerous area. Under the “Revised Draft Guidelines for Accessible Public Rights-of-Way,” the ADAAG specifically requires that detectable warnings consist of a surface of truncated domes aligned in a square or radial grid pattern.
SUMMARY
[0003] The present disclosure provides a method for producing detectable warnings on substrate surfaces, which includes providing a mat with a top surface and a bottom surface and a pattern of mat through holes extending through the mat. The through holes comprise a lower portion defining a lower mat opening and an upper portion defining an upper mat opening, wherein the upper mat opening is larger in transverse dimension than the lower mat opening. The method further includes placing the mat on a substrate surface, wherein the bottom surface of the mat is adjacent the substrate surface, and injecting into the mat through holes a viscous substance having the ability to cure into a solid. The method further includes removing the mat at the appropriate time to form raised detectable warnings on the substrate surface.
[0004] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
DESCRIPTION OF THE DRAWINGS
[0005] The foregoing aspects and many of the attendant advantages of the present disclosure will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
[0006] FIG. 1 is a perspective view of detectable warnings formed on a target, substrate surface;
[0007] FIG. 2 is a top perspective view of a mat including a plurality of openings, wherein the mat is secured to a target substrate surface and a blended material is injected into the openings;
[0008] FIG. 3A is a cross-sectional view of blended material being injected into the openings of the mat of FIG. 2 ;
[0009] FIG. 3B is a cross-sectional view of the mat of FIG. 3A being removed from the target substrate surface;
[0010] FIG. 3C is a cross-sectional view of the blended material adhered to the target surface after the mat of FIG. 3A has been removed from the target surface;
[0011] FIG. 3D is a cross-sectional view of the blended material adhered to the target surface, wherein the material has slumped partially to begin forming detectable warnings;
[0012] FIG. 3E is a cross-sectional view of detectable warnings formed on a target surface as shown in FIG. 1 ; and
[0013] FIG. 4 is a cross-sectional view of blended material being injected into an alternate embodiment of the mat of FIG. 2 .
DETAILED DESCRIPTION
[0014] Referring to FIG. 1 , a substrate or target surface 14 having a pattern of detectable warnings in the form of truncated domes 16 formed thereon is shown. The truncated domes 16 are illustrated as arranged in an “in-line” or “square” pattern as shown in FIG. 1 . The rows of truncated domes may instead be rotated (for example at 45 degrees) in relation to the substrate surface 14 to produce an offset pattern. Preferably, the truncated domes are spaced at least 1.6″ from the center of one truncated dome to the center of the adjacent truncated dome, and no more than 2.4″ apart for both the in-line pattern and the offset pattern. In addition, a multiple sinusoidal pattern in a stacked relationship, as shown in U.S. Pat. No. 5,385,770, may instead be used to provide a greater likelihood that an object in constant contact with surface 14 will encounter a truncated dome 16 in the shortest distance. For ease of illustration and clarity, only the in-line pattern is shown.
[0015] A cross section of a truncated dome 16 bonded to substrate 14 is shown in FIG. 3E . Inclined peripheral surfaces 20 may have curved upper and lower transitions 22 and 24 with upper surface 26 and substrate 14 , respectively, so that an object such as a cane, shoe, or foot, as well as an implement such as a shovel or squeegee, will not jam or lodge in the otherwise sharp corners or edges created at these interfaces. Beneficially, these curved transitions 22 and 24 increase the truncated dome's resistance to dislodgment from lateral impacts by permitting a certain degree of impact redirection. To comply with R304.1 (as mentioned in the background section of this application), the truncated domes 16 are at least 0.9″ in diameter along the bottom of the truncated dome 16 , and no more than 1.4″ in total diameter. Along the top of the truncated dome, the diameter is at least 50 percent and no more than 65 percent of the base diameter. The truncated domes 16 are approximately 0.2″ in height.
[0016] Other truncated shapes and sizes may also be used as detectable warnings. For instance, as shown in U.S. Pat. No. 5,385,770, additional designs may include an elongated elliptical design, a diamond shaped design, an asymmetrical elongated elliptical design, or a dumbbell design. Each detectable warning is characterized as having an inclined peripheral surface and somewhat rounded or curved transitions between both the lower substrate 14 and the upper surface of the detectable warning.
[0017] Now referring to FIG. 2 , a mat 30 or similar element may be used to create the afore-described detectable warnings or truncated domes 16 on a substrate surface 14 . The mat 30 may consist of either a rigid, flexible, or semi-flexible material, where the mat 30 may be formed using a molding technique, such as injection molding. The mold may include an upper and lower portion, and each portion of the mat mold may contain a portion of a mold cavity. The mold may also include inwardly extending projections that generally conform to the shape of the through holes 34 to form the through holes 34 during the molding process.
[0018] Referring to FIGS. 2 and 3C , each through hole 34 formed during the molding process represents a mold for forming the desired truncated domes 16 on the substrate surface 14 . The through holes 34 are shown as being of an inverted frusto-conical shape and include a lower portion 44 defining a lower mat opening 33 and an upper portion 32 defining an upper mat opening 35 . Preferably, the diameter of the lower mat openings 33 on the mat bottom surface 36 are about 0.50 inches to 0.90 inches and the diameter of the upper mat openings 35 on the mat top surface 136 are about 150% to 225% larger. However, it should be appreciated that through holes 34 of different sizes may be used to form various-sized detectible warnings 16 . The through holes 34 may be arranged in a desired pattern to enhance the detectability of the target surface.
[0019] Now referring to FIG. 2 and 3A , the truncated domes 16 are formed by first placing the mat 30 on a substrate surface 14 . The mat 30 may include a sealant or adhesive surface (not shown) on the mat bottom surface 36 so that the mat 30 temporarily adheres to the substrate surface 14 . After the mat 30 is placed upon the substrate surface 14 , a viscous material 40 is injected into and fills each through hole 34 . The material 40 is injected into the through holes 34 by using a manually operated squirt bottle or other manually operated or powered device. The material 40 may also be infused into the through holes 34 with a squeegee or similar device. After the material 40 has been injected or infused into all the through holes 34 , the mat 30 is removed.
[0020] Referring to FIG. 3B , when the mat 30 is lifted from the substrate surface 14 , the material 40 in the lower portion 44 of the through hole 34 falls downwardly through the lower mat opening 33 and adheres to the substrate surface 14 to form an initial base portion 42 . The material 40 is of a consistency such that it slumps slightly when it falls to the substrate surface 14 . At the same time the initial base portion 42 is being formed, the material 40 in the upper portion 32 of the through hole 34 is gravitationally forced downwardly and inwardly towards the center of the through hole 34 . Referring to FIG. 3C , the material 40 from the upper portion 32 falls through the lower mat opening 33 onto the initial base portion 42 to form an initial annular top ring 50 .
[0021] The material 40 in the initial annular ring 50 continues to fall inwardly and downwardly into the initial base portion 42 and causes the initial base portion 42 to slump further and become larger in size and diameter, as shown in FIG. 3D . The ring 50 continues to fall into the base portion 42 until a truncated dome 16 having a base diameter of approximately 0.9″ to 1.4″ is formed, as shown in FIG. 3E . The shape and size of the upper surface 26 of the truncated dome 16 is defined by the initial annular ring 50 , which is formed by material 40 that falls through the lower mat opening 33 in the mat bottom surface 36 . Thus, the dome upper surface 26 is roughly the same size and shape as the lower mat opening 33 , or about 50 to 60 percent of the base 27 diameter.
[0022] As the material 40 ceases slumping, the material 40 cures to form the truncated dome 16 , as shown in FIG. 3E . Once the truncated dome 16 has formed and cured, a final coat of viscous catalyzed material may be applied to the substrate surface 14 and the truncated domes 16 to smoothen any abnormalities or blemishes and help ensure an even appearance.
[0023] The truncated domes 16 of the present disclosure may be formed from material 40 , which may comprise a methacrylate monomer blended with binders, pigments, and an abrasive. Ideally, the blended material has good abrasion resistance, chemical resistance, and longevity. In one form of the present invention, the composition of the detectable warnings may be a methacrylate monomer blend having glass fiber binders, pigments, and reflective material. The use of a methacrylate monomer helps engender strong bond characteristics with normally encountered substrate surfaces such as asphalt, concrete, steel, and wood. The use of glass fibers enhances structural properties of the detectable warnings, increases traction, and reduces the amount of resin mixture needed for any given application. The percentage pigment chosen provides adequate color contrast under the provisions of the ADA. The use of reflective material such as glass spheres or beads enhances low light detection of the detectable warnings and further decreases the amount of monomer needed. Finally, the percentage abrasive not only increases the potential coefficient of friction of the warnings, but also provides additional strength as an aggregate and decreases the overall amount of resin needed for a given application.
[0024] Now referring to FIG. 4 , wherein corresponding numerals increased by 100 refer to like elements, a further embodiment of the mat 130 is depicted. The mat 130 is substantially the same as mat 30 except that the through holes 134 include a lower generally circular portion 144 defining a lower mat opening 133 and an upper curved portion 132 defining an upper mat opening 135 . The lower circular portion 144 extends from the mat bottom surface 136 at least partially through the mat thickness. The upper curved portion 312 extends from the lower circular portion 144 to the mat upper surface 138 . The upper curved portion 132 extends upwardly and outwardly towards the mat top surface 138 so that the diameter of the upper mat opening 135 is larger than the diameter of the lower circular portion 144 and the lower mat opening 133 .
[0025] Preferably, the diameter of the lower mat openings 134 (and the diameter of the lower circular portion 144 ) are about 0.50 inches to 0.90 inches and the diameter of the upper mat openings 135 on the mat top surface 136 are about 150% to 225% larger. The through holes 134 may be arranged in a desired pattern to enhance the detectability of the target surface.
[0026] The mat 130 is used to form truncated domes 116 (not shown) in substantially the same way as with mat 30 . Each through hole 134 in the mat 130 represents a mold for forming the desired truncated domes 116 on the substrate surface 114 . After the mat 130 is placed upon the substrate surface 114 , a viscous material 140 is injected into and fills each through hole 134 . After the material 140 has been injected or infused into all the through holes 134 , the mat 130 is removed. When the mat 130 is lifted from the substrate surface 114 , the material 40 in the lower circular portion 144 falls downwardly through the lower mat opening 134 and adheres to the substrate surface 114 to form an initial base portion 142 .
[0027] The material 140 is of a consistency such that it slumps slightly when it falls to the substrate surface 114 . At the same time the initial base portion 142 is being formed, the material 140 in the upper curved portion 132 of the through hole 134 is drawn downwardly and inwardly towards the center of the through hole 134 . The material 140 from the upper curved portion 132 falls through the lower mat opening 133 and onto the initial base portion 142 to form an initial annular ring 150 . The material 140 in the initial annular ring 150 continues to fall inwardly and downwardly into the initial base portion 142 and causes the initial base portion 142 to slump further and become larger in size and diameter. The ring 150 continues to fall into the base portion 142 until a truncated dome 116 having a base diameter of approximately 0.9″ to 1.4″ is formed. The shape and size of the upper surface 126 of the truncated dome 116 is defined by the initial annular ring 150 , which is formed by material 140 that falls through the lower mat opening 133 in the mat bottom surface 136 . Thus, the dome upper surface 126 is roughly the same size and shape as the lower mat opening 133 , or about 50 to 60 percent of the base diameter. When the material 140 has ceased slumping, the material 140 cures to form the truncated dome 116 .
[0028] While illustrative embodiments have been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention. | The present disclosure provides a method for producing detectable warnings ( 16 ) on substrate surfaces ( 14 ), which includes providing a mat ( 30 ) with a top surface ( 38 ) and a bottom surface ( 36 ) and a pattern of mat through holes ( 34 ) extending through the mat ( 30 ). The through holes ( 34 ) comprise a lower portion ( 44 ) defining a lower mat opening ( 33 ) and an upper portion ( 32 ) defining an upper mat opening ( 35 ), wherein the upper mat opening ( 35 ) is larger in transverse dimension than the lower mat opening ( 33 ). The method further includes placing the mat ( 30 ) on a substrate surface ( 14 ), wherein the bottom surface ( 36 ) of the mat ( 30 ) is adjacent the substrate surface ( 14 ), and injecting into the mat through holes ( 34 ) a viscous substance ( 40 ) having the ability to cure into a solid. The method further includes removing the mat ( 30 ) at the appropriate time to form raised detectable warnings ( 16 ) on the substrate surface ( 14 ). | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based upon and claims the benefit of priority from prior Chinese Patent Application No. 200910006550.3, filed Feb. 17, 2009, 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 load beam constituting a part of a suspension of a disk drive, suspension with the load beam, and a manufacturing method for the suspension.
[0004] 2. Description of the Related Art
[0005] Conventionally, a magnetic disk device, such as a hard disk drive (HDD) or magneto-optical drive, comprises a magnetic head. The head flies above a magnetic disk rotating at high speed with a fine space therebetween. Data on the disk is read or written by the head.
[0006] An example of a suspension is disclosed in, for example, Jpn. Pat. Appln. KOKAI Publication No. 10-162532 or 9-91909.
[0007] In recent years, the head size and flying height (above the disk surface) have been reduced with the development of disk devices with higher recording densities. In order to accurately read and write magnetic disk data, it is important to suppress vibration of a head portion, thereby precisely positioning the head.
[0008] As shown in FIG. 10 , a disk drive with a suspension generally comprises a magnetic head 1 , a suspension 2 supporting the head 1 , a block 3 to which the suspension 2 is fixed, etc. The suspension 2 generally comprises a load beam 10 formed of a precise thin-plate spring, a baseplate 11 , a flexure 12 formed of a plate spring thinner than the load beam 10 , etc. The magnetic head 1 is located on a gimbal portion formed at the distal end of the flexure 12 .
[0009] A head portion comprising the magnetic head 1 receives vibration from a device for driving the head portion, a motor (not shown) for rotating a disk 13 , etc. Thus, the suspension 2 formed of a plate spring, may be deformed so that the magnetic head 1 is dislocated. This results in a read or write error. Thereupon, the damper 14 , such as the one shown in FIG. 11 , may be used to reduce or remove vibration of the suspension 2 . The damper 14 is also referred to as a vibration damping member. The damper 14 comprises a metallic restrainer 15 and viscoelastic member 16 of a viscoelastic material, which are laminated thickness-wise. The damper 14 is affixed to the load beam 10 of the suspension 2 .
[0010] According to the suspension 2 with the damper 14 , the viscoelastic member 16 sandwiched between the vibrating suspension 2 and restrainer 15 is deformed as the suspension 2 vibrates. Molecular friction of the viscoelastic member 16 produces internal resistance, thereby converting vibrational energy into thermal energy. Thus, the vibrational energy directly received by the suspension 2 is greatly reduced, so that a vibration dumping effect can be obtained. FIG. 12A shows vibration characteristics observed before the damper 14 is affixed to the load beam 10 . FIG. 12B shows vibration characteristics observed after the damper 14 is affixed to the load beam 10 . As shown in FIG. 12B , a damping effect obtained from the damper 14 affixed to the load beam 10 lowers the peak value of gain in each vibration mode and provides the vibration damping effect.
[0011] As shown in FIGS. 3A and 4A , transversely opposite side edge portions 10 a of the load beam 10 are bent in order to enhance the rigidity of the load beam 10 . In this specification, the bending of the bent side edge portions 10 a is referred to as “rib bending”. In order to maintain an appropriate flying height of the magnetic head 1 above the surface of the disk, moreover, a proximal portion 10 b of the load beam 10 is slightly bent, as viewed laterally relative to the load beam 10 , as shown in FIG. 4A . The proximal portion 10 b is located near the block 3 and also functions as a hinge portion for warping the load beam 10 thickness-wise. In this specification, the bending of the proximal portion 10 b is referred to as “load bending”. If the damper 14 is affixed to the load beam 10 before this load bending, it may undesirably interfere with bending tool during the rib or load bending. In actual manufacturing processes, therefore, the damper 14 is affixed to the load beam 10 after the load beam 10 is bent, as shown in FIGS. 9A to 90 .
[0012] In order to cause the viscoelastic member 16 to adhere closely to the load beam 10 in affixing the damper 14 to the load beam 10 , however, the damper needs to be pressed against, the load beam 10 with a predetermined load. In some cases, the load beam 10 may be deformed by a pressing force on the damper 14 that is affixed to the bent load beam. If the load beam 10 is deformed, static properties, such as spring load, and dynamic properties, such as resonance, may vary. Variations of these properties impair the commodity value and working properties of the suspension.
[0013] If the damper is dislocated with respect to the load beam when it is affixed to the load beam, moreover, it may adversely affect the properties of the suspension. Conventionally, it is difficult to accurately position the damper, since the damper is affixed to the load beam formed of a flat thin-plate spring that carries no indication of a damper mounting position.
[0014] According to the conventional manufacturing processes in which the damper is affixed to the bent load beam, the opposite side edge portions 10 a that are bent like ribs hinder the operation for affixing the damper 14 . Since one damper 14 is affixed to each load beam 10 , furthermore, the affixing operation is time-consuming, that is, work performance is poor.
[0015] Conventionally, the viscoelastic member is sometimes caused to project much from the periphery of the damper by the pressing force on the damper that is affixed to the load beam. In such a case, it is troublesome and difficult to thoroughly remove a projecting part of the viscoelastic member. In some cases, the periphery of the viscoelastic member is covered by a resin coating material after the damper is affixed to the load beam. In these cases, the usage of the coating material is too much to reduce the weight of the load beam.
BRIEF SUMMARY OF THE INVENTION
[0016] Accordingly, the object of the present invention is to provide a load beam having stable properties such that it is less deformed by a damper affixed thereto, a suspension, and a manufacturing method for the suspension.
[0017] A load beam of the invention is formed of a thin-plate spring and constitutes a part of a suspension which supports a magnetic head, and a recess is formed in a part of the load beam so as to accommodate the damper. The recess may be formed by either partial etching or pressing. Alternatively, the recess may be formed by boring a through-hole greater than the damper in one of two plates which are superposed to each other to form the load beam. The depth of the recess should preferably be greater than the thickness of the damper.
[0018] A suspension according to the invention is the one which supports the magnetic head and comprises the above-described load beam, the damper being affixed to a bottom surface of the recess of the load beam.
[0019] In a method for manufacturing the suspension, the load beam is bent after the damper is affixed to the bottom surface of the recess of the load beam.
[0020] Further, the suspension manufacturing method described above may comprise fabricating a continuous load beam blank comprising a plurality of the load beams from a thin-plate spring material, forming the recess for accommodating the damper in each of the load beams of the load beam blank, affixing the damper to the bottom surface of the recess of each of the load beams, and bending each of the load beams after the damper is affixed thereto and separating the load beam from a scrap portion of the load beam blank.
[0021] According to the present invention, as described above, the recess greater than the damper is formed in the load beam, corresponding to a position where the damper is affixed. The damper is contained in the recess. Thus, the damper can be prevented from interfering with a bending tool even if the load beam is bent with the damper affixed thereto. Therefore, the damper can be affixed to the unbent flat load beam. Accordingly, the load beam cannot be easily deformed, so that the static and dynamic properties of the suspension can be prevented from varying. The recess should only be sufficiently large to accommodate the damper. In consideration of the work performance for the affixture of the damper to the load beam and the projection of the viscoelastic member, the recess should preferably be slightly larger than the damper.
[0022] The recess is formed by, for example, partial etching. Since the recess formed by partial etching can be used as a guide for the affixture of the damper, the damper can be easily positioned with respect to the load beam.
[0023] Since the damper can be affixed to the unbent flat load beam, moreover, the operation for affixing the damper can be easily automated. Since the damper can be affixed to each load beam of the continuous load beam blank that comprises a plurality of unbent load beams, in particular, the damper affixing operation can be automated with higher speed and accuracy and less deformation. In this case, the efficiency of the damper affixing operation can be further improved.
[0024] As the damper is pressed against and affixed to the load beam, a part of its viscoelastic member may sometimes be caused to project from the periphery of the restrainer. According to the present invention, however, the damper is contained in the recess, so that the projecting part of the viscoelastic member can be confined within a groove defined between the inner side surface of the recess and the side surface of the damper. Thus, the viscoelastic member can be prevented from projecting outside the load beam. Since the groove exists inside the recess, moreover, a coating material (e.g., resin) can be easily filled around the damper, and the usage of the coating material can be reduced.
[0025] Thus, according to the present invention, the damper is contained in the recess formed in the load beam. The weight of the load beam itself can be reduced by a margin corresponding to the recess. Consequently, an increase in weight attributable to the presence of the damper can be compensated with a reduction of the weight of the load beam, so that the suspension can be made lighter in weight.
[0026] Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out hereinafter.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0027] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention, and together with the general description given above and the detailed description of the embodiments given below, serve to explain the principles of the invention.
[0028] FIG. 1A is a plan view of a conventional suspension;
[0029] FIG. 1B is a plan view of a suspension according to one embodiment of the invention;
[0030] FIG. 2 is a partial sectional view typically showing a load beam and damper of the suspension shown in FIG. 1B ;
[0031] FIG. 3A is a sectional view of the suspension taken along line 3 A- 3 A of FIG. 1A ;
[0032] FIG. 3B is a sectional view of the suspension taken along line 3 B- 3 B of FIG. 1B ;
[0033] FIG. 4A is a sectional view of the suspension taken along line 4 A- 4 A of FIG. 1A ;
[0034] FIG. 4B is a sectional view of the suspension taken along line 4 B- 4 B of FIG. 1B ;
[0035] FIG. 5A is a sectional view showing how a viscoelastic member of a damper of the conventional suspension projects from the periphery of restrainer;
[0036] FIG. 5B is a sectional view showing how viscoelastic member of a damper of the suspension according to the invention projects from the periphery of a restrainer;
[0037] FIG. 6A is a sectional view showing how the periphery of the damper of the conventional suspension is covered by a coating material;
[0038] FIG. 6B is a sectional view showing how the periphery of the damper of the suspension of the invention is covered by a coating material;
[0039] FIG. 6C is a sectional view showing another example of the load beam of the suspension of the invention;
[0040] FIG. 7A is a sectional view showing the load beam formed with a recess before bending work;
[0041] FIG. 7B is a sectional view showing the load beam shown in FIG. 7A and the damper before a fixture;
[0042] FIG. 7C is a sectional view showing how the damper shown in FIG. 7B is affixed to the load beam;
[0043] FIG. 7D is a sectional view showing the load beam and damper after rib bending;
[0044] FIG. 8A is a plan view showing a load beam blank with recesses;
[0045] FIG. 8B is a plan view showing how each load beam of the load beam blank shown in FIG. 8A is provided with the damper;
[0046] FIG. 9A is a sectional view showing a conventional load beam before bending work;
[0047] FIG. 9B is a sectional view showing the conventional load beam after the bending work;
[0048] FIG. 9C is a sectional view showing the conventional load beam and the damper before affixture;
[0049] FIG. 9D is a sectional view showing how the damper is affixed to the conventional load beam;
[0050] FIG. 10 is a perspective view showing a part of a disk drive;
[0051] FIG. 11 is a sectional view showing a part of the damper;
[0052] FIG. 12A is a diagram showing vibration characteristics of a suspension without a damper; and
[0053] FIG. 12B is a diagram showing vibration characteristics of a suspension with a damper.
DETAILED DESCRIPTION OF THE INVENTION
[0054] One embodiment of the present invention will now be described with reference to the accompanying drawings.
[0055] FIG. 1A is a plan view of the suspension 2 comprising the conventional load beam 10 . FIG. 15 is a plan view of a suspension 2 ′ comprising a load beam 10 ′ according to the invention. FIG. 2 is a sectional view typically showing the load beam 10 ′ and a damper 14 according to the invention. A recess 20 is formed in a part of the load beam 10 ′. FIG. 3A is an enlarged sectional view taken along line 3 A- 3 A of FIG. 1A . FIG. 3B is an enlarged sectional view taken along line 3 B- 3 B of FIG. 1B . FIG. 4A is an enlarged sectional view taken along line 4 A- 4 A of FIG. 1A . FIG. 4B is an enlarged sectional view taken along line 4 B- 4 B of FIG. 1B .
[0056] The load beam 10 shown in FIG. 3A is bent so that its transversely opposite side edge portions 10 a rise like ribs. A central part of the conventional load beam 10 has a flat surface. In the load beam 10 shown in FIG. 4A , the proximal portion 10 b near the block 3 ( FIG. 10 ) is slightly bent. In the conventional load beam 10 , the damper 14 is affixed to the flat surface between the side edge portions 10 a . Thus, in the conventional suspension 2 , the damper 14 projects to a height equal to its thickness above the flat surface of the load beam 10 .
[0057] As shown in FIG. 3B , on the other hand, the load beam 10 ′ according to the present invention is formed with the recess 20 larger than the damper 14 in that part thereof on which the damper is located. The “recess greater than the damper” implies that the recess 20 is wider than the damper 14 when the load beam 10 ′ is viewed vertically from above ( FIG. 1B ). The damper 14 is contained in the recess 20 . The load beam 10 ′ is formed of a thin-plate spring. This thin-plate spring is a springy stainless-steel plate with a thickness of, for example, 50 to 100 μm.
[0058] As shown in FIG. 4B , a proximal portion 10 b of the load beam 10 ′ is slightly bent thickness-wise, as viewed laterally relative to the load beam. The proximal portion 10 b is located near the block 3 and also functions as a hinge portion for warping the load beam 10 ′ thickness-wise. The recess 20 is formed in a region including this hinge portion (or proximal portion 10 b ). Thus, a part of the damper 14 is located in the hinge portion (or proximal portion 10 b ).
[0059] As shown in FIG. 11 , the damper 14 comprises a metallic restrainer 15 and viscoelastic member 16 , which are laminated thickness-wise. The restrainer 15 is affixed to a bottom surface 20 a of the recess 20 with the viscoelastic member 16 between them. As shown in FIG. 2 , the upper surface of the restrainer 15 , that is, a surface 14 a of the damper 14 , is located within the recess 20 . In other words, the surface 14 a of the damper 14 does not project outside a surface 10 d of the load beam 10 ′.
[0060] According to the load beam 10 ′ of the present embodiment, therefore, interference of a bending tool with the damper 14 can be avoided while the load beam with the damper 14 thereon is being bent. Thus, the load beam 10 ′ can be bent after the damper 14 is affixed thereto. In addition, the recess 20 can be used as a positioning guide in affixing the damper 14 to the load beam 10 ′. Accordingly, the damper 14 can be easily positioned with respect to the load beam 10 ′.
[0061] In affixing the damper 14 to the bottom surface 20 a of the recess 20 , the damper 14 is pressed against the load beam 10 ′. By this pressing force, a part of the viscoelastic member 16 may sometimes be caused to project from the periphery of the restrainer 15 . In the case of the conventional suspension 2 shown in FIG. 5A , a part 16 a of the viscoelastic member projects much from the periphery of the restrainer 15 if the pressing force on the damper 14 is heavy. Thus, an operation is needed to remove the projecting part 16 a of the viscoelastic member.
[0062] According to the load beam 10 ′ of the present invention, however, a groove 25 is formed between an inner side surface 20 b of the recess 20 and the side surface of the restrainer 15 , as shown in FIG. 5B . Thus, the part 16 a of the viscoelastic member projecting from the periphery of the restrainer 15 is confined within the groove 25 . Consequently, the operation to remove the projecting part 16 a of the viscoelastic member can be omitted.
[0063] Conventionally, as shown in FIG. 6A , the side surface of the damper 14 is located outside the load beam 10 , so that a considerable amount of a coating material 30 is used to cover the side surface of the damper.
[0064] According to the suspension of the present invention, however, a coating material 30 is filled into the groove 25 between the inner side surface 20 b of the recess 20 and the damper 14 after the damper 14 is affixed to the bottom surface 20 a of the recess 20 , as shown in FIG. 6B . Thereupon, the side surface of the damper 14 is covered by the coating material 30 . Thus, the usage of the coating material 30 can be reduced compared to the conventional case.
[0065] FIG. 8A shows a load beam blank 41 comprising a plurality of load beams 10 ′ and scrap portions 40 . The load beam blank 41 is formed by, for example, etching. Each recess 20 should preferably be formed by partial etching as the load beam blank 41 is etched. Further, the recess 20 may be formed by pressing. Alternatively, as shown in FIG. 6C , each load beam 10 ′ may be formed by superposing two thin plates 50 and 51 on each other, and each recess 20 may be formed by boring a through-hole 52 greater than each damper 14 in the one plate 50 .
[0066] Each load beam 10 ′ is bent with the damper 14 affixed to the bottom surface 20 a of the recess 20 . In order to avoid interference between the bending tool and damper 14 , a depth D 1 ( FIG. 2 ) of the recess 20 should preferably be made greater than a thickness T 1 of the damper 14 . In this embodiment, the recess 20 is formed in that one of the obverse and reverse surfaces of the load beam 10 ′ which is located opposite from a flexure 12 . Alternatively, however, the recess 20 may be formed in the same surface as the flexure 12 .
[0067] The following is a description of processes for manufacturing the suspension with the load beam 10 ′. As shown in FIG. 7A , the recess 20 is formed in the load beam 10 ′ that is not yet bent. As shown in FIG. 7B , thereafter, the damper 14 is opposed to the bottom surface 20 a of the recess 20 . Then, the damper 14 is affixed to the bottom surface 20 a of the recess 20 , as shown in FIG. 7C . Thereafter, the rib bending and load bending of the load beam 10 ′ are performed by means of the bending tool, e.g., a die set (not shown).
[0068] According to this embodiment, the damper 14 is affixed to the unbent flat load beam 10 ′ ( FIGS. 7A to 7C ). Therefore, rib-like opposite side edge portions 10 a can be prevented from interfering with a device for affixing the damper 14 . Thus, the operation for affixing the damper 14 to the load beam 10 ′ can be automated more easily than in the case of the conventional suspension ( FIG. 1A ).
[0069] As shown in FIG. 8A , the continuous load beam blank 41 comprising the plurality of load beams 10 ′ may be formed by etching. As shown in FIG. 85 , in this case, the damper 14 should be affixed to the recess 20 of each load beam 10 ′ of the load beam blank 41 . By doing this, the damper affixing operation can be automated with higher speed and accuracy and less deformation, so that the operation efficiency can be further improved.
[0070] The present invention is not limited to the embodiment described herein, and its constituent elements may be embodied in various forms without departing from the scope or spirit of the invention. Further, the invention is also applicable, to suspensions of other disk drives than hard disk drives.
[0071] Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents. | A suspension for supporting a magnetic head is provided with a load beam formed of a thin-plate spring. A recess for accommodating a damper is formed in the load beam. The damper is affixed to a bottom surface of the recess. | 8 |
TECHNICAL FIELD
[0001] The present invention relates to a method and system for detecting a vehicle rollover or dangerous situations that may precede a rollover of a vehicle.
BACKGROUND OF THE INVENTION
[0002] The purpose of the rollover detection system is activation of protection devices such as seat belts pretensioners, pop-up rollover bars or air bags, especially air bags protecting occupants during rollover accident.
[0003] There are number of ways for detecting rollover events. The most of the current systems use angular rate sensor (ARS) for calculating vehicle angle with respect to the horizontal plane. In such solutions, the algorithm numerically integrates the time dependent roll rate signal and provides the roll rate based angle as an output. As the ARS sensor signal always contains some errors (e.g. sensor drift, noise, etc.), these errors are accumulated during the integration process. As a result, the long term integration of ARS signal, without additional corrective mechanisms, can not be relied upon in determining the car inclination.
[0004] Known solutions, e.g. disclosed in U.S. Pat. No. 6,618,656, which are incorporated herein by reference, provide kinds of blending of the roll rate based angle with an accelerometer based angle. Nevertheless even in the case of using two independent accelerometers, during specific driving scenarios the averaged accelerometer based angle may contain errors.
SUMMARY OF THE INVENTION
[0005] The aim of the present invention is to provide an inexpensive and reliable solution for detecting the vehicle rollover using only the angular rate sensor (ARS) and lateral Low-G sensor (YLG) signals, as well as a few additional signals provided by external vehicle control systems, installed in almost all modern vehicles, and available at the vehicle communication bus.
[0006] The roll rate based angle is more accurate in case of quick car rotations. On the other hand accelerometer based angle is more accurate during slow and steady changes of car position as angle is calculated on the basis of the short term sensor measurements and does not depend on previous measurements, as opposite to the roll rate based angle. Consequently, another aim of the invention is to provide the reliable trade-off between these oppositions.
[0007] According to the invention there is provided a method for detecting a vehicle rollover, comprising the steps of (a) measuring the set of input signals including at least vehicle velocity, vehicle steering angle, vehicle lateral acceleration, and vehicle roll rate; (b) integrating the vehicle roll rate to obtain the vehicle roll angle increment; (c) determining the vehicle state on the basis of the input signals; (d) determining the vehicle estimated lateral acceleration, corresponding to the vehicle true roll angle, on the basis of at least the vehicle state, vehicle lateral acceleration and the centrifugal acceleration; (e) determining the vehicle estimated roll angle on the basis of at least the vehicle roll angle increment, the vehicle estimated lateral acceleration and the vehicle state; and (f) generating an output activation signal determining a possibility of rollover of the vehicle, as a function of at least vehicle estimated roll angle and the vehicle roll rate.
[0008] Advantageously the vehicle state and/or other signals are additionally used as inputs for said function generating an output activation signal.
[0009] The vehicle state is preferably chosen from at least parking, straight driving and turning.
[0010] The calculation of the centrifugal acceleration performed in step (d) of determining the vehicle estimated lateral acceleration, is preferably based on the vehicle velocity and the vehicle turn radius.
[0011] In such a case the turn radius is preferably calculated as a function of a steering angle, vehicle parameters and vehicle velocity.
[0012] Said function generating an output activation preferably comprises a sequence of serially executed steps of checking whether input values are simultaneously higher than the boundary values defined separately for each step, said sequence starting with the higher boundary values.
[0013] Alternatively said function generating an output activation signal may be a lookup table.
[0014] A method according to the invention preferably further comprises the step of activation at least one protection device for an occupant of a vehicle.
[0015] According to the invention there is provided a system for detecting a vehicle rollover implementing the method described above.
[0016] The method and system of the present invention guarantee accurate calculation of car roll angle during all recognizable driving conditions. As initial roll angle error calculated by the algorithm (before the rollover event occurrence) is vital for accurate prediction and detection of rollover event, the invented method results in exceptional rollover detection performance and enables to avoid false triggering.
[0017] The method and system of the invention is efficient and inexpensive. It requires only two sensors i.e. ARS and YLG; the rest of the signals, which are usually available in each modern vehicle are retrieved from the communication bus thereof.
[0018] By introducing the vehicle state or driving scenario parameter, the absolute angle error of the algorithm operation can be greatly reduced, as the algorithm features some sort of an “artificial intelligence”.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The invention is presented below with reference to exemplary embodiment and drawings on which:
[0020] FIG. 1 is a block and circuit diagram of one embodiment of a microcontroller realizing the method of the present invention;
[0021] FIG. 2 is a flowchart of an embodiment of a block 3 from FIG. 1 ;
[0022] FIG. 3 is a flowchart of an embodiment of a block 5 from in FIG. 1 ;
[0023] FIG. 4 is a flowchart of an embodiment of a block 6 from in FIG. 1 ;
[0024] FIG. 5 is a graphical figure plotting time dependent angle adjustment executed by an embodiment of a block 6 shown in FIG. 4 ;
[0025] FIG. 6 is a flowchart of an embodiment of a block 7 from FIG. 1 ;
[0026] FIG. 7 is a further graphical figure showing the rollover confidence estimation as executed in an embodiment of a block 7 shown in FIG. 6 ; and
[0027] FIG. 8 is a flowchart of another embodiment of a block 7 from FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0028] An exemplary microcontroller 8 implementation of the present invention is shown in FIG. 1 , where all the essential features of the invention are implemented as a modular system comprising seven electronic circuits or processing blocks 1 to 7 , cross linked with each other as described below. It is to be understood, however that other, in particular software implementations of the invention are possible as well.
[0029] The microcontroller 8 comprising processing blocks 1 to 7 is connected to vehicle lateral acceleration (YLG) sensor 9 and vehicle roll rate (ARS) sensor 10 . Furthermore, the microcontroller 8 receives the vehicle velocity (V), additional high-g lateral acceleration (YHG) and vehicle steering angle (SA) signals from the vehicle communication bus 11 .
[0030] The preferable ranges and resolutions of the ARS and YLG sensors are presented in the Table 1 below.
TABLE 1 Sensor Sensor Range Resolution ARS −200 . . . 200 deg/s 0.5 deg/s YLG −2 . . . 2 g 0.01 g
[0031] Blocks 1 and 2 are pre-processing blocks. Block 1 processes steering angle, vehicle velocity and other signals delivered by other car subsystems, received from the vehicle communication bus, while ARS and YLG sensors 9 and 10 are connected to the block 2 . The term “pre-processing”, as used herein, involves noise removal, signal drift removal, low pass filtering, scaling and/or other actions on input signals, as well as their combinations. Pre-processing involves also testing the accessibility and validity of ranges of the input signals. All operations of the above kind are well known to persons skilled in the art.
[0032] After pre-processing all signals are delivered to the block 3 , which determines the vehicle state, which is a characteristic feature of the present invention.
[0033] An exemplary and relatively simple implementation of the block 3 is presented in a form of a flowchart in FIG. 2 . The input signals 31 of this block are vehicle velocity (V), vehicle lateral acceleration, as determined by lateral low-g sensor (YLG), vehicle roll rate (ARS) and vehicle steering angle (SA). The output of the block 3 is the vehicle state chosen from PARKING, STRAIGHT_DRIVING, TURNING or UNIDENTIFIED.
[0034] As shown, the state is preliminary set to UNIDENTIFIED. Subsequently the algorithm checks if the conditions corresponding to a specific state, other than UNIDENTIFIED are fulfilled. If the vehicle velocity is less than V min and simultaneously the vehicle lateral acceleration is less than 0.3 g and the vehicle roll rate is less than 10 deg/s, the decision block 31 is activated. The activation of the block 31 is verified by the timer block 34 for a predetermined period. The verification denotes checking if the activation conditions are constantly met in this period, and if so the vehicle state is eventually set to PARKING.
[0035] In case the vehicle velocity is greater than V min two other vehicle states may be determined. Firstly, if the vehicle lateral acceleration is less than 0.3 g, the vehicle roll rate is less than 20 deg/s and the vehicle steering angle is less than 3 deg the activation of the decision block 32 verified by the timer block 35 for a predetermined period, sets the state to STRAIGHT_DRIVING. Secondly, if simultaneously the YLG is greater than 0.2 g, the ARS is less than 15 deg/s and the SA is greater than 3 deg the vehicle state determined by decision block 33 and verified by the timer block 36 shall indicate the TURNING state.
[0036] In a situation other than limited by the conditions indicated above the block 3 shall return the preliminary set UNIDENTIFIED state.
[0037] Predetermined periods or time windows of timer blocks 34 , 35 and 36 , are set in this embodiment to two seconds. In other words, if the activation conditions of a given block 31 , 32 or 33 are fulfilled during the last two seconds before making the assessment, the corresponding output STATE is set. Obviously the time windows may also be set individually for each timer block. The algorithmic implementation of this operation is relatively easy for persons skilled in the art.
[0038] Other embodiments of a block 3 may recognize much more vehicle states (e.g. quick slalom, side slide, spinning), as the vehicle state assessment performed by block 3 is a key factor of the whole system reliability. Consequently the block 3 is the most important and most complex part of the rollover detection system of the present invention that for a given vehicle should be implemented individually. Other signals such as weight, geometry and type of the vehicle, installed protection devices, centre of gravity and presence of other rollover detection systems may also be used by various algorithms implementing the block 3 function.
[0039] The vehicle state determined by block 3 becomes the input value of the block 5 , example embodiment of which is shown in FIG. 3 . The aim of this block is to calculate the vehicle estimated lateral acceleration (YLG_EST), corresponding to the vehicle true roll angle. On the base of the vehicle state, block 5 corrects the measured lateral acceleration value (YLG) by removing the factors not indicating the true vehicle position and originating from the vehicle movement.
[0040] As shown, if the vehicle state is PARKING the YLG_EST value is calculated by the block 51 as the moving average value of the YLG signal during the last two seconds.
[0041] If the vehicle is driving straight (STATE=STRAIGHT_DRIVING), the YLG_EST value is calculated by the block 52 as the low pass filtered value of the YLG signal.
[0042] If the vehicle state is UNDENTIFIED the YLG_EST is set by the block 54 to zero.
[0043] When the vehicle turns, the body thereof is subjected to centrifugal force. The centrifugal force influences the measured lateral acceleration, which now becomes a combination of factual vehicle lateral acceleration and the centrifugal acceleration. As only the first one originates from the vehicle inclination and may indicate the rollover event, it is desirable to introduce correction mechanisms in order to remove the centrifugal factor from the measured acceleration value.
[0044] The centrifugal acceleration may be calculated as:
YLG_TURN= V 2 /R
where V is the vehicle linear velocity, accessible on the vehicle communication bus and R is the turn radius. The turn radius may be easily expressed as a function of a steering angle. However, mainly, due to the vehicle sliding, which intensity in turn depends not only on vehicle velocity but also on such parameters as vehicle weight, vehicle velocity, suspension stiffness, etc., this function is rather empirical than analytical and should be determined individually for a given vehicle.
[0045] Obviously for the same steering angle there may be more than one value of turn radius. The turn radius function may thus be stored in the system memory as a look-up table, example of which is presented below in Table 2.
TABLE 2 V = 10 km/h V = 60 km/h V = 80 km/h SA [deg] R [m] R [m] R [m] 5 50 50 50 10 40 42 43 15 30 34 35 20 20 26 27
[0046] The above relation may also include other parameters, accessible at the vehicle communication bus. In such a case, the above table shall be a multidimensional array. As the look-up table contains only some discrete values, to provide the turn radius for different conditions, one may alternatively use a simple interpolation function.
[0047] After determining the centrifugal acceleration during the vehicle turn, the true lateral acceleration can be easily estimated by the block 53 as:
YLG_EST=YLG−YLG_TURN
[0048] It should be noted that other implementations of the block 5 may take into account other vehicle states determined by implementations of block 3 different than the one described with reference to FIG. 2 . For example, if the block 3 sets the vehicle state to quick slalom, the lateral acceleration shall be set by the block 5 to 0 m/s 2 corresponding to 0 deg of the accelerometer based angle (what is partially true as the car quickly rotates around 0 deg), and such value shall be transmitted to block 6 as estimated lateral acceleration signal. Since during slalom driving, such quick changes of a vehicle angle may be correctly calculated only by ARS sensor, the algorithm shall determine the rollover confidence only on the base of the ARS sensor signals, simultaneously ignoring the lateral acceleration.
[0049] The first preliminary stage of calculating of the estimated angle, performed by the block 4 shown in FIG. 1 , is a multiplication of a measured vehicle roll rate (ARS) in a predefined time window ΔT to obtain the vehicle roll angle increment (ANG_ARS_DLT) in this predefined time window. This operation is known from the state of art and can be represented by the following formula:
ANG_ARS_DLT=ARS·Δ T
[0050] The time window (ΔT) is preferably within the range of 1 to 20 ms. The lower the ΔT, the more accurate calculations and more microcontroller throughput consumption. Practical value of ΔT should be a result of an engineering trade off.
[0051] As the ARS signal always contains some errors, the integration (or multiplication in the simplest case) thereof accumulates these errors and the roll angle obtained this way should not be used for determining the car inclination. Instead, as shown in FIG. 1 , the estimated roll angle (ANG_EST) calculation is performed by block 6 , the inputs of which are connected to block 4 providing the measured vehicle roll angle increment (ANG_ARS_DLT), block 5 providing the estimated lateral acceleration value (YLG_EST) and block 3 providing the vehicle state (STATE). The angle calculated by block 6 is therefore much more accurate than the roll rate based angle, accelerometer based angle or even simple combination of both angle types as disclosed in approaches known from the state of art.
[0052] An example implementation of the block 6 is shown in FIG. 4 as a flow chart. The block 6 is a closed loop and works periodically in such a manner that in calculating the estimated roll angle (ANG_EST) for each iteration, the value of ANG_EST obtained at the previous iteration is used. At the initialization of the whole rollover detection system, the output/input value being the estimated roll angle (ARS_EST) is set in step 61 to zero, as the true roll angle of the vehicle is not known at this point yet.
[0053] Each iteration begins with calculating at the step 62 the accelerometer based angle (YLG_ANG) defined as:
YLG_ANG=arcsin (YLG_EST/ g ).
[0054] Decision blocks 63 and 64 limit the accelerometer based angle to reasonable range of values that may practically arise. If the YLG_ANG value is greater than YLG_ANG_MAX or lower than YLG_ANG_MIN, i.e. out of the range boundaries, it shall be truncated by the corresponding decision block 63 or 64 and set in corresponding steps 65 or 66 to the boundary values, which in this example amount YLG_ANG_MAX=+20 deg and YLG_ANG_MIN=−20 deg.
[0055] Subsequently, in block 67 , the actual vehicle roll angle increment (ANG_ARS_DLT), calculated by the block 4 , is added to the estimated roll angle value (ARS_EST) from the previous iteration and result is written to temporary variable (ARS_EST_TMP).
[0056] Blocks 68 , 69 and 610 are activated correspondingly for a given vehicle state, setting the angle modification value (MOD_ANGLE) accordingly. The MOD_ANGLE controls the rate of tracking of the ANG_EST value to the YLG_ANG value during the algorithm execution, that shall be described later with reference to FIG. 5 , setting the appropriate tracking parameter MOD_ANGLE to ANGLE_STEP_ 1 (0.05 deg), ANGLE_STEP_ 2 (0.03 deg), ANGLE_STEP_ 3 (0.02 deg) or ANGLE_STEP_ 4 (0.1 deg) in dependence of the vehicle state.
[0057] Blocks 615 , 616 , 617 , 618 and 619 implement the tracking of the YLG_ANG angle by the ANG_EST. The rate of this operation depends on the value of the MOD_ANGLE. If temporary value (ARS_EST_TMP) exceeds the accelerometer based angle (YLG_ANG), the actual estimated roll angle is calculated according to the formula ANG_EST=ANG_EST_TMP−MOD_ANGLE, whereas if temporary value (ARS_EST_TMP) is below the accelerometer based angle (YLG_ANG), the actual estimated roll angle is calculated according to the formula ANG_EST=ANG_EST_TMP+MOD_ANGLE. Otherwise the actual estimated roll angle remains unchanged i.e. ANG_EST=ANG_EST_TMP.
[0058] Timer block 620 transmits the actual estimated roll angle and provides control again to the input of the block 6 with predefined delay. The time period of the block 620 is preferably set within the range of 1 to 20 ms and should equal ΔT in block 4 in order to avoid ARS based angle integration errors.
[0059] The ANG_EST value is delivered to the vehicle communication bus by block 621 .
[0060] FIG. 5 explains the tracking of the YLG_ANG angle by the ANG_EST for a given vehicle state. The tracking process progresses most quickly in the case of an UNIDENTIFIED state ( FIG. 5 a ) where ANG_EST signal approaches zero approximately at the rate of 30 deg/s. Also in the PARKING state ( FIG. 5 b ) the ANG_EST signal is relatively quickly set to the accelerometer based angle (YLG_ANG). During the STRAIGHT_DRIVING state ( FIG. 5 c ), the lateral acceleration (and in consequence YLG_ANG) is considered as accurate, so ANG_EST is also quickly modified. In TURNING state ( FIG. 5 d ) however, the lateral acceleration is influenced by centrifugal force, thus YLG_ANG is not considered as accurate and the ANG_EST signal is corrected the most slowly to avoid introducing mayor errors in angle calculation.
[0061] The final algorithm decision is undertaken by the block 7 , which as the other blocks of the system should be individually designed in dependence of a given vehicle type (e.g. SUV, convertible, truck, etc.), applied safety restraints, etc.
[0062] An exemplary implementation of the block 7 is shown in FIG. 6 . Here the only inputs of the block 7 are the estimated roll angle (ANG_EST) and the vehicle roll rate (ARS). For every iteration, in a sequence of serially executed steps, the decision blocks 71 to 77 checks, whether input values (ANG_EST, ARS) are simultaneously higher than the boundary values (ANG_EST_MAX(I), ARS_MAX(I)) defined separately for each step (I), starting with the higher boundary values. If it happens, the checking process is stopped at a given decision block and the output of the block 7 is a rollover confidence value (100, 90, 80 and 60%) corresponding to this set of input values. In this example the boundary values ANG_EST_MAX are set to 150, 100, 70 and 20 deg/s while the boundary values ARS_MAX are set to 50, 40, 30 and 25 deg. Such an algorithm provides shortening of a decision time and low program memory consumption in case of the microcontroller implementation.
[0063] The output of the block 7 is connected to the triggering block, not shown in FIG. 6 , and additionally to other car systems. The outputs of the triggering block are connected directly to particular protection devices and are activated in response to rollover confidence thresholds defined above. Thus in dependence of the estimated ROL_CONF value, the rollover detection system may deploy an appropriate protection device, e.g. resetable seatbelts in case the confidence is greater than 60%, rollover bars in case the confidence is greater than 80% and airbags if the confidence is higher than 90%.
[0064] FIG. 7 shows a mode of operation of a block 7 . As shown, the ROL_CONF thresholds are represented by semi-rectangular plane sectors delimited by appropriate boundary values ANG_EST_MAX(I) and ARS_MAX(I).
[0065] FIG. 8 shows another more advanced implementation of the block 7 . Reference numerals of the elements corresponding to the embodiment shown in FIG. 6 remain the same. In this example, the final algorithm decision is undertaken by block 7 on the basis of the estimated roll angle (ANG_EST), the vehicle roll rate (ARS), vehicle state (STATE) as well as additional signals from vehicle communication bus, i.e., vehicle velocity (V) and lateral acceleration (YHG), obtained from auxiliary lateral High-G sensor. It is worth noting that lateral High-G sensors are commonly used by front/rear/side crash detection systems and thus their signal is readily available in almost every car.
[0066] In the first step the decision block 710 checks if the vehicle speed exceeds predefined threshold value (V min ). If so, the rollover confidence is determined on the base of the values of ARS and ANG_EST in the same manner as described with reference to FIG. 6 . Subsequently, if such calculated rollover confidence is greater than zero, it may be modified on the base of the other signals mentioned above by group of blocks 712 to 717 . The modification may comprise the multiplication of the rollover confidence by appropriate coefficient (e.g. 1.1 or 1.3) in dependence of the vehicle speed and/or vehicle lateral acceleration exceeding the predefined thresholds of the decision blocks 712 , 714 and 716 . If the vehicle velocity is below the predefined threshold value (V min ), in which case the rollover is rather unlikely, the output of the block 7 is directly set to zero to suppress the rollover detection. Such a situation may happen e.g. in case of painting of the car with a key left in the ignition lock. | The present invention relates to a method and system for detecting a vehicle rollover or dangerous situations that may precede a rollover of a vehicle. The method comprises the steps of (a) measuring the set of input signals including at least vehicle velocity, vehicle steering angle, vehicle lateral acceleration, and vehicle roll rate; (b) integrating the vehicle roll rate to obtain the vehicle roll angle increment; (c) determining the vehicle state on the basis of the input signals; (d) determining the vehicle estimated lateral acceleration, corresponding to the vehicle true roll angle, on the basis of at least the vehicle state, vehicle lateral acceleration and the centrifugal acceleration; (e) determining the vehicle estimated roll angle on the basis of at least the vehicle roll angle increment, the vehicle estimated lateral acceleration and the vehicle state; and (f) generating an output activation signal determining a possibility of rollover of the vehicle, as a function of at least: vehicle estimated roll angle and the vehicle roll rate. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to clipboards, and more particularly, to a multi-function clipboard and report apparatus for law enforcement officers, including the provisions for report forms, lights, a gun, and other related apparatus.
2. Description of the Prior Art
For convenience in taking notes, filling out forms, and the like, in either the standing position or sitting position, the ordinary, simple clipboard is extremely useful. A simple clipboard comprises a relatively firm, flat or planar surface on which paper is disposed and a spring clip of some type to hold or secure the paper to the surface of the board and to maintain the paper in a desired orientation on the board. Such relatively simple clipboards have been in use for many years.
Law enforcement officers perform several different functions during their normal course of activity. Filling out accident investigation forms, filling out traffic or warning tickets, interviewing witnesses, and interviewing suspects are but a few of the functions performed by law enforcement officers and for which they are required to write either on a form or from a pad of forms. Typically, many different forms are carried in each law enforcement patrol car and the officer simply selects the appropriate form which he anticipates using as he leaves his patrol vehicle to either approach another vehicle or to approach individuals or groups of individuals. The officer must return to his vehicle each time a different form is required.
Night patrols bring new problems. In addition to the usual various forms which they use, they must also provide some type of light to illuminate their forms and also to view individuals, vehicles, or the ground, a roadway, or the like. In other words, in addition to accomplishing the normal duties that are accomplished during the day, light must additionally be supplied at night. Typically, an officer tries to hold a flashlight in one hand while he writes with the other hand, or he tries to hold a flashlight under his arm while using one hand to steady or hold a clipboard or form pad while he writes with the other hand.
One obvious solution to help alleviate some of the problems of the law enforcement officer is to provide a light source to illuminate the clipboard while he writes. Clipboards with lights have been used for many years by aircraft crews. The particular type clipboard used by pilots comprises the so-called knee clipboard which comprises a small clipboard secured to the thigh of the user by a strap. The light source in the clipboard is typically a small bulb powered by C or D size flashlight batteries. This type of light source may also be provided for a hand-held clipboard used by a law enforcement officer, but it does not answer the need for a flashlight or spotlight type of light source.
One of the perils or hazards that each law enforcement officer faces, particularly at night, is the problem of being attacked by one or more assailants while he has both hands busy holding a clipboard and a flashlight under his arm, and writing at the same time. With both hands occupied, it is difficult to use a service revolver or the like in a sudden emergency. In addition to a service revolver, law enforcement officers generally carry some type of chemical weapon, such as chemical mace, which, while non-lethal, is generally effective in controlling belligerent assailants or suspects. However, with his hands occupied, it is again difficult for an officer to use such non-lethal weapons in an emergency.
In a recent year, about eleven percent of the fatalities involving law enforcement officers occurred during traffic pursuits and stops. It is obviously not possible to determine whether any of the fatalities could have been prevented had the officers been equipped with the apparatus of the present invention. However, it is obvious that apparatus of the present invention would have given the officers an extra edge which may have made substantial difference. Such apparatus may have been useful in several different areas, such as the discharge of tear gas at a potential assailant, using the light to illuminate the interior of a vehicle and/or to partially blind any occupant/potential assailant in the car. Law enforcement officers are also periodically in need of a safety shield to ward off blows or to protect themselves from projectiles such as bullets, rocks, and the like. Such shields are in use currently in the form of bulletproof vests and riot shields, but shields are not immediately available to the officers.
In addition to the various problems noted above which confront an officer, there are other situations in which an officer finds himself where additional apparatus in a convenient package may be of great value, such as a tape recorder to record comments, testimony, and the like, of various individuals and other various circumstances. Obviously, tape recorders are well known in the art and may range in size from very small ind inexpensive to rather large, cumbersome, and expensive units. The cost and complexity of such tape recorders may vary substantially. However, for law enforcement work, primarily concerned with on-the-spot comments or testimony, a relatively small tape recorder is sufficient, if such tape recorder is handy.
The comments made above with respect to a tape recorder also apply to a camera. The taking of a photograph may be very important to an officer under a variety of possible circumstances. Future identification of an individual, or an immediate view of the occupants of an automotile, and other circumstances may arise in which an officer has a need for the ability to take a picture virtually immediately and "on the spot."
With respect to the above-noted situations or problems that confront law enforcement personnel, there has not been heretofore a single apparatus which cooperatively provides all or even some of the solutions to the various problems as discussed. The apparatus of the present invention may combine all or some of the apparatus, depending on the particular needs or emphasis desired by individual law enforcement officers or agencies. The apparatus disclosed and claimed herein provides an "extra edge" for efficient, safe law enforcement.
SUMMARY OF THE INVENTION
The apparatus disclosed and claimed herein comprises a multi-purpose or multi-function clipboard unit having a plurality of compartments for holding various papers or documents needed in law enforcement work, and the apparatus includes provisions for two separate light sources, one for illuminating the surface of the board on which an officer may write and a second light source for providing a spotlight type light source, and the apparatus further provides a gun for firing a tear gas cartridge or a bullet (projectile) cartridge, or a canister for spraying a chemical. A tape recorder and a camera may also be included in the apparatus, and all of the separate elements may be actuated virtually instantaneously by an officer holding the clipboard.
Among the objects of the present invention are the following:
to provide new and useful clipboard apparatus;
to provide new and useful clipboard apparatus including a plurality of storage compartments;
to provide new and useful apparatus having two separate light sources;
to provide new and useful cartridge firing apparatus;
to provide new and useful apparatus comrising the functions of storing paper and forms with the utilization of the forms;
to provide new and useful apparatus for illuminating a writing surface and for illuminating the area adjacent to the writing surface;
to provide new and useful apparatus for firing different types of cartridge;
to provide new and useful clipboard apparatus including a tape recorder and a camera; and
to provide new and useful clipboard apparatus for shielding the user of the apparatus from thrown or fired objects and missiles.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of clipboard apparatus of the present invention.
FIG. 2 is a view in partial section of the apparatus of FIG. 1 taken generally along line 2--2 of FIG. 1.
FIG. 3 is a view in partial section of a portion of the apparatus of FIG. 2 generally along line 3--3 of FIG. 2.
FIG. 4 is an enlarged view in partial section of a portion of the apparatus of FIG. 3 taken generally along line 4--4 of FIG. 3.
FIG. 5 is an enlarged view of a portion of the apparatus of FIG. 4 taken generally along line 5--5 of FIG. 4.
FIG. 6 is an enlarged perspective view of a portion of the apparatus of FIGS. 2 and 3.
FIG. 7 is a perspective view of an alternate embodiment of a barrel usable with the apparatus of FIG. 2.
FIG. 8 is a perspective view of the apparatus of FIG. 1 with a portion of the apparatus of FIG. 1 removed showing compartments within the clipboard apparatus.
FIG. 9 is a view in partial section of a portion of the apparatus of FIG. 8 taken generally along line 9--9 of FIG. 8.
FIG. 10 is a schematic diagram of the electrical circuitry and the switches usable with the apparatus of the present invention.
FIG. 11 is an enlarged detail view of a portion of the apparatus of the present invention.
FIG. 12 is a view of the apparatus of FIG. 11 taken generally along line 12--12 of FIG. 11.
FIG. 13 is a perspective view of an alternate embodiment of the clipboard apparatus of the present invention.
FIG. 14 is an enlarged view in partial section of a portion of the apparatus of FIG. 13, taken generally along line 14--14 of FIG. 13.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a perspective view of clipboard apparatus 10 of the present invention. The apparatus includes a generally rectangular base 20 which is compartmentalized, as illustrated below in conjunction with FIG. 8. The rectangular base 20 is closed by a sliding top 50. The sliding top 50 comprises the clipboard surface on which the user writes. Appropriate papers or documents, or the like, are secured to the top 50 by a spring-loaded clip 52. The clip 52 is of a well-known design which is secured to the top and a portion of which pivots away from the top under the finger or hand pressure of the user to allow paper, forms, or the like to be placed beneath the pivoting portion of the clip 52. When the clip is released, a spring force biases the clip downwardly to securely hold the paper onto the top 50.
The base 20, with the top 50, may be of any appropriate dimensions with respect to its length, width, and height. The height or thickness of the base will vary according to the equipment or accessories contained therein. The length and width may also vary according to the accessories included in the apparatus, and may typically be of either of the popular sizes, letter size or legal size. Obviously, any dimensions as desired may be used.
The base 20 includes a right wide wall 22, a left side wall 24, a back or lower end wall 26, and a forward end or portion 40. The right and left side walls 22 and 24 each include a top rim or edge 23 and 25, respectively. The slide or top 50 is disposed in a groove 30 which extends inwardly into the sides 22 and 24 to receive the slide 50. The top rims or edges 23 and 25 accordingly extend above the top surface of the slide 50. At the forward or front end of the base 20, at the juncture of the base and the forward end 40 is a top rim or edge 29 which extends between the top rims 23 and 25. The top rims 23, 29, and 25 are continuous. The back end wall 26 is lower than the sides 22 and 24 to accommodate the top or slide 50, and also to accommodate a subtray 290.
For convenience in moving the slide 50, an extension 54 extends rearwardly of the slide and an aperture 56 extends through the extension 54. The aperture provides a convenient finger or thumb hold which a user may use in moving the slide 50 in the groove 30 of the base 20.
The tray 290 is disposed beneath the top 50 in a groove 58 which is substantially identical to the groove 30. The groove 58 is disposed below, and spaced apart from, the groove 30. The subtray 290 is an auxiliary tray which may be used to supplement the compartments described in FIGS. 8 and 16 and discussed in detail in conjunction therewith. The tray 290 includes a plurality of relatively shallow depressions 292 in which may be disposed papers, forms, and the like. The subtray 290 may be pulled out of the base 20 independently of the slide 50 to provide quick and easy access to forms. In the alternative, slide 50 may be pulled out to provide access to the forms in the tray 290.
The tray 290 includes an extension 294 with an aperture 296 extending through the extension. The extension and aperture are for moving the tray relative to the base. They perform the same functions as the extension 54 and aperture 56 of tray 50. The extensions 54 and 294 are offset vertically and horizontally from each other, but are relatively close so they may be moved together by a user to provide access for the compartments in the base.
The forward end 40 of the clipboard apparatus 10 extends upwardly vertically to a height greater than that of the base 20. The reason for the vertical height is to accommodate the light and gun portions of the apparatus. The forward end includes a generally curved top portion 42 which extends upwardly from the front edge 29. The curved portion 42 extends to, and terminates at, a forward or front wall 44 which is substantially parallel to the lower or back end wall 26. The generally smoothly extending curvature of the top portion 42 is broken by a rearwardly extending hood 46 which extends rearwardly. The hood 46 includes a glass plate 48 which is disposed toward the top or slide 50. A lamp is disposed within the hood 46 and, when an appropriate electrical circuitry, controlled by switch 60 is closed, the lamp illuminates and shines through the lens 48 onto the top surface of the slide 50 to thus illuminate any forms, paper, or the like secured to the top by the clip 52.
The lamp within the hood 46, with its reflector, is designed to be of the floodlight type, rather than a spotlight type, to illuminate as wide an area of the top 50 as is practical.
The switch 60 controls also a second light, which is a spotlight 70. The spotlight 70 is located within the forward end 40 of the clipboard apparatus, and is directed substantially parallel with the longitudinal axis of the forward end 40, which is laterally with respect to the sides 22 and 24 of the clipboard apparatus. Included with the spotlight 70 is a ring or bezel 72, a portion of which extends outwardly from the side 22, and a portion of the bezel 72 is externally threaded to mate with an internally threaded portion of the forward end 40, as may be seen in FIG. 2. The spotlight shines away from the apparatus.
Beneath the spotlight 70 is a gun 120. The action for the gun 120 is disposed within the forward end 40 of the clipboard apparatus 10. A knurled portion 124 of a barrel 122 extends slightly outwardly from the side 22 of the clipboard apparatus 10.
Extending upwardly from the top portion 42 of the forward end 40 of the clipboard apparatus 10 is trigger mechanism 220 for firing the gun 120. Also on the top 42 of the forward end 40 is a safety 250 for the gun 180. A cocking lever or pin 212 extends outwardly from the front end wall 44 of the forward end 40. The details of the gun 120 will be discussed in detail below in conjunction with FIGS. 2, 3, 4, 5, and 6.
FIG. 2 is a view in partial section of a portion of the apparatus of FIG. 1 taken generally along line 2--2 of FIG. 1. It comprises a view in partial section through the forward portion 40 of the clipboard apparatus 10.
The forward portion 40 of the clipboard apparatus 10 is preferably of generally solid construction, and preferably made, with the rest of the base, of a relatively strong material, such as a polycarbonate marketed under the trademark "Lexan." The entire base 20, including the forward portion 42, may be molded out of such material in a single operation. Appropriate bores are disposed within the forward portion 40, as shown in FIG. 2.
At the upper left hand portion of the forward end 40, as viewed in FIG. 1 and in FIG. 2, is a bore 90. The bore 90 extends transversely of the clipboard apparatus, or longitudinally with respect to the forward portion 40. The bore 90 receives a pair of batteries 84 and 85 which comprise a power source, or a part of a power source, for the floodlight 48 and the spotlight 70. Within the base 90 is appropriate circuitry required for both of the lights, such as an electrical contact 92 which makes electrical contact with the positive terminal or battery 85. The batteries 84 and 85 are held within the bore 90, and against the electrical contact 92, by a battery end cap 80, which includes external threads to engage in internally threaded portions of the bore 90. An electrically conductive spring 82 extends between the end of battery 84 and the end cap 80 to provide the appropriate and necessary spring bias to maintain electrical contact between the batteries 84 and 85 and the spring also provides or comprises a negative terminal or electrical contact for the electrical circuitry within the apparatus. Additional batteries may be connected in series with batteries 84 and 85 by appropriate electrical conductors to provide additional voltage for the lights and other accessories in the clipboard apparatus.
Disposed above the batteries 84 and 85 in switch 60, which comprises a slide switch making appropriate mechanical contact with electrical conductors to make and break (open and close) electrical circuitry for the lamps. The electrical circuitry involved will be discussed in detail below in conjunction with FIG. 10.
At the right hand end of the forward portion 40 of the clipboard apparatus 10 is the spotlight 70. The spotlight 70 includes the bezel 72, a portion of which extends outwardly from the side 22 of the base 20 (see FIG. 1) and which includes an externally threaded portion which matingly engages in an internally threaded portion of the forward end 40 of the clipboard apparatus. The bezel 72 holds in place within the forward end 40 a reflector 74 which in turn is connected to a lamp 78. A lens 76 is held in place against the reflector 74 by the bezel 72. Appropriate electrical circuitry connects the lamp 78 with the batteries 84 and 85 through the switch 60, as explained below in conjunction with FIG. 10.
Beneath the batteries 84 and 85 and the lamp 70 is a transversely extending groove 110. The groove 110 is transversely extending with respect to the clipboard apparatus 10, but longitudinally extending with respect to the forward end 40 of the clipboard apparatus. The bore 110 includes internal threads at one end, the left end as shown in FIG. 2. The bore 110 communicates with, and is axially aligned with, a second bore 112 which extends from the right-hand portion of the front end 40, as shown in FIG. 2. The bore 112 is actually a continuation of the bore 110 but may be of a reduced diameter, as shown in FIG. 2.
Within the bore 112 is the barrel 122 of the gun 120. Within the communicating bore 110 are other components or elements of the gun 120, as discussed below. The bore 110 may include an appropriate slot or keyway for aligning a cylinder received in the bore.
The barrel 122 includes a knurled portion 124 which extends outwardly from the side 22 of the base 20, as viewed in FIG. 1 and as also shown in FIG. 2. The knurled portion 22 is of a greater diameter than the bore 112 in which the barrel 122 is disposed. The knurled portion accordingly comprises an external portion of the barrel and its purpose is to allow the barrel 122 to be removed from the clipboard apparatus for loading and unloading the cartridge, as explained in detail below. When inserted into the bore 112, the knurled portion 124 preferably seats against the side 22 of the base 20.
The barrel 122 includes a bore 126 which may include appropriate lands and grooves (rifling), such as is well-known in the art. The barrel 122 also includes external threads 128 at one end of the barrel remote from the knurled portion 124. The external threads matingly engage internal threads 146 of a cylinder 140 to secure the barrel 122 to the clipboard apparatus 10. A counterbore 130 is disposed on the end of the barrel adjacent the threads 128. The counterbore 130 is coaxial with the bore 126 and it receives a cartridge. The longitudinal axis of the barrel 122 is generally parallel to the light beam from the spotlight 70. The spotlight thus illuminates the potential general target area for the gun.
The cylinder 140 is disposed within the bore 110. One end of the cylinder 140 is disposed against shoulder 113 defined at the juncture of the bores 110 and 112. The shoulder 113 extends radially inwardly from the bore 110 to the bore 112.
The cylinder 140 is held against the shoulder 113 by a plug 134 which is disposed against a closed end 142 of the cylinder 140. The plug 134 is preferably a solid plug which includes an externally threaded portion 136 which matingly engages an internally threaded portion 111 of the bore 110. The plug 134 also includes a transversely or diametrically extending slot 138 which may receive the blade of a screwdriver, or the like, in order to remove and insert the plug 134, as desired. The cylinder 140 may also include an appropriate key which may matingly engage a keyway or slot in the bore 110 for proper alignment of the cylinder 140, as discussed above.
The cylinder 140 includes an internal bore 144 which extends from the closed end 142 and terminates at an open end at the shoulder 113. At the opened end of the bore 144 are the internal threads 146 which engage the external threads 128 of the barrel 122. An externally threaded block 148 is disposed in the threaded portion 146 of the bore 144 and the barrel 122 is disposed against a face of the block 148. An aperture 150 extends through the block 148. The aperture 150 extends axially through the block 148 concentrically with respect to the block. As shown, the aperture 150 may be a conical shaped bore. The base of a cartridge is held against the face of the block 148 within the counterbore 130 and the aperture 150 allows a firing pin to contact the primer in the base of the cartridge to fire the cartridge.
Within the bore 144 of the cylinder 140, and disposed against the end wall 142, is a holding block 152. The holding block 152 includes a longitudinally extending pair of grooves or recesses 154 and 156 (see FIG. 3) in which are disposed a pair of latching fingers 160 and 170, respectively. The latching fingers 160 and 170 are secured together by a screw 180 which extends through the cylinder 140, the holding block 150, and into the forward end 40. The screw 180 provides a dual function of first, providing a pivot point for the latching fingers, and second, providing an additional securement for holding the cylinder 140 in the bore 110 and to the base 20 of the clipboard apparatus. The screw 180 extends through enlarged, pivoted ends 162 and 172 of the fingers 160 and 170, respectively. Remote from the pivoted ends 162 and 172 are latches 164 and 174, respectively. The latches 164 and 174 are on the ends of the fingers, remote from the screw 180 and the pivoted ends, as discussed. Intermediate the ends of the fingers 160 and 170 are a pair of apertured tabs 166 and 176 which extend inwardly from the respective fingers 160 and 170 towards the opposite finger. A tension spring 184 extends between the two tabs to bias the latching fingers towards each other.
A second screw 182 also extends through the holding block 152 between the fingers and into the forward end 40 of the apparatus. Both screws 180 and 182 help to insure that the gun portion 120 of the clipboard apparatus is held securely within the forward end 40.
Remote from the ends 162 and 172 of the fingers on the holding block 152 is a spring base 196. The spring base 196 includes a spring seat 198 against which is disposed one end of a compression spring 186. The spring 186 is disposed intermediate the latching fingers and between the spring base 186 of the holding block 152 and an appropriate spring seat 204 on a bolt 200.
The bolt 200 is disposed in the bore 144 of the cylinder 140 intermediate the holding block 152 and the block 148. The latching fingers hold the bolt 200 against the bias of the spring 186 until the gun is fired. The bolt 200 includes a firing pin 210. When the latching fingers are released by trigger mechanism 220, the bolt is moved by the force of the spring 186 in the bore 144 against the threaded block 148 and the firing pin 210 moves through the aperture 150 to contact the primer of a cartridge within the bore 126 of the barrel 122.
The trigger apparatus 220 is used to release the latching fingers 160 and 170 to allow the bolt 200 to move in the bore 144 under the bias of the compression spring 186. The trigger mechanism 220 includes a cylindrical portion 222 disposed in a vertically extending bore 114 in the forward end 40 of the base 20 of the clipboard apparatus 10. The bore 114 intersects the bore 110 at substantially a right angle, as shown in FIG. 4. The cylinder 222 includes an externally threaded portion 228 which engages an internally threaded aperture 145 in the cylinder 140 (see FIG. 4). The cylinder 222 includes a longitudinally extending bore 224 in which is disposed a pin 234. A counterbore 226 is disposed coaxially with respect to the bore 224. The counterbore 226 is of a larger diameter than the bore 224 and a compression spring 236 is disposed in the counterbore 226 about the portion of the pin 234 which is located in and extends through the counterbore 226. A button or head 230 is secured to the pin 234. The diameter of the button or head 230 is slightly less than the diameter of the counterbore 226 and the button or head 230 accordingly moves axially in the counterbore 226. The compression spring 236 extends between the underneath portion of the button or head 230 and the lower end of the counterbore 226 to bias the button or head 230, and accordingly the pin 234 secured thereto, upwardly or out of the bore and counterbore.
The button or head 230 includes a circumferentially extending slot 232 in which may be disposed portions of a slide 252 of safety 250. The slide 252 is disposed within a groove 118 which communicates with a recess 116 in which is disposed the safety 250. With the slide engaging the button or head 230, the trigger 220 is unable to move. However, with the slide disengaged from the slot or groove 232, the button 230 may be moved downwardly or inwardly with respect to the forward end 40 and against the bias of the spring 236 to fire the gun.
The firing of the gun is accomplished by means of a cam portion 240 which is secured on one end of the pin 234 remote from the button or head 230. The cam 240 is disposed intermediate the fingers 160 and 170 and, as the button 230 is moved downwardly, the cam 240 biases the fingers 160 and 170 radially outwardly to unlatch the bolt 200. The bolt 200, when unlatched from the fingers 160 and 170, is moved by force of the compression spring 186, and the firing pin 210 moves through the aperture 150 to contact the primer at the base of the cartridge in the barrel 122.
FIG. 3 is a view in partial section of a portion of the apparatus of FIG. 2 taken generally along line 3--3 of FIG. 2. It comprises an enlarged view of a portion of the gun apparatus 120.
The plug 134 is disposed against the closed end 142 of the cylinder 140. The holding block 152 is disposed within the bore 144 (see FIG. 2) of the cylinder 140, and is held in place by screws 180 and 182, as best shown in FIG. 2. The screw 180 extends through the ends 162 and 172 of the fingers 160 and 170, respectively. The screw 182 also extends through the holding block 152 to help secure the holding block and the cylinder 140 to the forward end 40 of the base 20.
The holding block 152 includes a laterally or transversely extending bore 190. The bore 190 communicates with a pair of recesses or grooves 154 and 156 in the holding block 152, which are a part of a larger recess 153. The recess 153 receives the ends 162 and 172 of the fingers 160 and 170, respectively. The fingers 160 and 170 include a pair of inwardly extending tabs 166 and 176 to which is secured a tension spring 184. The tension spring 184 biases the latching fingers 166 and 167 towards each other to maintain a latching hold on the bolt 200.
The holding block 152 includes a circumferentially extending groove 192 which receives te cam 240 of the trigger 220 (see FIG. 2). The spring base 196 is connected to the holding block 152 by connecting rod 194. The cam 240 is thus disposed in the groove 192 between the spring base 196 and the block 152. The spring base 196 includes a spring seat or recess 198 in which is disposed one end of the compression spring 186. The slots 154 and 156, in which the latching fingers 160 and 170, respectively, are disposed, also extends through the spring base 196.
The bolt 200 is of a circular cylindrical configuration, movable in the bore 144 of the cylinder 140. The bolt 200 includes a spring base 202 remotely from the firing pin 210. The spring base 202 includes a spring seat or recess 204 in which is disposed one end of the spring 186. The spring seats or recesses 198 and 204 are substantially identical, and face each other to receive opposite ends of the compression spring 186.
A circumferentially extending groove 206 extends about the spring base 202 to receive latches 164 and 174 of the latching fingers 160 and 170, respectively. The spring base 202 of the bolt 200 includes a pair of axially extending grooves 214 and 216 in which, or through which, are disposed the latching fingers 160 and 170, respectively.
The firing pin 210 extends longitudinally or axially outwardly from the bolt 200 from a forward face 208 of the bolt.
When the trigger 220 is actuated to fire the gun, the safety 250 is moved out of engagement with the head or button 230 (see FIG. 2) and the head or button is depressed to move the pin 234 downwardly or toward the latching fingers 160 and 170. The cam 240 secured to the pin 234 biases the latching fingers 160 and 170 radially outwardly against the bias of the tension spring 184 and the latches 164 and 174 are accordingly moved out of the groove 206. When the latches 164 and 174 move outwardly from the groove 206, the bolt 200 moves axially in the bore 144 (see FIG. 2) under the bias of the compression spring 186 to cause the firing pin 210 to contact the primer of a cartridge.
After the cartridge has been fired, the barrel 122 must be removed by disengaging the threaded connection with the cylinder 140 (see FIG. 2). This is accomplished, as stated above, by means of the knurled portion 124 of the barrel 122 which is disposed externally of the front end 40 and against the side 22 of the base 20 (see FIGS. 1 and 2). The fired cartridge is then removed from the counterbore 130 of the barrel 122 (see FIG. 2).
After the fired cartridge has been removed, a new cartridge may be inserted into the counterbore 130 of the barrel 122 and the barrel may then be inserted into its bore 112 in the forward end 40.
After firing the gun, the bolt 200 must be cocked or moved axially rearwardly to cause the latching fingers to engage the bolt. This is accomplished by means of a cocking lever or pin 212 which is secured to the bolt 200 and which moves longitudinally axially with respect to the bolt in a slot on the forward end 40 of the base 20 which communicates with the bore 110 through an appropriate or mating slot in the cylinder 140 from the front end wall 44 of the base 20. The cocking lever or pin 212 is secured to the bolt 200 preferably by a threaded engagement.
The forward or front portions 168 and 178 of the latching fingers 160 and 170 are curved or rounded. They comprise camming surfaces which cause the latching fingers 160 and 170 to move radially outwardly with respect to the spring base 202 of the bolt 200 as the bolt 200 is moved axially rearwardly against the bias of the spring 186 by the cocking lever or pin 212. The front portions or cam surfaces 168 and 178 accordingly are cammed against a rear face 218 of the spring base 202 as the bolt is moved by the cocking lever 212. The cam surfaces 168 and 178 engage the face 218 adjacent the grooves 214 and 216. As the latch portions 164 and 174 of the latching fingers move axially in the grooves 214 and 216, respectively, the tension spring 184 biases the latching fingers toward each other. Thus, when the latches 164 and 174 move into the circumferentially extending groove 206, and out of the axially extending slots 214 and 216, the fingers are biased together to securely retain or hold the bolt 200 against the bias of the compression spring 186.
After firing the gun, the user of the apparatus releases the firing button 230. With the button 230 released, the button and the pin 234 and cam 240 accordingly move upwardly under the urging or biasing force of the compression spring 236 (see FIG. 2). The cam 240 is accordingly moved out of engagement with the fingers 240 to allow the reloading and cocking of the apparatus to be accomplished.
As a safety feature, the length of the compression spring 186, which extends between the bolt 200 and the holding block 152, is predetermined so that after the gun has been fired, the spring 186 will not continuously bias the bolt 200 against the threaded block 148 (see FIG. 2). The firing pin is thus not biased through the aperture 150 of the threaded block 148 and against the primer of a cartridge freshly or newly inserted into the bore 126 of the barrel 122. This prevents the cartridge from being fired inadvertently as the barrel 122 is screwed into the cylinder 140 when the bolt 200 is not cocked. If desired, a relatively weak compression spring may be provided between the block 148 and the face 208 of the bolt 200 to bias the bolt away from the block 148 after firing. However, the depths of the spring seats 198 and 204 are preferably such that with the spring 186 in its fully extended, uncompressed state, it is still retained in the spring seats.
The movement of the latching fingers 160 and 170 and of the bolt 200 is shown in phantom in FIG. 3 in the firing position. When the pin 234 is moved downwardly to engage the cam 240 against the latching fingers, the latching fingers are moved outwardly to the position shown in phantom to thus release the bolt 200. The bolt 200 accordingly moves axially to the position shown in phantom under the force of the compression spring 186 to cause the firing pin to contact a primer in a cartridge, thus firing the gun. After firing, the bolt 200 is then moved axially rearwardly against the bias of the spring 186 by means of the cocking lever 212.
FIG. 4 is a view in partial section of the apparatus of FIG. 3 taken generally along line 4-4 of FIG. 3. It comprises an enlarged view in partial section illustrating the operation of the trigger 220.
FIG. 4 is a view of the gun apparatus 120 included in the front portion 40 of the clipboard apparatus 10 illustrated in FIG. 1. Within the bore 110 in the forward end 40 is a cylinder 140. Disposed within the bore 144 of the cylinder 110 is the spring base 196, which is part of the holding block 152 (see FIGS. 2 and 3). The latching fingers 160 and 170 extend through the pair of recesses 154 and 156, respectively, in the spring base 196.
Extending downwardly from the top 42 of the forward or front end 40 is the bore 114 which intersects the bore 110. Disposed within the bore 114 is a cylinder 222 which includes a lower threaded portion 228. The externally threaded portion 228 of the cylinder 222 matingly engages an internally threaded aperture 145 which extends radially through the wall of the cylinder 140. The cylinder 222 and the cylinder 140 are thus secured together at their respective threaded portions.
Within the cylinder 222 is a bore 224 which extends longitudinally through the cylinder 222. The bore 224 communicates directly with the elongated counterbore 226 which extends downwardly from the top of the cylinder 222 adjacent the top 42 of the front end 40. The bore 224 extends upwardly from the bottom portion of the cylinder 222 to intersect, axially, the bore 226. The bores 224 and 226 are thus coaxial with respect to the cylinder 222. The bore 224 communicates directly with the bore 144 of the cylinder 140.
Disposed within the counterbore 226 is the button or head 230 of the trigger mechanism 220. The button 230 is secured to a pin 234 which extends through the counterbore 226 and through the bore 224 and into the bore 144 of the cylinder 140. The pin 234 is secured at its upper end directly to the button 230, and is secured at its lower end to cam 240. A radially extending shoulder 255 is defined between the bore 224 and the counterbore 226. The shoulder 225 is the lower end wall for the counterbore. A compression spring 226 is disposed within the counterbore 226 and the spring extends between the shoulder 225 and the bottom of the button or head 230. The compression spring 236 accordingly biases the button 230, the pin 234, and the cam 240, vertically upwardly, as viewed in FIG. 4. The upward movement of the cam 240, and of the pin or connecting rod 234, and the button or head 230, connected thereto, is limited by the cylinder 140.
Disposed within the slots or recesses 154 and 156 of the spring base 196 are the latching fingers 160 and 170. A pair of cam surfaces 244 and 246 of the cam 240 are disposed adjacent the inner portions of the fingers 160 and 170. That is, the fingers 160 and 170 are disposed outwardly with respect to the cam 240, and adjacent the cam surfaces 244 and 246. The cam 240 includes a circular upper top surface 244 which has about the same radius of curvature as the bore 144. Accordingly, when the trigger 220 is disposed in its uppermost position, as shown in FIG. 4, the upper surface 242 of the cam 240 is substantially adjacent the upper portion of the bore 144 of the cylinder 140.
The cam surfaces 244 and 246 extend inwardly and downwardly from the outer ends of the curved upper surface 242 of the cam 240. The cam surfaces 244 and 246 are preferably relatively straight, but inclined inwardly and downwardly, as indicated. The cam 240 also includes a generally inverted U-shaped recess or slot 248 in which is disposed the connecting rod 194 of the holding block 152 (see FIG. 3).
As the trigger button 230 moves downwardly in the bore 226, the cam 240 moves downwardly, as viewed in FIG. 4, and the cam surfaces 244 and 246 bear against the latching fingers 160 and 170, respectively. Movement of the cam 240 downwardly causes the latching fingers to be moved radially outwardly to the position shown in phantom in FIG. 3. The outward movement of the latching fingers 160 and 170 releases the bolt 200 (see FIGS. 2 and 3) to cause the gun to fire.
The firing of the gun is prevented by the engagement of safety slide 252 with the button 230. The slide 252 is disposed within a pair of matching slots 232 and 238. The slot 232 is the circumferentially extending slot on the button 230, and the slot 238 is a mating slot extending through the cylinder 222. The slide 252 includes a bifurcated portion comprising a pair of arms 254 ad 256. The arms 254 and 256 are disposed in the mating grooves 232 and 238 of the button and the cylinder, respectively. With the slide 252 disposed in both the cylinder and the button, movement of the button, and of the trigger apparatus 220, is thus mechanically prevented. The slots 232 and 238 are horizontally aligned, as shown in FIG. 4, when the button 230 is in its uppermost position, under the bias of the spring 236. The curved upper surface 242 of the cam 240 is accordingly disposed against the bore 144 of the cylinder 140. In the upper position, as shown in FIG. 4, the cam surfaces 244 and 246 are not in engagement with the latching fingers 160 and 170. Rather, the latching fingers 160 and 170 are biased together by the spring 184 (see FIG. 3) to securely hold the bolt 200 in the cocked position, as also shown in FIG. 3.
When the gun apparatus is fired, by the inward or downward depression of the button 230 and the cam 240, the latching fingers release the bolt, thus allowing the firing pin on the bolt to strike the primer of a cartridge disposed in the gun. When the button 230 of the triggering mechanism is released, the button and cam are returned to the position shown in FIG. 4 under the bias or force of the spring 236. The latching fingers are then free to pivot inwardly (see FIGS. 2 and 3) under the bias of the tension spring 184 to the position shown in FIG. 4 (and also FIG. 3). However, the trigger 220 must be in the "up" position, as shown in FIG. 4, in order for the bolt 200 to be cocked for future fitting. This is due to the fact that the cam surfaces on the ends of the latching fingers (see FIG. 3) cause the latching fingers to be moved outwardly by the bolt as the bolt is cocked and prior to the engagement of the latching fingers with the groove 206 to lock the bolt in the cocked position. If the latching fingers are not able to move inwardly to engage or latch with the bolt, the bolt will not stay in the cocked position. If the cam 240 is in its downward or firing position, the latching fingers will be prevented from moving inwardly to engage or latch the bolt 200.
FIG. 5 is a view of a portion of the apparatus of FIG. 4 taken generally along line 5-5 of FIG. 4. It comprises a vertical view in partial section of the safety 250. The safety 250 moves longitudinally with respect to the end portion 40 (see FIGS. 1, 2, and 4) in the forward or front end 40. The plate 252 of the safety includes a bifurcated portion comprising a pair of fingers 254 and 256. The fingers 254 and 256 are spaced apart and engage the firing button or head 230 of the trigger mechanism 220, as shown in phantom in FIG. 5. The slide 252 extends into the slot 232 of the button 230 to lock the button 230 relative to the end portion 40 (see FIGS. 2 and 4).
FIG. 6 is an enlarged perspective view of a portion of the apparatus of FIGS. 2 and 3. It comprises an enlarged view of the bolt 200. The bolt 200 includes a generally cylindrical portion 201 movable in the bore 144 (see FIG. 2). The firing pin 210 extends axially forwardly from the front face 208 of the cylindrical portion 201 of the bolt 200 (see FIGS. 2 and 3). Extending radially outwardly from the cylindrical portion 201 is the cocking lever or pin 212. The cocking pin 212 includes an externally threaded portion which engages a mating, internally threaded bore of the cylindrical portion 201. For disassembly of the cam apparatus, the cocking pin or lever 212 must be removed from the bolt 200 in order to allow the bolt to be removed with the cylinder 140 in which it is disposed.
Rearwardly of the cylindrical portion of the bolt 200 is the spring base 202. The spring base 202 includes a cup or recess 204 which comprises a seat for the compression spring 186 (see FIGS. 2 and 3). The spring 186 in turn provides the force for moving the bolt axially or longitudinally within the bore 144 of the cylinder 140 when the trigger apparatus 220 is depressed to fire the gun. The firing pin 210 which extends from the front face 208 (see FIG. 3) of the bolt 200 contacts the primer of a cartridge and results in the firing of the gun. The cup or recess 204 comprises an axially extending bore which extends forwardly from the rear face 218 of the spring base 202.
The spring base 202 is separated from the cylindrical portion 201 by a circumferentially extending groove 206. The groove may best be seen and understood by referring also to FIG. 2 and to FIG. 3. The latching fingers 160 and 170, also shown in FIGS. 2 and 3, lock onto, or latch onto the bolt 200 at the groove 206, as shown in FIGS. 2 and 3.
A pair of longitudinally axially extending slots 214 and 216 are disposed diametrically opposite each other on the spring base 202 and they extend inwardly from the outer periphery of the spring base. The slots 214 and 216 receive the latching fingers 160 and 170, respectively, as shown in FIG. 3. Movement of the latching fingers out of the slots 214 and 216 releases the bolt 200 and the bolt is then propelled forwardly in the bore 144 by the compression spring 186 (see again FIGS. 2 and 3).
FIG. 7 is a perspective view of an alternate embodiment of a barrel 260 usable with the gun apparatus 120 of the clipboard apparatus 10 of the present invention. The barrel 260 comprises a tear gas barrel for shooting tear gas cartridges in the gun apparatus 120.
The tear gas barrel 260 includes an elongated cylindrical portion 262 which has a bore extending therethrough. The cylindrical portion 262 has an externally threaded portion 264 at one end which matingly engages the internally threaded portion 146 of the cylinder 140 (see FIG. 2). Remote from the external threads 264 is an outwardly flaring portion 266. The flared portion 266 of the barrel 260 is disposed outwardly of the side 22 of the clipboard apparatus 10, as viewed in FIG. 1, when the barrel 260 is in place, secured to the gun 120. The barrel 262 is closed at one end by a perforated disc 270 which is secured to the outwardly flaring portion 266 by a knurled bezel 268. The perforated disc 270 closes the bore of the cylindrical portion 262 of the barrel and is perforated, with a plurality of holes or apertures, to allow tear gas to exit from the barrel. The outwardly flaring portion 266 allows the gas to spread outwardly so as not to direct the gas in a relatively narrow or limited area or pattern. Rather, the gas is allowed to spread out so as to be most effective in a relatively short distance. If desired, the end of the barrel 260 could be open, rather than closed by the perforated disc.
FIG. 8 is a perspective view of the clipboard apparatus of FIG. 1 with the top or slide 50 and the tray 290 removed to show an arrangement of various components and compartments disposed within the base 20.
The forward or front end 40 is viewed in FIG. 8 from a different angle than is shown in FIG. 1, and thus the battery end cap 80 is shown extending slightly outwardly from the left side 24 of the base 20. Beneath or below the end cap 80 is the plug 134 which extends into the bore 110, shown in FIG. 2. The slot 138 is shown recessed into the end of the plug 134. It will be noted, as shown in FIG. 2, that the plug 134 is substantially flush with the side 24 of the base 20. On the top 42 of the forward or front end 40 is the side switch 60 which makes and breaks the electrical circuitry for the two lights, including the spotlight 70 and the floodlight 45 which illuminates the top of the clipboard apparatus. The floodlight 45 is disposed within the hood 46 which extends rearwardly from the top portion of the front end 40 and extends slightly over the slide 50 (see FIG. 1). The lens 48 comprises a wall for the hood 46. The lens 48 is preferably removable to allow the lamp within the hood 46 to be replaced.
The trigger button or head 230 extends upwardly from the curved top surface 42 of the front end 40 and is disposed adjacent the safety 250. The cocking lever of pin 212 extends forwardly of the apparatus, substantially perpendicular to the longitudinal axis of the forward end 40. The cocking lever 212, the safety 250, and the trigger button 230 are components or elements of the gun apparatus illustrated in detail in FIGS. 2-7.
With respect to the portion of the base 20 behind or rearwardly of the front end 40, or that portion which, as shown in FIG. 1, is normally covered by the slide 50, the removal of the slide, and of the tray 240, discloses a plurality of compartments which may be appropriately used, as desired, for the storage of miscellaneous apparatus, such as pencils, pens, forms, a tape recorder, and the like.
The base 20 is shown with its side walls 22 and 24 extending upwardly from a bottom 38. A groove 38 extends inwardly into the sides 22, 24, and into the upper portion of a front wall 28 of the base 20 rearwardly of the foward portion 40 to receive the slide 50, as shown in FIG. 1. The groove 30 includes three portions, a right side portion 32, a forward or front portion 34, and a left side portion 36. The portions 32, 34, and 36 of the groove 30 are substantially continuous. The portions of the groove are spaced apart downwardly from top portions 23, 29, and 25, respectively, of the right side wall 22, the front 40, and the left side wall 24. The lower end wall 26 terminates with a top 27.
The back or lower end wall 26 is substantially parallel to the upper or front end wall 28. The distance between the front end wall 28 and the lower end wall 26 may be as desired, in accordance with the particular needs of the organization using the clipboard apparatus, with respect to the desired equipment, forms, and the like to be disposed within the base. The top 27 of the end wall 26 is generally in the same plane as the bottom of the groove 30 so that the slide 50 (see FIG. 1) rests on the top 27 as it does on the bottom portion of the continuous groove 30. The groove 58 for the tray 290 (see FIG. 1) is not shown in FIG. 8 because the tray and its groove may be omitted if desired. If the tray is utilized, the interior walls are shortened to terminate at the bottom of the groove.
The groove 58 is similar to the groove 30, parallel to it and beneath it.
Within the base 30, the bottom 38 preferably covers the entire bottom of the base 20, and there are a plurality of interior walls within the base which define a plurality of compartments. Various accessories, pencils, pens, forms, and the like, may be carried within the base. The tops of the interior walls are low enough to accommodate the tray 290.
Included within the base is a cartridge carrier portion 300 which includes a plurality of cylindrical depressions 304 extending downwardly from a top 302. The cylindrical depressions 304 receive cartridges, with the base of the cartridges extending upwardly, and the nose or front portion of the bullets or cartridges extending downwardly into the depressions 304. Each of the depressions includes a scallop 306 which extends from the top 302 downwardly and inwardly toward each of the cylindrical depressions 304. The purpose of the scallop is to expedite removal of the cartridges from the cylindrical depositories 304 by inserting a fingernail, or the like, at the rim of the cartridge to facilitate removal of the cartridges. Each depression 304 also includes a shallow counterbore 308 which receives the rim of a cartridge.
A law enforcement officer typically uses a revolver which holds six cartridges. A total of twelve cylindrical depressions or cartridge repositories are shown extending downwardly from the top 302 of the cartridge carrier 300. This comprises two complete refills for the revolver of the user. Tear gas cartridges may also be carried in a portion of the cartridge carrier, and such tear gas cartridges should be clearly marked, as for example, with a specific color coding on a portion of the cartridge carrier reserved for tear gas cartridges, or the like.
A compartment 320 is illustrated at the lower lefthand portion of the base 20. The compartment 320 is defined by a portion of the end wall 26, the left side wall 24, and a pair of interior walls or partitions 322 and 324. The partition 322 is substantially parallel to the side 24, and the partition 324 is substantially parallel to the end wall 26. The compartment 320 is dimensioned to receive, if desired, a tape recorder. For convenience in actuating the tape recorder without removing the slide 50, aperture 326 extends through the wall 24 and communicates directly with the compartment 320. Controls for the tape recorder, which may conveniently be a cassette recorder, are accessible through the aperture 326.
Another aperture 328 extends through the forward or front portion of the right side wall 22 adjacent the front portion 40 of the clipboard apparatus. The aperture 328 is illustrated as being round and it receives a microphone for use in conjunction with a tape recorder. In the alternative, the aperture 28 may include a recess or the like to hold the microphone. Obviously, appropriate circuit connectors extend between the aperture 328 and the compartment 320 for connection to the tap recorder apparatus disposed within the compartment 320. Such conductors are not illustrated in FIG. 8, but are known and understood in the art. Adjacent the compartment 320 is a compartment 330, which is preferably rectangular in configuration, similar to the compartment 320. The compartment 330 is defined by a portion of the side wall 322, a portion of the end wall 26, the intermediate partition 322, and a portion of the partition 324. Forms, and the like, may be stored in the compartment 330.
Forwardly of the compartments 320 and 330 is a compartment 340. As illustrated in FIG. 8, the compartment 340 extends between the side walls 22 and 24 and forwardly of the transversely extending partition 324. The compartment 340 is disposed adjacent the cartridge carrier portion 300 of the base 20 and it may be used for pencils, pens, and miscellaneous small or elongated elements.
A compartment 350 is located between the side 22 and the cartridge carrying portion 300 and forwardly of the compartment 340. The compartment 350 is smaller then either of the compartments 320 or 330, but it is also rectangular in configuration. Cards, and the like, may be disposed within the compartment 350.
Finally, a compartment 360 is disposed between the front walls 28 and the cartridge carrier 300 and the compartment 350. The compartment 360, like the compartment 340, is transversely extending between the side walls 22 and 24 and may be used for carrying batteries or a battery pack. to provide additional voltage for lamps. By placing batteries in series with the batteries 84 and 85, additional voltage may be provided. Or, by a parallel arranging of the batteries, additional power for a longer endurance life may be provided.
The arrangement of the compartments shown in FIG. 8 is but a sample of how the base 20 may be utilized for storage and for the disposition of various components. Obviously, the compartments within the base may be rearranged, redimensioned, or the like, as required by a user.
FIG. 9 is a view in partial section of the base 20 of FIG. 8 taken generally along line 9--9 of FIG. 8. It comprises a view in partial section to the cartridge carrier 300 and the compartment 350. The grooves 30 and 58 are shown extending into the side 22, the side 24, and the front 28. Above the groove 30 is the front portion 40 of the clipboard apparatus 10. The lens 48 of the floodlight is shown centrally disposed with respect to the clipboard apparatus 10.
With respect to the cartridge carrier portion 300 of the base 20, the cylindrical depressions 304 are shown extending downwardly from the top 302. The scallops 306 are shown extending also downwardly from the top 302, and radially inwardly toward the cylindrical depressions 304 which receive the cartridges. At the top of the depressions 304 are counterbored portions 308 which receive the outwardly extending flanges on the base of the cartridges. The depth of the counterbores is relatively shallow. They extend downwardly only a short distance to allow the base of the cartridges to be completely recessed downwardly from the top 302 within the cartridge carrier 300. Accordingly, the bases of the cartridge as disposed within the cartridge containing cylinders 304 are fully recessed downwardly from the top 302 and the cartridges are held in place within the cartridge carrier by the top or slide 50 and/or the tray 290 (see FIG. 1) and will remain within the cartridge carrier 300 as long as the tray or top covers them, regardless of the orientation of the clipboard apparatus 10.
As clearly shown in FIG. 9, the cartridge carrier portion 300 of the base 20 is substantially solid except for the cartridge receiving cylinders 304. Thus the bottom 38 is thicker at the cartridge carrier portion 300 than at the compartment 350, or any of the other compartments illustrated in FIG. 8, because, at the cartridge carrier 300, the bottom 38 is virtually solid, and it extends solidly up to the top 302 to accommodate the cylindrical depressions 304.
FIG. 10 is a schematic circuit view of the electrical switch 60 illustrating the control of the two different lights included in the clipboard apparatus 10. The switch 60 includes a slide 62. The slide 62 is shown separated from the pair of batteries 84 and 85 and away from electrical contacts 94 and 104. It is understood that the representation of the batteries 84 and 85 is for illustrative purposes only. As indicated above, more batteries, or battery packs, may be used to provide the voltage required for the apparatus.
On the bottom of the slide 62 are three cam portions, including cam portion 64, cam portion 66, and cam portion 68. The cam portions 64 and 66 are spaced apart laterally and longidudinally with respect to the slide 62 and they are also spaced apart from the cam 68. The cam 68 extends transversely across the slide 62, while the cams 64 and 66 extend only part way, about half way, across the width of the slide 62. The cam 68 is thus about twice the width of either of the cam portions 64 or 66. The cam portions 64, 66, and 68 complete electrical circuits by camming spring contacts 96 and/or 106 into electrical engagement by direct contact with electrical connectors 98 and 108. The spring contact 96 is secured to the electrical contact 94 by an upwardly extending portion 95. The electrical conductor 98 is disposed beneath the spring contact 96. The spring contact 106 is connected to the electrical connector 104 by an upwardly extending portion 105 and the spring contact 106 is disposed above the electrical conductor 108. The lamp 78 is electrically connected to the conductor 98 and to the spring 82, which is a conductive spring and which makes contact with the base or negative terminal of battery 84. The lamp 49 is electrically connected also to the spring 82 and to the electrical conductor 108. The lamp 49 is for the floodlight which illuminates the top of the clipboard apparatus, while the lamp 78 is used with the spotlight 70 disposed in the side of the forward portion 40 of the clipboard apparatus 10.
The positive terminal of the battery 84 is biased by the spring 82 against the base or negative terminal of the battery 85, and the positive terminal of the battery 85 is biased also by the spring 82 against the electrical contact 92, which is in turn electrically connected to both the electrical contacts 94 and 104. The lamps 49 and 78 are in separate parallel electrical circuits between the electrical contact 92 and the spring 82. The separate electrical circuits are in turn controlled by the switch 60 and, more particularly, by the cams 64, 66, and 68 of the switch 60.
As illustrated in FIGS. 1 and 2, and discussed in conjunction therewith, the switch 60 moves longitudinally with respect to the forward end 40 of the clipboard apparatus 10. In the far left position, as shown in FIG. 1, both lamps 49 and 78 are in the off position, with both lamp circuits open. As the switch 60 is moved axially with respect to the forward end 40 of the clipboard apparatus 10, the cam 64, which extends downwardly from the bottom of the slide 62 and which includes a curved cam surface, contacts the spring contact 106 mechanically and causes the contact 106 to be moved or biased downwardly against the electrical conductor 108. As the spring contact 106 makes mechanical contact with the conductor 108, electrical connection is also made to close the electrical circuit including the spring 82, the batteries 84 and 85, the electrical contact 92, the electrical contact 104, and from electrical contact 104 through the intermediate portion 105 and spring contact 106, to the electrical conductor 108 and the lamp 49. The lamp 49 thus illuminates.
If the slide 60 is moved forwardly, the cam 64 moves away from the spring contact 106 which then moves away under its own spring bias from the conductor 108 to open the circuit for the lamp 49. The spring contact 106 must be kept in electrical contact with the conductor 108 against the inherent bias of the spring contact 106 and the intermediate portion 105, and when the mechanical connection is broken between the spring contact 106 and the conductor 108, the contact 106 will, of its own inherent bias, move away from the conductor 108. Thus when the cam 64 disengages the spring contact 106, the contact moves away from the conductor 108 to open the circuit with respect to the lamp 49.
As the slide 60 is moved forwardly to release the mechanical connection between the spring contact 106 and the conductor 108, the cam 66 moves into engagement with the spring contact 96 to cause the spring contact 96 to mechanically contact the conductor 98. The electrical circuitry for the lamp 78 is accordingly closed by the physical, and electrical, contacts or connection between the spring contact 96 and the conductor 98 through the contact 94 and the intermediate portion 95. The closing of the circuit between the batteries 84 and 85 and the lamp 78 results in the illumination of the lamp 78. The electrical contacts 94 and 104, with their intermediate portions 95 and 105 and their spring contact portions 96 and 106, are substantially and respectively identical. Similarly, the cams 64 and 66 are substantially identical, simply spaced apart laterally and longitudinally with respect to the slide 62 to actuate the two lamp circuits, as desired. However, the cam 68 extends continuously across the slide 62 to simultaneously close the electrical circuitry to illuminate both the lamps 49 and 78 at the same time.
The cam 68 is spaced longitudinally from the cams 64 and 66 and it extends across the full width of the slide 62. Thus, as the switch 60 is moved axially forwardly, the cam 66 moves off or out of engagement with the spring contact 96 to release the spring contact 96 from electrical and physical connection to the conductor 98. The spring contact 96 then biases itself away from the electrical conductor 98 to open the circuit to lamp 78. Continued forward or longitudinally axial movement of the switch 60 causes the cam 68 to contact both the spring contacts 96 and 106 which in turn results in substantially simultaneously closing the circuits for the lamps 49 and 78 to cause both lamps to be illuminated. Rearward movement of the switch 60 causes both lamps to turn off, and, depending on where the switch 60 is left, forward or rearward movement of the switch 60 results in the turning on and turning off of either of the lamps 49 and 78.
FIG. 11 is an enlarged detail view of a portion of the apparatus of the present invention, comprising a lock arrangement for the slide 50 of FIG. 1. The lock arrangement comprises an alternate embodiment of the end wall 26 of FIG. 1, and the end wall in FIG. 11 is accordingly designated as end wall 26a. Extending outwardly, or rearwardly, from top 27a of end wall 26a is an extension tab 280. A lock button 282 extends upwardly from the top surface of the extension 280. The lock button 282 fits into the hole or aperture 56 of the slide 50. The extension 280 is of such resiliency that it maintains the button 282 in the hole or aperture 56 to prevent the slide 50 from moving until the button is forcibly removed from the hole or aperture 56 by downward pressure on the button through the hole 56.
FIG. 12 is a view of the apparatus of FIG. 11 in partial section taken generally along line 12--12 of FIG. 11. It shows the extension 280 with its button 282 extending substantially outwardly and upwardly, respectively, from the top surface 27a of the wall 26a. In the upper or upright position of the button 282 as shown in FIGS. 11 and 12, the button 282 will be disposed within the hole or aperture 56 to thus lock the slide 50 and its groove 30 (see FIGS. 1 and 8). However a downward force or pressure on the top surface of the button 282 causes the button 282 to pivot downwardly to the position shown in phantom in FIG. 12 which causes the button 282 to be moved out of the hole or aperture 56. With the button 282 thus free of the aperture 56, the slide 50 may be moved outwardly in the groove 30 with respect to the base 20. The extension 280 and the button thus comprise a lock to hold the slide 50 to the base 20. The extension 280 is of sufficient flexibility to allow the button 282 to be moved downwardly to release the button from the aperture 56 without causing a break between the end wall 26a and the extension 30. As indicated previously, the hole or aperture 56 is also convenient for use as a finger or thumb hole for movement of the slide 50.
FIG. 13 is a perspective view of clipboard apparatus 500, which comprises an alternate embodiment of the clipboard apparatus of the present invention. The clipboard 500 comprises a base 502 which includes a rear wall 504, a front wall 506, and a pair of side walls 508 and 510. Forwardly of the front wall 506 is a front end 520, which is substantially the same in overall configuration as is the front end 40 of FIGS. 1-8. It comprises a generally smoothly rounded top surface 522 which extends upwardly from the base 502 and it terminates in a smooth front wall 524. The front end 520 extends between the sides 508 and 510 with which it is substantially aligned.
Within the front end 520 are a pair of lights, including a floodlight 526 and a spotlight 528, both of which are operated by a switch 530. The lights 526 and 528, and their switch 530, are substantially identical to the lights 46 and 70 and their switch 60, as discussed above and as illustrated in detail in conjunction with FIGS. 1, 8, and 10.
Within the base 502 are a plurality of compartments for containing auxiliary equipment, such as a tape recorder 540, with its microphone 542 disposed on the side 508, adjacent the spotlight 528. The location of the microphone 542 is substantially the same location as illustrated above in conjunction with FIG. 8. The microphone 542 is disposed in a compartment 544 in the base 502, and connected to the recorder 540 by appropriate electrical conductors, not shown, extending between the recorder and the microphone.
In alignment with the compartment 544 is a compartment 546 which extends transversely across the clipboard apparatus 500 from the side 510 to the compartment 544 adjacent the front wall 506. The compartment 546 may be used for miscellaneous storage, as desired, such as additional batteries, or an alternate location for a mace cannister, which will be discussed below.
Rearwardly of the compartments 546 and 544, and extending inwardly from the side 508, is another compartment in which is disposed a camera 550. The camera 550 is disposed against the right side wall 508 of the base 502. Three apertures, 522, 554, and 556, extend through the side wall 508 for the camera 550. The aperture 552 communicates with a built-in flash unit in the camera 550, the aperture 554 communicates directly with the lens of the camera, and the aperture 556 communicates with an electric eye in the camera. A button or switch 558 extends outwardly from the side 508 adjacent the aperture 556. The switch 558 controls the shutter and thus the actuation of the camera 550.
Between the recorder 540 and the camera 550, and disposed between the rear wall 504 and the side wall 508, is a rechargeable battery pack 560. The battery pack may be used instead of the C or D size batteries discussed above. An aperture 562 extends through the end wall 504 to allow a recharger plug to connect directly to the battery pack. This allows the battery 560 to be recharged while in place in the clipboard apparatus 500. Appropriate conductors, not shown, extend from the battery pack to the lights 526 and 528, to the recorder 540, and to the camera 550.
Disposed within the front or forward end 520 is a mace cannister 570. The mace cannister is shown in phantom. The mace cannister 570 is an alternate to the gun apparatus illustrated above in conjunction with the embodiment of FIGS. 1-12. Mace from the cannister 570 is sprayed through an outlet aperture 572 in the side 508 below the spotlight 528.
The top of the clipboard, or slide, and a tray, as both illustrated in FIG. 1, have been omitted from the embodiment of FIG. 13 in order to illustrate fully the apparatus disposed within the base. It is understood that the top or slide and tray, if desired, for the clipboard apparatus 500 is substantially the same as the slide 50 and tray 290 illustrated in FIG. 1.
FIG. 14 is an enlarged view in partial section of a portion of the apparatus of FIG. 13 taken generally along line 14--14 of FIG. 13. It comprises a view in partial section through the front end 520 of the clipboard apparatus 500 illustrating the orientation and actuation of the mace cannister 570.
The mace cannister 570 is disposed within a bore 590 in the front end 520 of the clipboard apparatus 500. The bore communicates with the right side 508 of the base 502. The flashlight 528 is in part disposed within the bore 590. Within the bore 590 is a ridge 592 which extends radially inwardly circumferentially about the bore 590. The ridge 592 acts as a stop against which the cannister 590 is disposed. For removing and replacing a mace cannister 590, the bore 590 communicates with the exterior of the clipboard apparatus by well-known means.
The mace cannister 570 includes a nozzle 572 extending outwardly from the cannister and substantially in line with the longitudinal axis of the cannister. The nozzle 572 is a hollow tube which is secured to a flexible hose 574. The hose 574 extends from the nozzle 572 to the outlet 576. Upon actuation, chemical mace is propelled through the nozzle 572 and through the hose 574 outwardly of the apparatus through the outlet 576. The outlet 576 is simply an aperture or hole in the side wall 508 through which the chemical mace is sprayed from the hose 574.
The mace cannister is actuated to spray the chemical mace out of the cannister by movement of the nozzle 572. The movement of the nozzle 572 is accomplished by movement of the trigger 580. The trigger 580 includes an actuator 582 extending downwardly from the trigger and disposed against the nozzle 572. Preferably, the actuator 582 includes a bifurcated portion which is disposed about a nozzle 572.
The trigger 580 is disposed within a bore 594 which extends downwardly from the top surface 522 of the forward part 520 of the clipboard apparatus. The bore 594 includes a bottom end wall 596. The end wall 596 separates the bore 594 from the bore 590. An aperture or hole 598 provides communication between the bores 594 and 590. The actuator 583 extends through the aperture 598 to make contact with the nozzle 572.
A compression spring 586 is disposed within the bore 594 between the end wall 596 and the trigger 580. The compression spring biases the trigger upwardly out of the bore 594 to prevent actuation of the mace cannister 570. A retainer or pin 584 is secured to the nozzle 572 within the bore 590. The retainer is secured to the actuator 582 to limit the upward movement of the trigger with respect to the nozzle 572. The retainer accordingly prevents the spring 586 from causing the trigger 580 to move entirely out of the bore 594. As illustrated in FIG. 14, the retainer 584 is disposed against the wall of the bore 590 in the rest or off position.
When the trigger 580 is depressed downwardly with respect to the bore 594, the actuator 582 moves the nozzle 572 downwardly to the position shown in phantom in FIG. 14 to actuate the mace cannister to spray chemical mace out of the outlet or nozzle 576. Thus the trigger 580 must be manually depressed against the bias of the spring 586 to actuate the mace cannister 570. Upon release of the trigger 580, the spring 586 moves the trigger upwardly and the actuator 582 accordingly moves upwardly also.
The nozzle 572 of the mace cannister 570 is spring loaded to the neutral or unactuated position and must be manually moved against its inherent, spring-loaded bias in order to actuate the cannister. When the trigger 580, and its actuator 582, is in the up or neutral, unactuated position, the lower bifurcated portion of the actuator 582 allows the nozzle 572 to return and remain in its neutral and centered position.
The clipboard apparatus illustrated and discussed herein comprises a multipurpose tool for law enforcement officers of all types. The apparatus may be adapted to suit the needs of various types of law enforcement officers by varying the accessories included and by varying the design and layout of the compartments, the tray, and the like. By manufacturing the clipboard apparatus out of an appropriate material, such as "Lexan" polycarbonate, the apparatus may be effectively used also as a shield in an emergency.
While the principles of the invention have been made clear in illustrative embodiments, there will be immediately obvious to those skilled in the art many modifications of structure, arrangement, proportions, the elements, materials, and components used in the practice of the invention, and otherwise, which are particularly adapted for specific environments and operative requirements without departing from those principles. The appended claims are intended to cover and embrace any and all such modifications, within the limits only of the true spirit and scope of the invention. This specification and the appended claims have been prepared in accordance with the applicable patent laws and the rules promulgated under the authority thereof. | A multi-function clipboard and report apparatus is disclosed which includes a receptacle for the storage of various items and provisions for two types of lights, one for illuminating the top surface of the clipboard and a second for providing a spotlight or a flashlight, and the apparatus also includes a gun capable of firing either a tear gas cartridge or a bullet and which contains a camera, a tape recorder, and which may act as a shield against projectiles. | 1 |
This is a continuation of application Ser. No. 09/021,793, filed Feb. 11, 1998, which is a continuation of application Ser. No. 08/829,657, filed Mar. 31, 1997, which is a continuation-in-part of application Ser. No. 08/499,268, filed Jul. 7, 1995, now U.S. Pat. No. 5,724,571, all of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates to a method and apparatus for generating responses to queries to a document retrieval system. When a large corpus (database) of documents is searched for relevant terms (query terms), it is desirable to find small relevant passages of text (called “hits” or “hit passages”) and rank them according to an estimate of the degree to which they will providing the information sought.
If the document database is very large, the number of hit passages generated may be far too high to be helpful to the user. Mechanisms are needed to minimize the number of hit passages that a user must examine before he or she either has found the desired information or can reasonably conclude that the information sought is not in the collection of texts.
This type of specific, “fine-grained” information access is becoming increasingly important for on-line information systems and is not well served by traditional document retrieval techniques. The problem is exacerbated with the use of small queries (of only a few words), which tend to generate larger numbers of retrieved documents.
When both the query and the size of the target (hit) passage are small, one of the challenges in current systems is that of dealing effectively with the paraphrase variations that occur between the description of the information sought and the content of the text passages that may constitute suitable answers. Literal search engines will not return paraphrases, and therefore may miss important and relevant information. Search engines that allow paraphrases may generate too many responses, often without an adequate hierarchical ranking, making the query response of minimal usefulness.
Thus, another challenge which is not currently well met is the effective ranking of the resulting hit passages. A high-quality ranking of matching document locations in response to queries is needed to enhance efficient information access.
Classical information retrieval (also called “document retrieval”) measures a query against a collection of documents and returns a set of “retrieved” documents. A useful variant (called “relevance ranking”) ranks the retrieved documents in order of estimated relevance to the query, usually by some function of the number of occurrences of the query terms in the document and the number of occurrences of those same terms in the collection as a whole.
Document retrieval techniques do not, however, attempt to identify specific positions or passages within the retrieved documents where the desired information is likely to be found. Thus, when a retrieved document is sufficiently large and the information sought is specific, a substantial residual task remains for the information seeker; it is still necessary to scan the retrieved document to see where the information sought might be found, if indeed the desired information is actually present in the document. A mechanism is needed to address this shortcoming.
In most previous information retrieval procedures for passage retrieval, a passage granularity is chosen at indexing time and these units are indexed and then either retrieved as if they were small documents or collections of individual sentences are retrieved and assembled together to produce passages. See Salton et al., “Approaches to Passage Retrieval in Full Text Information Systems,” Proceedings of the Sixteenth Annual International ACM SIGIR Conference on Research and Development in Information Retrieval ( SIGIR 93) (incorporated herein by reference), ACM Press, 1993, pp 49-58; Callan, J. P., “Passage-Level Evidence in Document Retrieval,” Proceedings of the Seventeenth Annual International ACM - SIGIR Conference on Research and Development in Information Retrieval ( SIGIR 93) (also incorporated herein by reference), Springer-Verlag, 1994, pp 302-310; and Wilkinson, R., “Effective Retrieval of Structured Documents,” (also in Proceedings of the Seventeenth , etc., at pp 311-317). It would be useful to have a system that dynamically sized passages for retrieval based upon the degree to which the retrieved passage matches the query phrase.
Recently, a different approach has been proposed, based upon hidden Markov models and capable of dynamically selecting a passage. See Mittendorf et al., “Document and Passage Retrieval Based on Hidden Markov Models,” ( Proceedings of the Seventeenth , etc., pp 318-327). However, this approach does not deal with the entire vocabulary of the text material, and requires reducing the document descriptions to clusters at indexing time. It would be preferable to have a system that both encompasses the entire text base and does not require such clustering.
SUMMARY OF THE INVENTION
The present invention is directed to a method and apparatus for generating responses to queries with more efficient and useful location of specific, relevant information passages within a text. The method locates compact regions (“hit passages”) within a text that match a query to some measurable degree, such as by including terms that match terms in the query to some extent (“(entailing) term hits”), and ranks them by the measured degree of match. The ranking procedure, referred to herein as “relaxation ranking”, ranks hit passages based upon the extent to which the requirement of an exact match with the query must be relaxed in order to obtain a correspondence between the submitted query and the retrieved hit passage. The relaxation mechanism takes into account various predefined “dimensions” (measures of closeness of matches), including: word order; word adjacency; inflected or derived forms of the query terms; and semantic or inferential distance of the located terms from the query terms.
The system of the invention locates occurrences of terms (words or phrases) in the texts (document database) that are semantically similar to terms in the query, so as to identify compact regions of the texts that contain all or most of the query terms, or terms similar to them. These compact regions are ranked by a combination of: their compactness; the semantic similarity of the located phrases to the query terms; the number of query terms actually found (i.e. matched with some located term from the texts); and the relative order of occurrence of the located terms compared with the order or the corresponding query terms.
The identified compact regions are called “hit passages,” and their ranking is weighted to a substantial extent based upon the physical distance separating the matching terms (compared with the distance between the corresponding terms in the query), as well as the “similarity” distance between the terms in the hit and the corresponding terms in the query.
The foregoing criteria are weighted and the located passages are ranked based upon scores generated by combining all the weights according the a predetermined procedure. “Windows” into the documents (variably sized regions around the located “hit passages”) are presented to the user in an order according to the resulting ranking.
A significant advantage of relaxation ranking is that the system automatically generates and ranks hits that in a traditional document retrieval system would have to found by a sequence of searches using different combinations of retrieval operators. Thus, the number of times the information seeker is unsatisfied by a result—and therefore needs to reformulate the query—is significantly reduced, and the amount of effort required to formulate the query is also significantly reduced.
Another advantage is that the rankings produced by the current system are for the most part insensitive to the size or composition of the document collection and are meaningful across a group of collections, so that term hit lists produced by searching different collections can be merged, and the ranking scores from the different collections will be commensurate. This makes it possible to parallelize and distribute the indexing and retrieval process.
In addition, the system of the invention is more successful than traditional system at locating specific, relevant passages within the retrieved documents, and summarizes and displays these passages with information generated by the relaxation ranking procedure, so that the user is informed why the passage was retrieved and can thus judge whether and how to examine the hit passage.
The present invention has proven to be particularly effective at handling short queries, such as from two to six words. Accordingly, the retrieval system of the invention may handle different queries differently, using a conventional word search mechanism for searches based upon one-word queries or queries of more than six terms, and using the system of the invention for searched based upon two- to six-word queries.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is block diagram of a system of the invention.
FIG. 2 is a diagram of the interacting modules of an indexing and analysis system of the invention.
FIG. 3 is an illustration of an exemplary search result as generated by the system of the invention.
FIG. 4 is a flow chart of a generalized method for query processing according to the invention.
FIGS. 5-5A are flow charts illustrating a more detailed, preferred embodiment of the method of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The system of the invention will first be described in terms of its overall, general functionality, including specific types of ranking and penalty criteria that are used and configurations of hardware and software suitable for implementing the invention. A specific manner of implementing the relaxation ranking method is presented, as well as examples of search results generated by an actual implementation of the invention.
SECTION 1
THE APPARATUS OF THE INVENTION
FIG. 1 shows a computer system 10 implementing the invention. The system 10 may be a conventional personal computer or workstation, including a processor 20 , a memory 30 storing the operating system, applications and data files, a keyboard and mouse 40 , and a display or other output device (such as a printer) 50 . The precise configuration is not crucial; for instance, the memory 30 may be a distributed memory on a network, a shared memory in a multiprocessor, and so on. Output device 50 may alternatively and equivalently be a mass storage device or any device capable of receiving the output file resulting from a search query, whether in text, graphical or other format, for storing, display or other types of output. In the present application, “display” will be used generally to encompass any of these possibilities.
Input to the system, such as search queries, are made via the keyboard and mouse 40 . In addition, search queries may be generated in the course of executing applications that are stored in the memory 30 and executed on the processor 20 , or they may be received from remote hosts on a network or other communication channel. The source of the search queries is thus variable, the present invention being directed to the execution of the searches and handling of the results.
Memory 30 stores software including instructions for carrying out the method of the invention, including a retrieval engine 60 , which generally includes all program instructions or modules necessary to implement the invention. As will be appreciated in the following discussion, given the teaching of the present application it is a straightforward matter to generate programs or program modules to carry out the invention.
Memory 30 also stores a document corpus 70 , which includes all the documents in which a search is to be carried out, and a term occurrence index 80 comprising an index of all, or some specified subset of, the terms within the document corpus, as described in further detail below. In addition, generator store 85 is a portion of memory 30 where the processor 20 temporarily stores information generated during the course of a query response, before ultimately outputting the results to output buffer 90 (connected to the processor 20 ) for transfer to the display 50 .
The output buffer 90 is configured to store a user-defined or predetermined maximum number of hit passages, as discussed in further detail below, or the total number of hits generated by a query response, if that total is not greater than the predetermined maximum. The hit passages, i.e. the regions of retrieved text that include term hits, are stored in a ranked order according to the method of the invention, described below. (“Term hits” is used herein to refer to the individual terms that are retrieved as somehow matching the query terms.)
A proximity buffer 95 is also connected to the processor 20 , and is used by the processor to store positions and sizes of “windows” onto a target document—i.e., regions in a document, of dynamically variable sizes, currently being searched by the processor for terms that match the input query terms. A window may be specified as a starting location within a target document plus a size that determines how much of the document, starting from that starting location, is to be included in a hit passage. A hit passage is that portion of the document covered by such a window, and includes hit terms, i.e. the matching terms themselves.
The hit terms and hit passages are also stored in the proximity buffer 95 , correlated with the window information.
FIG. 2 illustrates the how the program modules may be organized to carry out the indexing and analysis operations that are applied to the document corpus 70 of text materials to be indexed in order to produce the term occurrence index 80 and the term/concept relationship network 110 used to support subsequent query operations.
The term indexing module 90 constructs the term occurrence index 80 which is a record of all the terms that occur in the corpus 70 together with a record for each term listing the documents in which that term occurs and the positions within that document where the term occurs. This operation is a conventional operation in information retrieval.
The terminology analysis module 100 analyzes each term in the corpus 70 to construct the term/concept relationship network 110 , which is a corpus-specific semantic network of terms and concepts that occur in the corpus 70 , or related terms and concepts that may occur in a query, together with a variety of morphological, taxonomic, and semantic entailment relationships among these terms and concepts that may be used subsequently to connect terms in a query with terms in the text.
The construction of the term/concept relationship network 110 draws upon and makes use of a lexicon 180 composed of a general purpose lexicon 190 of information about general English words and/or words of some other language and a domain-specific specialized lexicon 200 containing terms and information about terms that are specific to the subject domain of the corpus 70 . These lexicons contain information about morphological relationships between words and other information such as the syntactic parts of speech of words that are used by morphological analysis routines within the terminology analysis module 100 to derive morphological relationships between terms that may not occur explicitly in the lexicon. The operation and use of such lexicons and morphological analysis conventional in computational linguistics.
The construction of the term/concept relationship network 110 also makes use of a taxonomy 120 composed of a general purpose taxonomy 130 of taxonomic subsumption relationships (i.e., relationships between more general and more specific terms) that hold between general words and concepts of English and/or some other natural language and a domain-specific specialized taxonomy 140 of subsumption relationships that are specific to the subject domain of the corpus 70 . This operation also makes use of a semantic network of semantic entailment relationships 150 composed of a general purpose entailments database 160 of semantic entailment relationships (i.e., relationships between a term or concept and other terms or concepts that entail or imply that term) that hold between general words and concepts of English and/or some other natural language, and a domain-specific entailments database 170 of semantic entailment relationships that are specific to the subject domain of the corpus 70 . The operation and use of such semantic taxonomies and semantic networks are conventional in the art of knowledge representation. See John Sowa (ed.), Principles of Semantic Networks: Explorations in the Representation of Knowledge, San Mateo: Morgan Kaufmann, 1991 (incorporated herein by reference).
Each of these modules is utilized by the preferred embodiment of the invention, in a manner to be described below, though different and equivalent configurations may be arrived at to implement the invention.
SECTION 2
THE METHOD OF THE INVENTION
FIG. 4 illustrates a generalized embodiment of the method of the invention, and FIGS. 5-5A illustrate more specifically the steps taken according to the preferred embodiment of the invention.
2A. Basic Method: Ranking and Penalty Procedures
FIG. 4 corresponds to the twelve ranking and penalty procedures discussed below. At box 410 , a search query phrase (consisting of one to many terms) is input, either entered by the user or requested by an executing process on the processor 20 . Boxes 420 - 550 represent steps taken to penalize, rank and display the retrieved passages from the document corpus and are related to ranking procedures 1‥12 listed below. The numerals in circles in FIG. 4 indicate the correspondingly numbered ranking criteria.
In this more general discussion, the order of listing criteria/procedures 1-12 below and the order of boxes 430 - 550 in FIG. 4 do not indicate a required order of ranking or penalty assignments; rather, many different such orders are possible.
The penalization and ranking criteria discussed below (especially those of procedures 1-7) are referred to herein as relaxation ranking criteria, since they allow for flexible ranking of retrieved passages of text.
Procedure 1: Proximity ranking penalties. (Boxes 420 and 470 of FIG. 4.) Hit passages are identified as compact regions of text containing one or more matches for the query terms, and the hit passages are penalized depending upon how closely or far apart the matching terms occur together; i.e. the farther apart the located terms relative to their proximity in the query phrase, the higher the penalty.
It should be noted that proximity penalization herein is not the same as the conventional information retrieval technique of using “proximity operators,” in which a user specifies a set of terms and a distance threshold within which occurrences of those terms must be found in order for a match to be counted. In the traditional technique, the resulting hits are ranked by how many of the terms occur rather than by how closely the terms occur together, as in the present invention.
Procedure 2: Permutation penalties. (Box 480 of FIG. 4.) Hit passages are penalized by the degree to which their relevant phrases occur in a different order from the corresponding terms in the query phrase, using a measure of permutation distance between the order of the query terms and the order of their corresponding term hits.
Procedure 3: Morphological variation penalties. (Box 430 of FIG. 4.) Query terms are compared to terms in the target text that may be inflected or derived forms of the query terms, and are ranked by a small penalty factor so that exact matches are preferred over inflectional or derivational variants, but only slightly so.
Procedure 4: Taxonomic specialization penalties. (Box 440 of FIG. 4.) Query terms are compared to terms in the text that are more specific according to a taxonomy listing generality relationships among terms and concepts, such as taxonomies 180 in FIG. 2 . Terms and concepts in the text that are more specific than terms and concepts in the query are automatically retrieved and may be ranked with a penalty for not being exact matches to the query.
Procedure 5: Semantic entailment penalties. (Box 450 of FIG. 4.) Hit passages that contain terms with a high degree of “semantic” similarity to the query terms, or that logically entail the query terms, are penalized less than those with more remote semantic similarity or a lower strength of entailment.
Procedure 6: Missing term penalties. (Box 460 of FIG. 4.) Include hit passages that contain matches for some but not all of the query terms, and penalized them according to the number of query terms that are missing from the hit passage. In this way, when no complete matches occur, the user is automatically presented with information about the best matches that can be found. The hit passages are also ranked according to a determination of the importance of the missing terms.
Procedure 7: Overlap suppression. (Box 500 of FIG. 4.) Hit passages that overlap (i.e. occupy at least a portion of the same “window” onto a target document as) other hit passages with a better ranking are suppressed, i.e. discarded. Hit passages with the same ranking as another overlapping hit passage are likewise suppressed, since they add nothing to the overall ranking of the located document.
Procedure 8: Positional ordering. (Box 510 of FIG. 4.) All other factors being equal, hits with equal ranking scores are ordered primarily in order of a default preferred document order, and secondarily according to the positions of given hit passages within the document in which they occur.
Procedure 9: Dynamic passage sizing and internal boundary penalties. (Box 520 of FIG. 4.) Hit passages are identified by a passage of text consisting of the smallest sequence of sentences containing the hit region, or if the hit region is within a portion of text that does not have sentence structure (e.g., a table or a figure), then the smallest coherent region containing the hit region. The terms within the current query passage that were specifically involved in determining the hit passage are highlighted, if possible, when such identifications are displayed. If a sentence ending (such as a period) or paragraph boundary occurs within a given hit passage, that passage is penalized.
Procedure 10: Match summaries. (Box 530 of FIG. 4.) Hit passages are summarized by a list of the terms in the hit passages that match the corresponding terms in the query, with specific identification of query terms that are not matched in each such hit passage.
Procedure 11: Ranking of lists. (Box 540 of FIG. 4.) When the query is processed, the user is presented with a ranked list of the term hits that have been discovered, each of which has a ranking score that reports the quality of the match (with lower overall penalty totals indicating higher quality). Thus, each hit passage is identified by a match summary and a display of the passage of text that constitutes the hit. The term hits are listed in the order determined by combining the above ranking factors, and hit passages that are otherwise of equal rank are ordered according to their position in the corpus and text (i.e., hit passages in preferred documents are presented first and earlier hit passages within a document come before later hit passages).
Procedure 12: Interactive passage access. (Box 550 of FIG. 4.) Each of the term hits in the result list includes at least one active button or hyperlink that can be selected in order to view the corresponding hit passage in its surrounding context in the document within which it occurs. Hit passages are highlighted when viewed in the context of their occurrence, and the terms in the hit passage that resulted in the match are marked. The user can then move around within the document at will, and can return to the highlighted hit passage at will.
Once the procedure 400 has executed the steps 420 - 550 , it is ready to begin with another query, as indicated at box 560 of FIG. 4, and otherwise to stop, as at box 570 .
2B. Basic Method: Ranking by Physical Proximity and Similarity
The basic method of the invention is to find regions of the indexed text in which all of the query terms occur close together, or where most of the query terms (or terms similar to most of the query terms) occur close together. These hit passages are graded by the relaxation ranking criteria and presented to the user in order of this ranking.
For example, if a user has submitted a query to locate the phrase “jump to end of file” in a document corpus (such as an on-line user's manual for a text editor application), a hit passage returned by the retrieval engine might be “move the cursor to the end of the input buffer”. In this case, the retrieved term “jump” corresponds to the query term “move” as a term with close semantic distance, and the intervening phrase “the cursor” leads to a small penalty on the basis of a criterion comparing the compactness of the retrieved passage vis-a-vis the original query phrase. Another retrieved passage that does not include intervening words would not receive this penalty.
In this example, the phrase “the input buffer” corresponds to the query term “file” by some measurable entailment relation. As indicated above, entailment indicates that a query term is implied to some extent a retrieved term; in this case, “input buffer” may be considered to entail the virtual presence of the term “file”. One term entails another if the latter is implied by the former; in general, the entailing term will be narrower or more specific than the entailed term, but will sometimes be essentially synonymous. (Thus, “bird” entails “animal”, and “plumage” entails “bird”.)
The hit passage “jump to end of file” would be assigned a quantitative rank on the basis of the overall length of the hit, the number of missing terms (if any), and the strength of semantic similarity or entailment between the aligned terms of the query and the corresponding hit passage.
The method utilizes a term occurrence index (whose generation is discussed in Section 1 above) that can deliver the following information for each term of the query:
1. an enumeration of the set of all documents in the corpus that contain that term;
2. for a given document, the positions (e.g., as byte offsets) within the document where the term occurs; and
3. statistical information such as the number of occurrences of the term in the collection, the number of documents in which it occurs, the number of times it occurs in each document, and the total number of documents and word tokens in the collection.
The construction of such an index is a conventional operation in information retrieval.
The method may further use facilities (also discussed in Section 1 above) for obtaining stems or morphological variants of terms, semantically related terms, more specific terms, and terms that entail a term. Each of these related terms may have an associated numerical “similarity distance” between a query term and the retrieved term. This similarity distance is used as an associated penalty to be assigned when matching a query term against the retrieved term.
For example, for a query term “change”, morphological variants would include “changed”, “changing” and “interchange”; a semantically related term might be “influence”; more specific terms would include “alter” and “damage”; and an entailing term might be “move” (since moving something entails a change of position). In the description below, these related terms will be generally referred to as “similar terms” or “entailing terms”, and numeric penalties are associated with each similar or entailing term based on the kind of association between the query term and the entailing term, together with the similarity distance between the two terms.
A “generator” is constructed for each term in the query. The generator is a data structure or database stored in memory that enumerates positions in documents at which the query term or any of its similar terms occur. It is these occurrences of the query term or its similar terms that are referred to as the “(entailing) term hits” for that term.
The documents in the collection are assigned an arbitrary order, such as the order in which they were indexed or preferably an ordering in which more popular, informative, or useful documents precede documents that are less likely to be useful. The generator for each query term is initialized to generate the first occurrence of a term hit for that query term in the first document in the collection in which a term hit for that term occurs.
Intuitively, the method proceeds by moving a window through each document containing any of the term hits for any of the terms of the query, determining whether that window contains a match for the query as a whole, choosing whether to extract a hit passage from that window, and if so then ranking the selected passage.
The size of the query window is determined by a (temporarily) fixed location parameter plus a window size parameter, determined as the product of a predetermined factor multiplied by the length of the query. These two parameters can be manipulated by the information seeker or an executing process, or may be set to predetermined useful values.
A window 300 onto a document 305 is shown in FIG. 3, and includes lines of text 310 . 1 - 310 . 11 including a hit passage 320 containing n terms 320 . 1 - 320 .n (t 1 , t 2 , . . . , tn). The hit passage 320 has a beginning marked by a start position 330 and an end marked by an end position 340 .
The window 300 can move over the body of the document 305 to include different portions thereof. For instance, as it moves down relative to the text illustrated, it will omit line 310 . 1 and include line 310 . 12 (which would be the next line below 310 . 11 ), then omit line 310 . 2 and include line 310 . 13 , and so on. The use of the window construct is presented in detail below.
Other parameters (either predetermined or set by the user or a process) determine the weighting of each of the different dimensions of relaxation (e.g., proximity, permutation, morphology, taxonomy, entailment, and deletion), and two parameters specify penalties to be assigned if a hit passage contains a sentence boundary or a paragraph boundary. Each of these parameters can either be made available for manipulation by the information seeker or set to predetermined useful values. The ranking of a passages is determined by the net penalty that is the sum of its assigned penalties from various sources.
2C. General Method for Generating Hit Passages in Order of Desired Ranking
The following methodology gives a generalized procedure for generating hit passages and for ordering them in a ranking that best reflects the search query. Further below is a discussion of a specific implementation of this methodology.
Let the query q be a sequence of terms q 1 , q 2 , . . . , qm, each of which is a word or phrase, and let x be a text document including a sequence of words x 1 , x 2 , . . . , xn. A term-similarity distance function is used that assigns to ordered pairs of terms (p, p′) a distance measure d=d(p, p′), where p and p′ are terms and d is a similarity distance between the terms.
A similarity distance of zero will represent identity or full synonymy of the terms, or some other circumstance in which no penalty is assigned to matching query term p to text term p′. Larger similarity distances will correspond to terms that are only partially synonymous or otherwise related—e.g., because one is more general than another or entailed by the other, or because some sense of one is partially synonymous to some sense of the other, or because the terms are semantically similar in some other way.
Given a query q, we want to find an alignment a=(q 1 , xi 1 ), (q 2 , xi 2 ), . . . (qm, xim) of terms in the query with terms in the text such that
(1) each pair consisting of a term from the query and a term from the text have a small similarity distance;
(2) the terms in the text that are aligned with terms in the query occur near each other in the text; and
(3) we rank such an alignment more highly if the term hits in the text occur in the order that their corresponding query terms occur in the query.
Alignments are also considered that have text correspondences for only some subset of the query terms, and they are ranked worse (penalized more) than alignments that contain more of the query terms, by giving them penalties determined by the kind of term that is missing and/or the role that it plays in the query.
A similarity distance metric is organized so that, given a query term qi (either a single word or a phrase including a sequence of words), a function call is made that returns a list of term-distance pairs (t 1 d 1 ), (t 2 , d 2 ), . . . ,(tj, dj) in increasing order of the distance value dj, where dj is the similarity distance between the query term qi and the potential text term tj. Let us call this function “similar-terms”.
The text sequence x 1 , x 2 , . . . , xn is indexed in advance, so that a function call “term-index” for a given term tj locates: (1) all of the documents in which that term occurs; and, for each document, (2) all of the positions i at which a match for the term tj occurs in the text. If tj is a sequence of words w 1 , w 2 , . . . , wp, then a match exist for tj at position i if xi=w 1 , xi+1=w 2 , . . . , and xi+p−1=wp.
For each term qi in the query q, a sequence of term hits (exact matches or entailing “close hits”) is constructed for the term qi by combining the term-index entries for that term and for all of its similar (entailing) terms. Each of these term hits will have a weight or penalty corresponding to the similarity distance between the query term and the matching text term (or zero for exact matches of the term).
Generally, the method for generating and returning hit passages for a given query q is as follows:
1. Set up a generator of term hits for each significant term in the query (certain function words such as “of” and “the” may be judged insignificant and ignored). These generators will generate term hits in documents in which a term hit occurs in the order of the documents in the collection and within a document in the order of the position of the term hit within the document.
2. Overall hit passages for the query q are generated sequentially by starting at the position of the first similar term (t) generated by any of the terms of the query. This term hit may be referred to as the “root”. Thus the root for the first hit passage is the earliest word in the earliest document in the collection that is a term hit for one of the terms in the query. Then the method inspects all of the term hits generated by any of the other terms in the query that are in the same document and within a window determined by a threshold proximity distance (the proximity horizon) from the position of the root term t. For each combination of term hits from the other (non-root) generators that occur within this window, a net penalty score for this combination is computed from the distances between the individual term hits, the similarity distances or match penalties involved in each of the term hits, syntactic information about the region of the hit passage (such as whether there is a sentence or paragraph boundary contained in the hit passage) and an appropriate penalty for any term in the query that has no corresponding hit within the window (this penalty depending on the kind of word that is missing and/or its role in the query or frequency in the collection). These hit passages are also assigned a penalty for crossing a sentence boundary or crossing a paragraph boundary, depending on the parameter settings for sentence boundary penalty and paragraph boundary penalty. The best such combination is selected and generated as a hit passage for the query.
3. After generating a hit passage, the generator for the root term (t) is stepped to the next term hit for that term and the generators for all of the other terms in the query are restored to the values they had when the previous root term t was first selected. A new root is now selected (the earliest term hit of any of the currently generated term hits) and the process is repeated.
4. This process of generating hit passages for the query is repeated either until a sufficient number of zero penalty hit passages has been generated (determined by a specified limit), or until there are no more term hits to generate, after which all of the hit passages that have been found are sorted by their net overall penalty. Hit passages that are contained within or overlap better hit passages or earlier hit passages with the same score are suppressed, and the best remaining hit passages (up to the specified limit) are presented to the information seeker in order of their overall penalty score (smallest penalty first). Alternatively, hit passages can be provided to a display window as they are generated and each new hit is inserted into the display at the appropriate rank position as it is encountered. To avoid replacing a displayed hit passage that overlaps with a later better hit passage, sending hit passages to the display should be delayed until the search window has moved beyond the point of overlap.
5. Each hit passage in the presented query hits list is displayed with its penalty score, a summary of the match criteria (including a list of the corresponding term hits for each query term), an identification of the position of the passage within its source document (such as a document id and the byte offsets of the beginning and end of the passage), and the text string of the retrieved passage. The retrieved passage is determined by starting with the latest sentence or segment boundary in the source document that precedes the earliest term hit in this match and ends at the first sentence or segment boundary that follows the latest term hit.
6. The displayed term hit list can be used to access a display of the retrieved passages in the context in which they occur. This is done by opening a viewing window on the document in which the passage occurs, positioning the text within the viewing window so that the retrieved passage is visible within it, highlighting the passage within the window, and if possible marking the term hits that justified the passage so that they are visible to the user.
Unlike conventional document retrieval, the system of the present invention locates specific passages of information within the document, not simply the document itself. This is similar to what has been called “passage retrieval” in information retrieval literature, but in the present invention the passages are constructed dynamically in response to the query using a general-purpose full-text index of terms and positions, and the size and granularity of the passage is variable depending on what is found in the match.
2D. Examples of Queries and Results
The following example is a portion of a summarized term hit list produced by an actual implementation of this method used by applicant, indexing the tutorial documentation for the well-known Emacs text editor. In the listing, each hit entry comprises a data structure including a sequence number, a penalty score, a list of matching terms, the document in which the hit occurred, and the positions of the hit within the document in the following format:
++++++++++++++++++++<hit sequence number>
(hit <penalty score><list of matching terms>
<file where hit was found><beginning position>
<end position>)
<retrieved text passage>
Here are results generated for the query phrase “move to end of file”, i.e. a search in a predefined document corpus for this phrase. (The document corpus in this example, as noted above, is a portion the Emacs text editor documentation.)
The first three entries of the resulting hit list were:
++++++++++++++++++++ 1
(hit 0.115 (“GO” “TO” “END” “FILE”) “/home/emacs-tutorial” 5881 5898) M−>Go to end of files
++++++++++++++++++++ 2
(hit 0.155 (“MOVES” “TO” “END” “FILE”) “/home/emacs-tutorial” 4984 5012) which moves to the end of the file.
++++++++++++++++++++ 3
(hit 2.849 (“DASHES” (MISSING TO) “ENDS” “FILE”)
“home/emacs-tutorial” 15624 15753)
begins and ends zenith dashes, and contains the string “Emacs: TUTORIAL”. Your copy of the Emacs tutorial is called “TUTORIAL”. Whatever file you find, that file's name will appear in that precise spot.
(The italicized portions above are the actual retrieved hit passages located as matches for the input query phrase “move to end of file”.)
The following excerpted portions of the associated text for the above results illustrate the display of the respective hit passages in context, in which the hit region (passage) is underlined, and the located term hits appear in bold:
No. 1. For hit 0.115 (“GO” “TO” “END” “FILE”):
M-a Move back to beginning of sentence
M-e Move forward to end of sentence
M−<Go to beginning of file
M−>Go to end of file
>>Try all of these commands now a few times for practice. Since the last two will take you away from this screen, you can come back here with M-v's and C-v's. These are the most often used commands.
No. 2. For hit 0.155 (“MOVES” “TO” “END” “FILE”):
Two other simple cursor motion commands are: M−<(Meta Less-than), which moves to the beginning of the file, and M−>(Meta Greater-than), which moves to the end of the rile. You probably don't need to try them, since finding this spot again will be boring. On most terminals the “<” is, above the comma and you must use the shift key to type it. On these terminals you must use the shift key to type M−< also; without the shift key, you would be typing M-comma.
No. 3. For hit 2.849 (“DASHES” (MISSING TO) “ENDS” “FILE”):
If you look near the bottom of the screen you will see a line that begins and ends with dashes, and contains the string “Emacs: TUTORIAL”. Your copy of the Emacs tutorial is called “TUTORIAL”. Whatever file you find, that file's name will appear in that precise spot.
There is a gradual relaxation from good matches to successively less likely matches, with appropriate penalty scores to indicate the degree of poorness of the match. In this example, penalty scores greater than 2 indicate substantial likelihood that the match is not useful. Note that the system is not sensitive to how context determines senses of words, so it accepts “dashes” as a specialization of “move” even though in this context it is clearly a plural noun rather than a verb. In contrast, in the first hit, “move” is correctly matched to the more specific term “go,” while in the second, it correctly matches the inflected form “moves.”
The method of the invention thus finds passages within texts that contain answers to a specific information request, and ranks them by the degree to which they are estimated to contain the information sought.
2E. Specific Method for Generating Hit Passages in Order of Desired Ranking
FIG. 5 is a top-level flow chart of the method of the invention. A search query is input at box 510 , and at box 520 the method identifies target regions in the corpus that contain matches for the query (search) terms. This is carried out using the outputs of the term indexing modules 90 and 100 shown in FIG. 2, according to the procedure detailed in Section 2F below.
At box 530 , the processor 20 fills the output buffer with the sorted list of query hits, in a procedure detailed in FIG. 5 A and Section 2F below. The ranked list of hits is then displayed on display 50 , and/or may be stored as a file in mass storage for future use.
At box 550 , the actual hits are displayed and/or stored according to their assigned ranks. Hit terms are highlit, and hyperlinks are provided to targeted text, i.e. the documents in which the hit passages were located.
This completes the processing of a given query, if there is another query, the method proceeds from box 560 to box 510 , and otherwise ends at box 570 .
2F. Method for Identifying Target Regions and Sorting Query Hits
This section discusses the method of the invention for carrying out step 520 of FIG. 5 . The following six steps are carried out to accomplish this. When the query is made, documents are located by using the results of the index modules 90 and 100 , as mentioned above, thus providing to the processor a series of documents within with matches for the query terms should be found. Within each such document in which query term matches are found to occur, the following steps 0-6 are executed by the processor. Their operation becomes clearer in the subsequent discussion of FIG. 5 A.
0. The proximity buffer is initially seeded with the first entailing term hit generated by the entailing term generator for this document and an operating parameter penalty-threshold is set to *maximum-penalty-threshold*, the maximum penalty that will be accepted for a query hit. (In the preferred embodiment, this parameter is set to 50. This parameter can obviously be varied and can be made subject to control by the user.)
As mentioned above, the proximity buffer corresponds to the “window” that the method effectively moves through a given document, defining regions of the document where term hits are to be found. The proximity buffer stores everything in a given window, as well as information identifying the size of the window and its position in the document. The “size” of the window may be defined by the beginning position of the window in the document plus the proximity horizon, i.e. the end of the window in the document, which is a variable position as discussed below.
1. The proximity horizon is set based on the position of the first hit in the proximity buffer by adding the proximity window size determined for this query. The proximity buffer is then filled with all qualified entailing term hits, i.e. all of the entailing term hit occurrences that occur within the proximity horizon, by stepping the entailment term hit generator until the next hit would be beyond the proximity horizon or until there are no more entailing term hits. If an entailing term hit is generated that is beyond the proximity horizon, it is left in the generator store to be generated later. These entailing term hits are generated by the method described below in Section 2H.
In the preferred embodiment, the proximity horizon is set to pick up entailing hits within a number of characters equal to: (a) the number of terms in the query times the parameter *proportional-proximity* (e.g. 100), if this parameter is set (by the user or an application); or to (b) a *proximity-threshold* (e.g. 300) number of characters from the position of the first hit in the buffer, if the proportional-proximity parameter is not set. These parameters can be varied or made to depend on the query in other ways, and can be made subject to control by either the user or an executing application or process, or both.
2. The best scoring query hit that can be made from the current contents of the proximity buffer and whose penalty is less than the penalty-threshold is found by the method described below in Section 2G. If no such match can be made, skip to step 6.
3. If this query hit scores no better than the worst hit in the output buffer and the output buffer is already full, this hit is discarded and the method skips to step 6 below. If this query hit overlaps another query hit already in the output buffer, then that hit is replaced with this hit if this hit has a better score, or else this hit is discarded if its score is not better. Otherwise, this query hit is inserted into the output buffer at the appropriate rank according to its penalty score, throwing away the worst hit in the buffer if the buffer was already full. If the output buffer is now full, the parameter penalty-threshold is set to the worst query penalty in the output buffer.
4. If the output buffer is full and the last hit has zero penalty, then the method stops generating hits and return the contents of the output buffer.
5. If there are no more entailing hits to generate, then the method stops and returns the contents of the output buffer.
6. Otherwise, the first term hit in the proximity buffer is removed from the proximity buffer, and the method proceeds to step 1.
The foregoing summary of the method of identifying and sorting query hits is clarified by the flow chart of FIG. 5 A. In general, the method 600 involves the steps of moving a window on the document, the window having a fixed length depending upon the query size, and anchoring the window at some point on the document (beginning with the first entailing term hit). For each window position, the method searches for a passage containing matches for the query terms. The best such matches are put in the output buffer until predetermined maximum number of perfect matches has been located, or until the search has exhausted all documents.
At box 610 of FIG. 5A, the method begins identification of target regions containing matches for the query terms.
At box 620 , the proximity buffer is seeded with the first entailing term hit for the current document, and at box 630 the penalty threshold is set to a predefined maximum. An “entailing term hit” may be defined as follows: for each in the query, there is some set of terms in the term/concept relationship network that could entail that query term. A match for a given query term may include either that query term precisely or some other term that entails that query term. Either type of match is thus referred to herein as an entailing term hit, and the set of all such entailing term hits relative to all such query terms may be referred to as the “entire entailing set”.
At box 640 , the proximity horizon is set as discussed above, i.e. the window is positioned at the next entailing term hit for the current target passage. (At the first pass through this box, the “next” entailing term hit is the first entailing term hit.) At box 650 , the proximity buffer is then filled with all qualified entailing term hits as defined in step 1 above.
At box 660 , the method determines whether there is any query hit that can be made from the term hits in the proximity buffer with a penalty better than (i.e. lower than) the current penalty threshold. On the first pass through, this will be a comparison with the predefined maximum penalty threshold. If there is no such query hit that can be made from the term hits within the proximity buffer, then the first hit in the proximity buffer is removed at box 740 , and the proximity horizon is reset at box 640 with the beginning of the window at the (new) first term in the proximity buffer.
At box 650 , the proximity buffer is again filled with qualified entailing term hits (defined in step 1 above), which in this example results in effectively moving the proximity window down one entailing term hit relative to the previous iteration of step 650 . At box 660 , it is again determined whether there is any query hit that can be made from the (new) contents of the proximity buffer with a penalty lower than the current penalty threshold, and the process continues.
If a query hit is found that meets this test, then the method proceeds to box 670 , where the best query hit (i.e. the query hit with the lowest penalty) in the proximity buffer is designated as the “current” query hit. The best-scoring query hit in the proximity buffer is determined as described generally in Sections 2A-2C above, and a detailed procedure for doing so according to a preferred embodiment is set forth in Section 2G below.
At box 680 , it is determined whether the current query hit's penalty is better (lower) than the worst hit in the output buffer (where the best query hits are stored in preparation for output to display or to a file upon completion of the search procedure). If not, then the current query hit is discarded at box 730 , the first query hit is removed from the proximity buffer at box 740 , and the method proceeds back to box 640 as before, to reposition the window for another try at a better query hit.
If at box 680 the current query hit was better than the worst hit in the output buffer, then at box 690 any lower-scored overlaps are suppressed, meaning that any query hit whose target passage overlaps with the target passage of the current query hit is compared with the current query hit, and the query hit with the lower-score (higher penalty) is discarded. If these two query hits have the same penalty score, then the first query hit is retained.
At box 700 , if the output buffer is full, then at box 710 the processor discards the lowest-scoring entry in the output buffer. The method then proceeds to step 720 , where the current query hit is inserted into the output buffer. This is done by an insertion sort, i.e. the penalty of the current query hit is compared with the first hit in the output buffer, and if it is lower it is inserted above the latter and all the other hits are moved down. If not, then the current hit's penalty is compared with that of the next hit in the output buffer, until one is found that the current hit's penalty exceeds, and the current hit is inserted at that point and the other hits are moved down. This ensures that the output buffer is always sorted upon insertion of the current hit.
Other variations are possible, such as inserting by comparing with the lowest-scoring hit in the output buffer and moving up (coming from the opposite end, in effect), or doing a sort after the search is completed. Other sorts (such as tree sorts) would also be suitable; however, an insertion sort is one convenient method for comparing new current hit penalties with those already stored, and for filling the output buffer and sorting it simultaneously.
At box 750 , the method determines whether the output buffer is now full, given the addition of the latest current query hit. If it is, then the penalty threshold is set to that of the worst query in the output buffer (box 760 ), and in either case the method proceeds to box 770 . Here it is determined whether the last query hit in the output buffer had zero penalty; if so, this indicates that the output buffer is full with zero-penalty hits, and there is no point in searching further, so the method proceeds to box 790 , where the contents of the output buffer are returned, and the method proceeds back to step 540 for displaying, storing, etc. the hits, as before. Note that the size of the output buffer may be selected by the user or set by an executing process, so in general it is variable in size.
If at box 770 the last query hit in the output buffer does not have a zero penalty, then at box 780 the method determines whether there are any more entailing term hits to generate, i.e. whether all entailing term hits from the index have been exhausted. If there are no more hits to be generated, then the method proceeds to box 790 . Otherwise, it proceeds to box 740 , where the first entailing term hit is removed from the proximity buffer, so as to reposition the proximity window to the next entailing term hit. The method then proceeds again to box 640 .
Upon completion of the method 600 of FIG. 5, the output buffer is filled with query hits in a ranked order from best (lowest penalty) to worst.
2G. Method for Determining Best-Scoring Query Hit
Following is a suitable method for determining which of the entailing term hits in the current proximity buffer can be used in conjunction with one another to form a query hit having the best score, i.e. the lowest aggregate or combined penalty. Thus, this method provides a procedure for actually scoring the term hits located within a window on a document.
A. Let q 1 , q 2 , . . . , qm, be the successive query terms of the query q and let x 1 , x 2 , . . . , xn be the sequence of entailing term hits in the current proximity buffer (i.e., within the proximity horizon of the first entailing term hit in the proximity buffer). Search all possible alignments a=(q 1 , xi 1 ), (q 2 , xi 2 ), . . . (qm, xim) of terms in the query with entailing hits from the proximity buffer such that the first term x 1 in the proximity buffer is aligned with one of the query terms and each query term is paired with either one of the xij's in the proximity buffer that entails it or with a marker that indicates that it is missing. These alignments are searched in order to find the best ranking such hit—i.e., the hit with the lowest penalty score as assigned by the following ranking algorithm:
B. For each pair (qj, xij) sum the following penalties:
1. morphological variation penalty—if qj and xij have the same morphological root, but are not the same inflected or derived form (i.e., are not either both root forms, or both singular nouns, or both third person singular verbs, etc.), then penalize each of the two that is not a root form by an amount determined by the parameter *inflection-penalty* or *derivation-penalty* depending on whether the morphological relationship involved is one of inflection or of derivation. (In the preferred embodiment, these penalties are 0.08 and 0.1, respectively. This component of the ranking penalty can obviously be modified to use different penalties or to incorporate different penalties for different kinds of inflection or derivational relationship.)
2. taxonomic specialization penalty—if (the root of) qj is a more general term than (the root of) xij according to the subsumption taxonomy, then penalize the alignment by an amount determined by the parameter *descendants-penalty*. (In the preferred embodiment, this parameter is 0.1. This component of the ranking penalty can obviously be modified to use a different penalty or to incorporate a dimension of semantic distance between the more general term and the more specific term.)
3. semantic entailment penalty—if (the root of) qj is semantically entailed by (the root of) xij according to the known entailment relationships, then penalize the alignment by an amount determined by the parameter *entailments-penalty*. (In the preferred embodiment, this parameter is 0.1. This component of the ranking penalty can obviously be modified to use a different penalty or to incorporate a dimension of entailment strength between the query term and the entailing term.)
4. missing term penalty—if (the root of) qj cannot be aligned with any of the xij terms in the proximity buffer by one of the above relationships (same morphological root, taxonomic specialization relationship between roots, or semantic entailment relationship between roots) and is therefore marked as missing, then penalize that term with a penalty determined as follows:
if the term is in one of the following syntactic word classes:
(adverb auxiliary conjunction initial interjection modal nameprefix operator possessive preposition pronoun punctuation title)
then penalize it by *missing-qualifier-penalty*
if the term is or can be a verb
then penalize it by *missing-verb-penalty*
if the term is one of the syntactic word classes
(adjective, determiner)
then penalize it by *missing-adjective-penalty*
otherwise penalize it by *missing-term-penalty*
(In the preferred embodiment, the missing-qualifier-penalty is 2; the missing-verb-penalty is 5; the missing-adjective-penalty is 7.5; and the missing-term-penalty is 10. This component of the ranking penalty can be modified to use different penalties or different categories of penalties or to incorporate a dimension of term frequency or term importance or syntactic role to determine the penalty for a missing term.)
C. To the above accumulated penalties, add the following penalties that are determined for the alignment as a whole:
5. proximity ranking penalty—For each successive pair of entailing terms in the alignment in order of their occurrence in the text, penalize any gap between them that is larger than a single character by an amount equal to the parameter *gap-penalty-factor* times one less than the number of characters between them. (In the preferred embodiment, this parameter is 0.005. This component of the ranking penalty can obviously be modified to use a different penalty factor or to use a word count or other proximity measure other than a character count to measure the gap between words.)
6. permutation penalty—For each successive pair of query terms, if the corresponding entailing terms in the alignment are not in the same order in the text, then penalize this hit by an amount equal to the parameter *out-of-order-penalty*. (In the preferred embodiment, this parameter is 0.25. This component of the ranking penalty can obviously be modified to use a different penalty factor or to use various other measures of the degree to which the order of the terms in the hit is different from the order of terms in the query.)
7. internal boundary penalty—Scan the portion of the text covered by the region from the earliest entailing hit of the alignment to the latest entailing hit of the alignment and for each sentence boundary or paragraph boundary contained in that portion of the text, add a penalty equal to the parameter *cross-sentence-penalty* or *cross-paragraph-penalty* depending on whether the boundary is an end of sentence or a paragraph boundary. (In the preferred embodiment, these parameters are 0.1 and 50, respectively. This component of the ranking penalty can obviously be modified to use different penalties.)
If at any point it can be determined that the penalty score of a partially generated alignment is already worse than the score of some other alignment that can be generated or is worse than the specified penalty threshold, then the inferior partial alignment can be discarded at that point and not considered further. There are many conventional techniques for performing such searches to be found in the literature on computer science search algorithms.
D. Choose the alignment with the best (smallest) total penalty if one can be found that is better than the penalty threshold. This completes the penalty scoring of the terms, and hence the location of the best-scoring query hit from the current proximity buffer.
2H. Method for Generating Entailing Term Hits
This method utilizes the term/concept relationship network 110 , which can either be constructed manually off-line or automatically constructed during the indexing process by the method described Section 1, and further described in Section 2I below, using a knowledge base of manually constructed relationships and morphological rules. In this network, any given term that occurs in the corpus of indexed material or may occur in a query term is represented and may be associated with one or more concepts that the term in question may denote. These words and concepts in turn can be related to each other by the following morphological, taxonomic, and semantic entailment relationships:
1. term x is a root form of an inflected or derived term y.
2. term or concept x taxonomically subsumes term or concept y (i.e., term or concept x is a more general term or concept than term or concept y).
3. term or concept x may be entailed by term or concept y.
In general, these relationships must be looked up in knowledge bases of such relationships ( 120 , 150 and 180 ), which are constructed off-line by data entry. Some morphological relationships, however, can be derived automatically by morphological rules applied to inflected and derived forms of words encountered in the text. Such morphological rules are generally part of the conventional systems in computational linguistics.
The entailing terms for a query q=q 1 , q 2 , . . . , qm (the “entire entailing set”) will be the set of all terms that occur in the corpus that entail any of the terms qi in q, where a term x entails a term qi if any of the following hold:
1. x or a root of x is equal to qi or a root of qi
2. x or a root of x taxonomically subsumes qi or a root of qi or a concept denoted by x or a root of x taxonomically subsumes qi or a root of qi or a concept denoted by qi or a root of qi
3. x or a root of x is semantically entailed by qi or a root of qi or a concept denoted by x or a root of x is semantically entailed by qi or a root of qi or a concept denoted by qi or a root of qi.
The entailing term hits for a query q=q 1 , q 2 , . . . , qm will be the sequence of all term occurrences in the corpus that entail any of the terms qi in q or any concepts that are denoted by terms qi in q. These entailing term hits are generated in order of their occurrence in the corpus by creating a collection of generators for each entailing term, each of which will generate the occurrences of that term in order of their occurrence in the corpus (determined first by a default ordering of all of the documents of the corpus and secondarily by the position of the term occurrence within a document). At any step of the generation, the next generated entailing term hit is generated by choosing the entailing term generator with the earliest hit available for generation and generating that term hit. At the next step of generation, a different entailing term generator may have the earliest hit available to generate. This entailing term hit generator can be called repeatedly in order to find all of the entailing term hits that occur within a window of the corpus starting at some term occurrence in some file and continuing until some proximity horizon beyond that root term occurrence has been reached.
2I. Generating the Term/Concept Relationship Network
During indexing as described in Section 1 above (or in a separate pass) as each word or phrase in the indexed material is encountered, it is looked up in a growing term/concept relationship network 110 of words and concepts and relationships among them that is being constructed as the corpus is analyzed. If the word or phrase is not already present in this tern/concept relationship network 110 , it is added to it.
The first time each such word or phase is encountered, it is also looked up in manually constructed external knowledge bases of word and concept relationships ( 120 , 150 and 180 ), and if it is found in these external networks, then all words and concepts in the external networks that are known to be entailed by this word or phrase or that are derived or inflected forms of this word or phrase are added to the growing term/concept relationship 110 network together with the known relationships among them. If such a word or phrase is not found in the external network, then it may be analyzed by morphological rules to determine if it is an inflected or derived form of a word that is known in the external knowledge bases ( 120 , 150 and 180 ), and if so, its morphological relationship to its root is recorded in the term/concept relationship network and its root form is treated as if it had occurred in the corpus (i.e., that root is looked up in the external networks and all of its entailments, inflections, derivations, and relationships are added).
At the end of this process, a term/concept relationship network will have been constructed that contains all of the terms that occur in the corpus plus all of the concepts entailed by or morphologically related to them, together with all of the known morphological, taxonomic, and entailing relationships among them. This network is then used in processing queries to find entailing term hits for query terms.
2J. Query Size Procedural Adaptation
The system of the invention has in trial runs proven to be particularly effective for handling short queries of two or three words, or perhaps up to about six, in contrast to traditional retrieval methods, which are generally poor at handling short queries. Thus, a further enhancement of the invention may be had by using conventional word search techniques when one or more than some number N words are to be searched. The number N may be preset or may be selected by the user or a process in response to the success of the searching results, and may be 3-6 or more, depending upon the generated results. Such a system uses the best of both conventional techniques and the present invention, whose operation would thus be confined to the particularly difficult region of queries with just a few words.
The system of the invention has in trial runs proven to be particularly effective for handling short queries of two or three words, or perhaps up to about six, in contrast to traditional retrieval methods, which are generally poor at handling short queries. Thus, a further enhancement of the invention may be had by using conventional word search techniques when one or more than some number N words are to be searched. The number N may be preset or may be selected by the user or a process in response to the success of the searching results, and may be 3-6 or more, depending upon the generated results. Such a system uses the best of both conventional techniques and the present invention, whose operation would thus be confined to the particularly difficult region of queries with just a few words.
2J. Document Retrieval Application
This passage retrieval technique can be applied to conventional document retrieval problems, to retrieve and rank documents by giving each document the score of the best passage it contains. | The present mechanism relates to a method and apparatus for generating responses to queries to a document retrieval system. The system responds to a specific request for information by locating and ranking portions of text that may contain the information sought. It locates small relevant passages of text (called “hit passages”) and ranks them according to an estimate of the degree to which they correspond to the information sought. The system minimizes the number of these hit passages that need to be examined before an information seeker has either found the desired information or can safely conclude that the information sought is not in the collection of texts. A relaxation ranking mechanism is provided to accommodate paraphrase variations that occur between the description of the information sought and the content of the text passages that may constitute suitable answers, by retrieving phrases that are dissimilar to the query phrase to different degrees according to a predefined set of rules, and penalizing the retrieved phrases based upon the degree of this dissimilarity, thus providing the user with a priority organized query hit list. | 8 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This application is a continuation application of U.S. patent application Ser. No. 12/863,602, filed on Jul. 20, 2010 (issuing as U.S. Pat. No. 8,684,678 on Apr. 1, 2014), which claims priority to German patent applications DE 10 2008 005 406.2 filed on Jan. 21, 2008, DE 10 2008 000 776.5 filed on Mar. 20, 2008, and PCT/EP2009/05053 filed on Jun. 27, 2009. All of these applications are hereby incorporated by reference in their entirety.
TECHNICAL FIELD
The invention relates to a turbine, in particular for an exhaust gas turbocharger with a turbine rotor rotatably mounted in a housing, which is associated with at least one guide apparatus forming a radial inlet channel for a medium driving the turbine rotor.
Furthermore, the invention relates to an exhaust gas turbocharger, in particular for a motor vehicle having a turbine and a compressor which are operationally connected with each other mechanically.
BACKGROUND
Turbines, in particular in motor vehicle construction, are known from the prior art in connection with gas turbochargers having a turbine rotor rotatably mounted in a housing, which is associated with a least one guide apparatus forming a radial inlet channel for a medium driving the turbine rotor. In motor vehicle construction turbochargers are used to increase the power and the rotational moment of a combustion engine. The turbine more specifically the turbine rotor of the turbine of such an exhaust gas turbocharger is driven by an exhaust gas flow of the combustion engine and in turn drives a compressor which in turn compresses and drives drawn-in fresh air into the cylinders of the combustion engine. By compressing the fresh air the fresh air component introduced in the cylinders of the combustion engine is increased and the power and rotational moment increase achieved as a result. Since the turbine is driven by the exhaust gas of the combustion engine no additional units for increasing the charging volume of the cylinders are necessary. In the meantime, turbines are also used which have a so-called variable turbine geometry (VTG). Turbines with variable turbine geometry are based on the mode of operation of the Francis turbine and serve to better or optimally adjust/adapt the power output and the response characteristics of the turbine or the exhaust gas turbocharger to different points of operation. To achieve this, a turbine with variable turbine geometry comprises a guide apparatus assigned to the turbine rotor and which forms a radial inlet channel for the medium (in this case the exhaust gas of the combustion engine) driving the turbine rotor. In the inlet channel formed by the guide apparatus adjustable guide vanes are arranged which radially surround the turbine rotor. These guide vanes can be adjusted with respect to their vane angle to change the flow cross section of the inlet channel. Usually, the guide vanes are distributed evenly or at equal angles over the circumference of the turbine rotor and, spaced from this, on a guide vane bearing ring of the guide apparatus. The vane angle of the guide vanes for example is set in such a manner that with a low throughput of the medium driving the turbine rotor and with simultaneously high power requirement the flow cross section in the inlet channel is reduced so that the medium is directed onto the turbine vanes in an accelerated manner, as a result of which the rotational speed of the turbine and thus the power of the compressor or the exhaust gas turbocharger is increased. Conversely, with a high throughput of the medium and a low power requirement, the flow velocity of the medium can be reduced through a large flow cross section, as a result of which the power of the turbine and thus that of the exhaust gas turbocharger is reduced.
From the European Patent Publication EP 0160460 B1 a turbine as described above is known, wherein the vane bearing ring is mounted axially displaceably and, together with a housing section of the housing of the turbine, axially delimits the inlet channel.
SUMMARY
The invention provides for a turbine with a turbine rotor rotatably mounted in a housing, which is associated with at least one guide apparatus forming a radial inlet channel for a medium driving the turbine rotor, wherein the guide apparatus comprises a guide vane bearing ring as well as a guide vane cover ring having a plurality of guide vanes radially surrounding the turbine rotor and located in the inlet channel, and wherein the inlet channel is axially delimited by the guide vane bearing ring and the guide vane cover ring and the guide apparatus is mounted in the housing in an axially and/or radially moveable manner for material relaxation. The turbine according to the invention thus comprises a guide apparatus which, in addition to the guide vane bearing ring comprises a guide vane cover ring, which together with the guide vane bearing ring axially delimits the inlet channel for the medium driving the turbine rotor. The guide vane bearing ring and the guide vane cover ring, as the name implies, are each designed as a ring. Throughout the present application, guide vane bearing ring and guide vane cover ring each therefore does not mean a bush or a bush-like element but a ring, comprising a simple cross section preferably substantially rectangular in shape, whose radial extension is substantially equal or preferentially greater than its axial extension. Here, the guide vane cover ring is arranged parallel to the guide vane bearing ring, wherein the distance between the guide vane bearing ring and the guide vane cover ring substantially corresponds to the width or the axial extension of the guide vanes.
The guide vane cover ring has the advantage that stresses and/or deformations of the housing of the turbine, which for example develop based on mechanical overloading and/or based on temperature-related stresses and/or deformations, do not impair the efficiency of the guide apparatus. The design of the guide apparatus by means of rings guide vane bearing ring and guide vane cover ring allows particularly simple and cost-effective manufacture of the turbine.
In the mentioned prior art the guide vanes directly contact the housing of the turbine. Any deformation of the housing for the above mentioned reasons in this case will result in high friction values between the guide vanes and the housing in the event of an adjustment or a change of the vane angle of the guide vanes. It this stresses and deformations of the housings are sufficiently high, the guide vanes can no longer be adjusted or actuated. The variable turbine geometry is thus no longer functional. The guide vane cover ring thus substantially decouples the housing of the turbine, so that the guide vane cover ring acts like a buffer for the stresses and deformations that occur in the housing. In addition to this, the guide vane cover ring is advantageously manufactured of a high-quality material. The guide vanes which in operation contact the guide vane cover ring and move if required, easily lead to rapid corrosion, erosion and/or rapid wear of the contact points on the guide vane cover ring. These corrosion points can be so pronounced that the guide vanes “seize” on the guide vane cover ring. This also prevents adjusting of the flow cross section of the inlet channel by means of the guide vanes. The advantageous guide vane cover ring which, as already mentioned, is manufactured of the high-quality material, prevents such corrosion because of its material properties. Obviously it will also be conceivable to manufacture the entire turbine housing of the high-quality material, but this would result in extremely high costs and high manufacturing expenditure, which can be avoided through the use of the advantageously designed guide vane cover ring. According to the invention, the entire guide apparatus consisting of the guide vane bearing ring, the guide vanes and the guide vane cover ring is now mounted axially and/or radially moveable in the housing for material relaxation. The guide apparatus is not fixed to the housing for example by means of a screw connection. The guide apparatus mounted axially and/or radially moveable allows relative movement between itself and the housing, as a result of which stresses both in the guide apparatus as well as in the housing are reduced and because of this the lifespan of the guide apparatus or the turbine is increased. This allows temperature-related expansion/extension of the individual components of the guide apparatus without stresses developing in the guide apparatus, particularly when hot exhaust gasses of a combustion engine are admitted to the turbine. In radial and/or axial extension of the guide apparatus play is practically provided to the housing which is of such a size that the material of the guide apparatus and/or of the housing can expand even under high (temperature) loading without “jamming” the guide apparatus in the housing. The mounting of the guide apparatus thus allows relaxation of the material through axial and/or radial (compensatory) movement.
According to a further development of the invention the guide apparatus is mounted axially moveable without preload. The guide apparatus now lies in the housing in a “loose” or “floating” manner so that it can freely move for material relaxation.
However, the guide apparatus is preferably subjected to an axial preload and/or radial clamping which fix the guide apparatus axially and/or radially in the housing in such a manner that the guide apparatus is pressed against the housing and wobbling for example due to shocks or vibrations is thus prevented. Practically, the preload is selected such that it is significantly smaller than the stresses that occur in the guide apparatus, in particular due to temperature. The guide apparatus is thus mounted in the housing in a floating manner (without preload) or with at least a (small) preload.
Advantageously the guide vane bearing ring and the guide vane cover ring each lie in an axial depression of the housing. The axial depression in this case can for example be milled, turned or bored into the housing in a simple manner. Practically, the contour of the axial depression substantially corresponds to that of the guide vane bearing ring or that of the guide vane cover ring, so that these have the necessary play for material relaxation at their disposal.
According to a further development of the invention the housing is designed in multiple parts. This makes possible particularly simple and cost-effective assembly of the guide apparatus in the housing or in the axial depressions of the housing. Practically, the guide apparatus is initially placed axially in the axial depression of a housing part and the other housing part subsequently pushed onto the (axial) free end of the guide apparatus.
Advantageously, the first housing part is a turbine housing. The turbine housing substantially surrounds the turbine rotor of the turbine and practically comprises a radial, more preferably ring-spiral shaped inlet channel which directs the medium towards the inlet channel of the guide apparatus and a central or axial outlet channel, which extends in the axial extension of the turbine rotor.
Practically, the second housing part is a bearing housing. In the bearing housing a shaft, on which the turbine rotor is mounted in a rotationally fixed manner, is rotatably mounted. Particularly preferably, the shaft is mounted in the bearing housing by means of one or a plurality of rolling bearings such as for example grooved ball bearings, tapered roller bearings etc. Slide bearing mounting of the shaft is also conceivable. The bearing housing axially follows the turbine housing.
Furthermore it is provided that the axial depression for the guide vane bearing ring is formed in the bearing housing and the axial depression for the guide vane cover ring in the turbine housing. In principle, reverse arrangement is also possible, wherein the guide vane bearing ring lies in the axial depression in the turbine housing and the guide vane cover ring in the axial depression of the bearing housing. Preferred, however, is the first version, since in this case the necessary mechanism for the displacement of the guide vanes for package reasons (space) can be more easily arranged in the bearing housing than in the turbine housing, which has to be designed particularly flow-favourable for the medium driving the turbine rotor.
An advantageous further development of the invention provides that the turbine comprises at least one axial spring element for generating the axial preload. As already mentioned above, the spring load, compared to the temperature-related stresses of the guide apparatus, is selected small. Here, it can be provided that merely an axial spring element is used, which presses the guide apparatus against one of the axial depressions, or two or more axial spring elements can be provided which are each arranged for example at an axial end of the guide apparatus.
Preferably, the axial spring element is arranged between the guide vane bearing ring and the housing, or the bearing housing, and/or between the guide vane cover ring and the housing, or the turbine housing. If the axial spring element is arranged between the guide vane bearing ring and the bearing housing, this has the advantage that the axial spring element is not severely heated since the bearing housing is relatively cool. The reason for this is that it does not come in contact with the hot exhaust gas or only to an extremely minor degree. Through the arrangement of the axial spring element of the bearing housing the lifespan of the spring is thus increased or guaranteed. If the axial spring element however is arranged (axially) between the guide vane cover ring and the turbine housing it is located on the hot side of the turbine. Because of this, the guide apparatus is pressed in the direction of the cold side, that is against the bearing housing. Through the direct contact of the guide vane bearing ring with the bearing housing the guide apparatus is “cooled” by the bearing housing.
Advantageously, the axial spring element is designed as helical spring, coil spring or disc spring. Wherein, in addition to the mentioned axial spring element types, the use of an O-ring, taper ring, barrel spring ring, B-ring, C-ring, a metal sealing ring or a sponge-like fabric is conceivable for example. The material of the axial spring element can be of a wide range of types such as for example metal or a composite material or ceramic. Particularly preferred, the disc spring is simultaneously designed as heat shield and/or as seal.
Furthermore, it is provide that the turbine comprises at least one radial spring element for radiating the radial preload. This is preferably arranged between the housing and the outer and/or inner circumference of the guide vane cover ring. Like the axial spring element the radial spring element has a spring force which relative to the stresses developing in the guide apparatus, is small, so that the guide apparatus can radially expand freely so that its material remains low-stressed or “relaxed”.
Particularly preferably, the radial spring element is designed as a wavy ring. The wavy ring, also called bearing compensation ring, in this case extends over the entire inner or outer circumference of the guide vane cover ring or the guide vane bearing ring. Obviously an open guide vane cover ring or guide vane bearing ring is also conceivable.
In an advantageous further development of the invention the turbine comprises at least one radial-axial spring element for generating the axial and the radial preload. Instead of an axial spring element and a radial spring element it is thus provided to use a single radial-axial spring element which simultaneously generates the axial and radial preload, applying it to the guide apparatus. The radial-axial spring element can for example be formed of a pleated ring with radial pleats which contacts the housing and the guide apparatus both axially as well as radially.
Furthermore, it is provided in an advantageous further development of the invention that the guide vane bearing ring and the guide vane cover ring are axially and/or radially displaceable relative to each other for material relaxation. Here, not only the entire guide apparatus is moveably mounted in the housing, but the individual components/parts of the guide apparatus are also moveably mounted relative to one another. Wherein in the case of preload-free mounting of the guide apparatus the guide vane bearing ring and the guide vane cover ring are also loose, that is moveable, relative to each other without preload. If the guide apparatus is subjected to axial preload this obviously also has an effect on the components of the guide apparatus so that the guide vane bearing ring is axially pressed against the guide vane bearing ring (or vice versa). The free moveability or the loose arrangement of the guide apparatus and that of the guide vane bearing ring to the guide vane cover ring results in that the play of the guide vanes between the guide vanes and the guide vane cover ring can be designed particularly small, as a result of which the (thermodynamic) efficiency of the turbine is improved. The turbine thus designed with “floating” variable turbine geometry makes possible minimal deformations and stresses. Through the free moveability of the guide vane bearing ring and the guide vane cover ring the friction between the guide vanes and the guide vane cover ring is reduced so that in this case corrosion formation, erosion and/or wear are also prevented.
Advantageously, at least one, preferably a plurality of axial spacers is provided between the guide vane bearing ring and the guide vane cover ring. These axial spacers secure a minimum spacing of the guide vane bearing ring from the guide vane cover ring which is defined by the axial extension of the axial spacer. The size of the axial spacer is practically selected in such a manner that between the guide vanes and the guide vane cover ring and the guide vane bearing ring preferably small play is present and a preferably low friction is in effect when adjusting the guide vanes.
Advantageously, the axial spacers are arranged or fixed on the guide vane bearing ring and/or the guide vane cover ring. Thus all of the axial spacers can be arranged on the guide vane cover ring or on the guide vane bearing ring or for example alternately on the guide vane cover ring and the guide vane bearing ring. In addition to this is conceivable that the axial spacers are designed in two parts, wherein one part is arranged on the guide vane bearing ring and the other part opposite on the guide vane cover ring. Because of the geometry of the components and the different temperature loading the guide vane cover ring is not deformed as much as the guide vane bearing ring. For this reason, the axial spacers are preferably arranged or fixed on the guide vane cover ring. Inclined positioning of the guide vane cover ring due to temperature-related stresses is only minor so that the axial spacers change their contact with the guide vane bearing ring only to a minor degree and thus the axial extension or the width of the inlet channel and thus also the play between the guide vanes and the guide vane cover ring and the guide vane bearing ring is changed/influenced only to a minor degree.
Particularly preferably, the axial spacers are unitarily formed with a guide vane bearing ring or the guide vane cover ring. Practically, the axial spacers are arranged evenly or equiangularly or unevenly or non-equiangularly on the end face of the guide vane bearing ring and/or the guide vane cover ring facing the inlet channel. If the axial spacers are designed in two parts the two parts are each preferably designed unitarily with the guide vane bearing ring or the guide vane cover ring.
Furthermore, it is provided that the turbine comprises at least one pin connection for positioning and/or aligning the guide apparatus, the guide vane bearing ring and/or the guide vane cover ring on the housing. Preferably the pin connection comprises at least one pin which is inserted in a pin reception of the guide apparatus or one of its components and/or the housing. By using one or a plurality of pin connections the assembly of the turbine remains simple and cost-effective.
Practically, at least one pin reception is designed as elongated hole so that relocating or moving of the guide apparatus, the guide vane bearing ring or the guide vane cover ring relative to the pin inserted in the pin reception is possible.
Preferably, the elongated hole is orientated radially or axially in its longitudinal extension. If the elongated hole is orientated radially, radial movement of the pin engaging in the elongated hole or an extension of the component comprising the pin is possible without generating stress. If the elongated hole in its longitudinal extension is orientated axially, that is parallel to the rotational axis of the turbine rotor, corresponding expansion of the material due to rising temperatures is possible in axial direction without stresses being generated.
Advantageously, the pin is orientated axially and/or radially. In both cases it acts as positioning device or anti-rotation safety. If it is orientated axially, it allows axial movement of the guide apparatus or its components for material relaxation. If it is orientated radially it correspondingly allows radial movement/expansion for material relaxation. Obviously in both cases it is presumed that the pin in its longitudinal extension is moveably mounted with adequate play.
Furthermore, it is provided that at least one pin of a pin connection is formed by one of the axial spacers. Here it is provided that the axial spacer protrudes through the guide vane bearing ring or the guide vane cover ring and stands away on the face end located opposite the inlet channel from the corresponding ring and engages in a pin reception of the housing. Alternatively to this, the pin is likewise designed unitarily with the respective ring or the housing.
Particularly preferably, the turbine is additionally designed in such a manner that the line of flux of the axial preload through the guide apparatus substantially runs parallel to the rotational axis of the turbine rotor. It is thus provided that the line of flux of the axial preload substantially runs axially or axially through the guide apparatus. In the case of large spring forces and under unfavourable transient conditions during which for example the axial spring element on the one hand is still cold and brings about a great axial force or preload and on the other hand the guide vane cover ring is already heated and can no longer tolerate high stresses, the guide vane bearing ring and/or the guide vane cover ring can be deformed particularly dish-like through the force of the axial spring element if the line of flux through the guide vane bearing ring and/or through the guide vane cover ring substantially runs radially or in radial direction. Through the substantially axial course of the line of flux the occurrence of moments in the guide apparatus resulting in deformations is prevented. As a consequence, greater axial spring forces can be tolerated, deformations particularly under transient conditions are smaller so that the play of the guide vanes can be selected smaller, as a result of which the efficiency of the turbine is improved and the lifespan increased. More favourable materials can also be used.
Practically, at least one axial spring contact region of the guide apparatus is substantially located on the same radius as the axial spacer or, for example if a plurality of axial spacers and/or axial spring elements or axial spring contact regions are provided, as the axial spacers. This guarantees a substantially axial line of flux of the axial preload from the axial spring element through the guide apparatus via the axial spacers. The axial spring contact region in this case is obviously arranged on the side of the guide vane bearing ring or the guide vane cover ring facing away from the axial spacer, depending on which side the of the guide apparatus the axial spring element or elements is/are provided/arranged.
Advantageously, the axial spring contact region is arranged aligned with the axial spacer. If a plurality of axial spring elements and a plurality of spacers are provided, the corresponding axial contact regions are each arranged or orientated aligned with an axial spacer. The axial spring contact region or the axial spring contact regions are thus arranged in the imagined extension of the axial spacer or spacers. Because of this, it is prevented that moments occur in circumferential direction which can likewise result in deformation of the guide vane cover ring and/or the guide van bearing ring. If, therefore, the axial force introduction point from the axial spring element and the force transmission point to the axial spacer are approximately at the same height, no undesirable stresses and deformations occur.
Advantageously, at least one axial contact region of the housing is substantially located on the same radius as the axial spacer and/or as the axial contact region of the guide apparatus. The guide apparatus of the contact region in this case obviously means the region of the housing which the guide apparatus with the guide vane cover ring or, if applicable, with the guide vane bearing ring contacts axially. Thus the axial guide apparatus contact region is formed for example through one of the axial depressions described above in which the guide apparatus lies. Wherein, if the guide apparatus with the guide vane cover ring contacts the axial contact region with the entire area of the guide vane cover ring, the line of flux through the guide apparatus already runs substantially axially because of the arrangement of the axial spacer/the axial spacers and of the axial spring contact region/the spring contact regions. If, however, in the housing advantageously one or a plurality of clearances or recesses open at the edge towards the guide vane cover ring are provided through which the medium driving the turbine rotor can flow for heating the guide vane cover ring on both sides, the guide vane cover ring only partially contacts the housing, wherein the axial contact region of the housing, as described above, is then practically arranged substantially on the same radius as the axial spacer or axial spacers. If a plurality of clearances or recesses are arranged distributed equiangularly over the circumference of the guide vane cover ring or the axial contact region of the housing, the axial (part) contact regions located in between are preferably arranged aligned with the spacers so that in this case moments in circumferential direction resulting in deformations are also prevented. Obviously, the axial contact region and/or the axial spring contact region can each be also designed as contact point or line.
Finally, it is provided that the line of flux of the axial preload does not deviate by more than 20% from the radius on which the spacer or spacers are located. Because of this a line of flux flow range is defined, within which the line of flux substantially runs axially or is axial. Through corresponding arrangement of the axial spring element or the axial spring contact region, of the axial spacer/or the axial contact region of the housing, as described above, this preferred line of flux flow range can be achieved.
BRIEF DESCRIPTION OF THE DRAWINGS
The exhaust gas turbocharger according to the invention is characterised by a turbine as has been described above.
In the following the invention is explained in more detail by means of several drawings. Here it shows
FIG. 1 An exemplary embodiment of a turbine with a guide apparatus that is axially and radially moveable with-out preload,
FIG. 2 A turbine with an axial spring element between the guide apparatus and a turbine housing,
FIG. 3 The turbine with the axial spring element between the guide apparatus and a bearing housing,
FIG. 4 A further exemplary embodiment of the turbine with pin connections,
FIG. 5 A further exemplary embodiment of the turbine with axial spacers,
FIG. 6 The turbine from FIG. 5 with a pin connection,
FIG. 7 A further exemplary embodiment of the turbine with a radial spring element,
FIG. 8 An enlarged detail of the turbine from FIG. 7 ,
FIG. 9 The turbine of FIG. 7 with an alternative radial spring element,
FIG. 10 A further exemplary embodiment of the turbine with a pin connections,
FIG. 11 A further exemplary embodiment of the turbine with pin connections,
FIG. 12 A further exemplary embodiment of the turbine with pin connections,
FIG. 13 An exemplary embodiment of the turbine with a radial-axial spring element,
FIG. 14 A further exemplary embodiment of the turbine with an axial spring element and a radial spring element,
FIG. 15 The turbine with an alternative radial-axial spring element,
FIG. 16 A further exemplary embodiment of the turbine with two axial spring elements on a side of the guide apparatus,
FIG. 17 A further exemplary embodiment of the turbine with a coil spring as axial spring element,
FIG. 18 A further exemplary embodiment of the turbine with recesses and,
FIG. 19 A preferred line of flux flow through the guide apparatus.
DETAILED DESCRIPTION
FIG. 1 shows a turbine 1 of an exhaust gas turbo-charger for a motor vehicle which is not shown in more detail here in a schematic sectional representation. The turbine 1 comprises a turbine rotor 4 rotatably mounted about a rotational axis 3 in a housing 2 , wherein only the part above the rotational axis 3 is shown. The housing 2 of the turbine 1 is designed in two parts, wherein one part forms a turbine housing 5 and the other part a bearing housing 6 , wherein the bearing housing 6 with respect to the rotational axis 3 axially follows the turbine housing 5 , and between the turbine housing 5 and the bearing housing 6 a flow cross section for a medium driving the turbine rotor is formed. The medium, in the present exemplary embodiment the exhaust gas of the combustion engine, can radially flow into the housing 2 to the turbine rotor 4 and once it has performed work on the turbine rotor 4 , again axially exists from the turbine housing 5 as indicated by the arrows 42 .
In the housing 2 of the turbine 1 a guide apparatus 7 , which has a variable turbine geometry and forms a radial inlet channel 9 for the medium in the flow-through cross section between the turbine housing 5 and the bearing housing 6 , is additionally mounted. The guide apparatus 7 comprises a guide vane bearing ring 10 , which coaxially to the rotational axis 3 lies in an axial depression 11 of the bearing housing 6 . On the guide vane bearing ring 10 a plurality of guide vanes 8 of which only one is shown here are equiangularly arranged distributed over the guide vane bearing ring 10 , so that they surround or frame the turbine rotor 4 . The guide apparatus 7 additionally comprises a guide vane cover ring 12 which is orientated coaxially to the rotational axis 3 and lies in an axial depression 13 of the turbine housing 5 . The guide vane bearing ring 10 and the guide vane cover ring 12 thereby axially delimit the inlet channel 9 for the medium driving the turbine rotor 4 . The axial spacing of the guide vane bearing ring 10 from the guide vane cover ring herein corresponds substantially to the width of the guide vanes 8 . By adjusting the vane angle of the guide vanes the flow-through cross section in the inlet channel can thus be adjusted or influenced in operation. By means of this, the power of the turbine 1 can for example be adapted to different operating conditions/operating points. For adjusting, the guide vanes 8 each have a lever arm 14 . Advantageously, for actuating or adjusting the vane angle of the guide vanes 8 , an adjusting ring which is not shown in more detail here is provided, which is arranged on the side of the guide vane bearing ring 10 located opposite the inlet channel 9 and operationally connected with the lever arms 14 so that by twisting the adjusting ring all guide vanes 8 can be simultaneously adjusted with respect to their vane angle.
In the exemplary embodiment of FIG. 1 the guide apparatus 7 is mounted axially and radially moveably without preload for material relaxation. To this end, axial play is provided between the guide vane bearing ring 10 and the bearing housing 6 and/or between the guide vane cover ring 12 and the turbine housing 5 , which allows expansion of the components of the guide apparatus 7 because of the high temperature of the exhaust gas without the guide apparatus 7 or it components (guide vane bearing, guide vanes, guide vane cover ring) having to be clamped in the housing 2 in such a manner that stresses develop in the components and/or the individual components are deformed. In operation, the guide apparatus 7 can thus expand axially for example as a result of which material stress is reduced/prevented or material relaxation is guaranteed. Material relaxation here substantially means the prevention of the occurrence of stresses in the material of the components of the guide apparatus 7 such as for example the material of the guide van bearing ring pin or of the guide vane cover ring 12 . The radial moveability of the guide apparatus 7 or its components or parts is guaranteed through a suitably wide formation of the axial depressions 11 and 13 , so that the guide vane bearing ring 10 in the bearing housing 6 is arranged radially spaced from the bearing housing 6 and the guide vane cover ring 12 is arranged radially spaced from the turbine housing 5 . Thus the guide apparatus 7 or its components can radially grow unimpeded, so that no stresses are generated. In the present exemplary embodiment the components of the guide apparatus 7 loosely contact the housing 2 or one another. In other words, the guide apparatus 7 is mounted in the housing 2 of the turbine 1 in a floating manner. This mounting of the guide apparatus 7 allows relative movement between the guide apparatus 7 and the housing 2 or among the components the guide apparatus 7 , as a result of which stresses in the components are reduced and the lifespan of the turbine 1 is increased. This makes it possible that a particularly small play can be selected between the guide vanes 8 and the guide vane cover ring 12 . In that the guide apparatus 7 or its components are mounted axially moveably it is prevented that the guide vanes 8 also ‘) am” between the guide van bearing ring 10 and the guide vane cover ring 12 under high temperature loading. The friction between the guide vanes 8 and the guide vane cover ring 12 is likewise reduced when adjusting the vane angle of the guide vanes 8 . Because of this it is additionally prevented that rapid corrosion/rapid wear of the guide vane cover ring 12 or the guide vanes 8 takes place. Because of the floating mounting or because of the absence of screws and/or threaded bores this concept is particularly favourable in production and can be easily assembled. The guide apparatus 7 in this case can be provided and installed in the turbine 1 as a preassembled assembly. Alternatively the components of the guide apparatus 7 can be inserted individually.
In order to secure a minimum axial spacing between the guide vane bearing ring 10 and the guide vane cover ring 12 , axial spacers 15 are provided between the guide vane bearing 10 and the guide vane cover ring 12 . These are advantageously arranged equiangularly, while obviously uneven distribution is also conceivable. The axial spacers 15 can be optionally arranged or fixed on the guide vane bearing ring 10 , on the guide vane cover ring 12 or alternately on the guide vane bearing ring 10 and the guide vane cover ring 12 . Particularly preferably the axial spacers 15 are designed unitarily with the guide vane bearing ring 10 or the guide vane cover ring 12 .
The turbine rotor 4 is arranged on a shaft 16 which leads into the bearing housing 6 where it is suitably mounted rotatably for example by means of rolling bearings and/or slide bearings. On the end of the shaft 16 located opposite the turbine rotor 4 a compressor rotor of a compressor of the exhaust gas turbocharger is suitably arranged on the shaft 16 in a rotationally fixed manner. To prevent that hot exhaust gas flows into the bearing housing 6 , a sealing element 17 is additionally arranged between the shaft 16 and the bearing housing 6 .
FIG. 2 shows a further exemplary embodiment of the turbine 1 known from FIG. 1 , wherein elements known from FIG. 1 are provided with the same reference characters and are not explained again. This applies also to the following FIGS. 3 to 17 , in which already known elements are provided with already used reference characters. FIG. 2 shows the turbine 1 in a further simplified representation, wherein the guide apparatus 7 in a simplified manner is merely shown as a box 107 . In contrast with the preceding exemplary embodiment the guide apparatus in FIG. 2 is subjected to axial preload. This is generated by an axial spring element 18 which is arranged between the guide apparatus 7 or the guide vane cover ring 12 which is not shown here and the turbine housing 5 . The axial spring element 18 thus presses the guide apparatus 7 against the bearing housing 6 . Thus the guide apparatus 7 contacts the bearing housing 6 as a result of which heat can be effectively and efficiently discharged to the bearing housing 6 , so that the guide apparatus 7 is cooled by the bearing housing 6 . Through the axial preload the individual components of the guide apparatus 7 are also pressed against one another. Thus the axial spring element loads the guide vane cover ring 12 , which in turn presses onto the guide vanes 8 or, if, present, onto the axial spacers 15 which determine the guide vane play and thus onto the guide vane bearing ring 10 . The spring force of the axial spring element 18 is advantageously selected so small that temperature-related deformations of the guide apparatus 7 or its components do not result in (jamming) stresses in the components or in the guide apparatus 7 . The guide apparatus 7 and particularly its components are thus mounted sufficiently moveable axially for material relaxation.
FIG. 3 shows a further exemplary embodiment of the turbine 1 which differs only slightly from the preceding exemplary embodiment from FIG. 2 . The substantial difference lies in that the axial spring element 18 is arranged between the guide apparatus 7 and the bearing housing 6 , wherein in the following exemplary embodiment the axial spring element 18 is designed as coil spring 19 . The coil spring 19 lies in a spring reception 20 of the bearing housing 6 , which for example can be formed as a bore or as a circumferential groove. The coil spring could likewise be guided or orientated and positioned by means of a spigot. Alternatively, the axial spring element 18 can also be designed as helical spring, sponge-like fabric, elastomer element or similar. The arrangement of the axial spring element 18 between the bearing housing 6 and the guide apparatus 7 has the advantage that the spring is located on the cool side of the turbine 1 . Because of this, the axial spring element 18 is not heated so severely but cooled through the contact with the cool bearing housing 6 .
FIG. 4 shows a further exemplary embodiment of the turbine 1 in a detailed sectional representation, wherein the turbine rotor 4 as well as the shaft 16 are not shown. The turbine 1 of FIG. 4 substantially corresponds to the turbine 1 from FIG. 3 , wherein the axial spring element 18 is designed as a disc spring 21 . In addition to this, the turbine 1 has two pin connections 22 and 23 . The pin connection 22 consists of a pin 24 which is orientated axially—that is parallel to the rotational axis 3 and lies in a pin reception 25 in the turbine housing 5 and engages in a pin reception 26 of the guide vane cover ring 12 . The pin reception 26 in the guide vane cover ring 12 in this case is designed as elongated hole 27 which is radially orientated in its longitudinal extension. The pin connection 23 likewise comprises a pin 24 which lies in a pin reception 25 of the turbine housing 5 and engages in a pin reception 26 of the guide vane cover ring 12 . By designing the pin reception 26 of the pin connection 22 as elongated hole 27 the guide vane cover ring 12 can grow radially without obstruction so that no (jamming) stresses can develop in the guide vane cover ring 12 due to high temperature.
FIG. 5 shows the turbine 1 of FIG. 4 with the distinction that the pin 24 of the pin connection 23 is formed by an axial spacer 15 . To this end, the axial spacer 15 is designed in such a manner that it reaches through the guide van cover ring 12 and engages in the pin reception 25 of the turbine housing 5 .
FIG. 6 shows an enlarged region of the turbine 1 . Here, a pin connection 29 with a pin 24 is provided between the turbine housing 5 and the guide vane cover ring 12 , wherein in contrast with the preceding exemplary embodiments the pin 24 is orientated radially or perpendicularly to the rotational axis 3 or the turbine rotor 4 . On the whole, the pin connections substantially serve as anti-rotation safety of the guide apparatus 7 and allow radial and axial movement of the guide apparatus 7 . To this end, the pin reception 25 is formed in the turbine housing 5 with open edge as elongated hole 30 which in its longitudinal extension is orientated axially or parallel to the rotational axis 3 of the turbine rotor 4 . Here it must be mentioned that with all exemplary embodiments shown in the figures there is radial and axial moveability of the guide apparatus and its components.
FIG. 7 shows a further exemplary embodiment of the turbine 1 in a sectional representation, wherein the axial spacers 15 are arranged or fixed on the guide vane bearing ring 10 . To this end, the axial spacers 15 are each inserted in a corresponding opening formed in the guide vane bearing ring 10 . While in the preceding exemplary embodiments of FIGS. 2 to 6 the guide apparatus 7 is loaded with an axial preload, the guide vane cover ring 12 in the present exemplary embodiment is additionally loaded with a radial preload. This is guaranteed by means of a radial spring element 31 which is designed as wavy ring 32 and clamped between the inner radius of the guide vane cover ring 12 and the turbine housing 5 . The wavy ring 32 positions the guide vane cover ring 12 radially in the turbine housing 5 and thereby allows radial expansion of the guide vane cover ring 12 so that no temperature-related stresses develop in the guide vane cover ring.
FIG. 8 shows the wavy ring 32 in an enlarged representation of a detail of FIG. 7 . Through the wavy shape of the wavy ring 32 the spring force of the radial spring element 31 is ensured. The wavy ring 32 additionally comprises an arched cross section.
FIG. 9 shows an alternative design of the wavy ring 32 , which in contrast with the preceding wavy ring 32 from FIG. 8 has a straight cross section.
FIG. 10 shows a further exemplary embodiment of the turbine 1 , wherein in this case the pin connection 29 from FIG. 6 is not arranged between the turbine housing 5 and the guide vane cover ring 12 , but between the turbine housing 5 and the guide vane bearing ring 10 .
FIG. 11 shows an exemplary embodiment of the turbine 1 which substantially corresponds to the exemplary embodiment of FIG. 4 , wherein here the pin connections 22 and 23 are provided between the bearing housing 6 and the guide vane bearing ring 10 , while the radially orientated elongated hole 27 is formed in the face end of the guide vane bearing ring 10 facing away from the inlet channel. The pins 24 of the pin connections 22 and 23 in this case are orientated axially or parallel to the rotational axis 3 .
FIG. 12 shows a combination of the pin connections 29 and 23 , wherein the pin connection 29 is formed or provided between the turbine housing 5 and the guide vane cover ring 12 and the pin connection 23 between the bearing housing 6 and the guide vane bearing ring 10 .
FIG. 13 shows an exemplary embodiments of the turbine 1 with a radial-axial spring element 33 , which is arranged between the guide vane bearing ring 10 and the bearing housing 6 . The radial-axial spring element 33 is designed as a pleated spring ring 34 with radial pleats, which contacts the bearing housing 6 and the guide vane bearing ring 10 both axially as well as radially. Because of this the guide apparatus 7 or the guide vane bearing ring 10 is loaded with a preload both axially as well as radially.
FIG. 14 likewise shows an exemplary embodiments for simultaneously radial and axial preloading of the guide apparatus 7 , wherein for the axial preloading the already know axial spring element 18 and for the radial preloading the radial spring element 31 are provided, which in this case is designed as L-shaped ring spring element 35 which with a leg areally loads/fixes the guide vane bearing ring 10 radially.
FIG. 15 shows an alternative embodiment of the radial-axial spring element 33 from FIG. 13 , which is substantially formed L-shaped and in its leg radially loading the guide vane bearing ring 10 comprises an axial spring pleat 36 which serves for generating the axial preload. A heat shield 37 , which can be omitted as an option, is axially connected between the radial-axial spring element 33 and the guide vane bearing ring 10 .
FIG. 16 shows a further exemplary embodiment for generating an axial preload, wherein in this case two disc springs 21 are provided which are both in contact between the bearing housing 6 and the guide vane bearing ring 10 .
FIG. 17 shows an alternative embodiment of the axial spring element 18 . Here, the axial spring element 18 is designed as a coil spring 39 which lies in axial spring receptions 40 which are formed in the bearing housing 6 and in the guide vane bearing ring 10 . It is also conceivable to provide a coil spring 39 which has a conical longitudinal extension or longitudinal section, for example with wide support surface in the bearing housing 6 and with small support surface in the guide vane bearing ring 10 . Obviously the use of other known spring types such as for example elastomer element, sponge-like fabrics and similar resilient elements is likewise possible. An undercut 41 , which in the turbine housing 5 is formed with open edge to the guide vane cover ring 12 , is fluidically connected with an inlet channel 9 , so that a part of the hot exhaust gas can enter the undercut 41 and thus also heats the guide vane cover ring 12 from “behind”. Through its wavy shape the wavy ring 32 in this case secures the fluidic connection in that it positions the guide vane cover ring 12 radially spaced from the turbine housing 5 . The guide vane cover ring 12 is thus subjected to the temperature of the medium or the exhaust gas on both sides, as a result of which uneven deformation of the guide vane cover ring 12 is prevented and thus the play between the guide vanes 8 and the guide vane cover ring 12 can be selected smaller. All mentioned spring elements can be designed closed or segmented.
FIG. 18 shows a further exemplary embodiment of the turbine 1 in a simplified representation. In this exemplary embodiment an axial preload is generated by means of the axial spring element 18 , as for example also shown in FIG. 4 . Likewise shown is the undercut 41 , which can be subjected to an inflow downstream of the guide vanes 8 as indicated by an arrow 43 . Furthermore, a second undercut 44 is provided which is formed/arranged radially spaced from the undercut 41 , and which can be subjected to inflow downstream of the guide vanes 8 , as indicated by an arrow 45 . Between the undercuts 41 and 44 there remains a support region 46 in which the guide vane cover ring 12 is in contact. Between the guide vane cover ring 12 and the support region 46 a seal 47 is advantageously arranged which prevents that medium flow past the guide apparatus 7 .
In principle, the embodiments described above can be combined with one another in any way, for example both the guide vane cover ring as well as the guide vane bearing ring are pinned or positioned/held by means of pin connections.
In addition it is possible to arrange/fix at least one axial spacer with pins or pin-like designs of the axial spacer in the guide vane bearing ring and/or in the guide vane cover ring.
FIG. 19 substantially corresponds to FIG. 18 , so that in the following merely the differences are explained. FIG. 19 shows a preferred embodiment of the turbine 1 , where the line of flux of the axial preload, shown as a line 48 in FIG. 19 , substantially runs parallel to the rotational axis 3 of the turbine rotor 4 . To this end, the axial spring element is arranged in such a manner that it contacts the guide apparatus 7 or the guide vane bearing ring 10 in an axial spring contact region 52 which substantially lies on the same radius as the axial spacer 15 . In the present exemplary embodiment the substantially circle-cylindrical axial spacer 15 with its longitudinal axis or its rotational axis lies on the radius r_m (pitch circle radius) to the rotational axis 3 , as shown by an interrupted line 49 . Similar applies to the further axial spacers arranged over the circumference which are not shown here. Because of this, the line of flux (line 48 ) from the axial spring element 18 is substantially directed axially or parallel to the rotational axis 3 of the turbine rotor 4 through the guide vane bearing ring 10 onto the axial spacer 15 . The support region 46 , which forms an axial contact region 53 of the housing 2 for the guide apparatus 7 is likewise arranged substantially at the same height or on the same radius as the axial spacer 15 , so that the line of flux (line 48 ) continues to run from the axial spacer 15 via the guide vane cover ring 12 substantially axially or parallel to the rotational axis 3 of the turbine rotor 4 into the housing 2 .
On the whole, the line of flux (line 48 ) thus runs substantially axially or parallel to the rotational axis 3 through the guide apparatus 7 . This has the advantage that the elements of the guide apparatus 7 , particularly the guide vane cover ring 12 and the guide vane bearing ring 10 , particularly in the case of unfavourable transient conditions, are not deformed.
If advantageously instead of the disc spring 21 or a plurality of axial spring elements 18 , such as for example the coil springs 39 , are provided, these are arranged and orientated aligned with the spacers 15 , that is in the imagined extension of the spacers 15 . Because of this, stresses and deformations in circumferential direction in the guide vane bearing ring are avoided.
Furthermore, two radii r_i and r_a are shown in FIG. 19 by means of interrupted lines 50 and 51 respectively, wherein the radius r_a is larger and the radius r_i is smaller than the radius r_m of the spacers 15 . The radii r_i and r_a define a line of flux flow range, characterized by a double arrow 54 , within which the line of flux (line 48 ) is to run. Practically, the line of flux and the (pitch circle) radii (to the rotational axis 3 ), on which the different elements (axial spacer 15 , axial spring element 18 and axial spring contact region 52 and support region 46 or axial contact region 53 ) or the respective contact regions are each arranged between the elements, each only deviate by 20% from the radius r_m in both directions.
Instead of the disc spring 21 , as shown in FIG. 18 , the heat shield 37 known from FIG. 15 is provided in FIG. 19 , which is of a disc spring design, while its spring force is substantially smaller than that of the disc spring 21 and merely serves for sealing. | The invention relates to a turbine ( 1 ), in particular of an exhaust gas turbocharger, having a turbine rotor ( 4 ), which is rotatably mounted in a housing ( 2 ), with which at least one radial inlet channel ( 9 ) for a guide apparatus ( 7 ) forming a medium which drives the turbine rotor ( 4 ) is associated, wherein said guide apparatus ( 7 ) has multiple guide vane bearing rings ( 10 ), which radially enclose said turbine rotor ( 4 ) and have guide vanes ( 8 ) which lie in said inlet channel ( 9 ), and a guide vane cover ring ( 12 ), and wherein said inlet channel ( 9 ) is axially delimited by said guide vane bearing ring ( 10 ) and said guide vane cover ring ( 12 ) and said guide apparatus ( 7 ) is mounted in the housing ( 2 ) so it is axially and/or radially movable for material relaxation. Furthermore, the invention relates to an exhaust gas turbocharger, in particular for a motor vehicle. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION(S) AND CLAIM OF PRIORITY
The present application claims priority to application entitled “Method For Transmitting Signal In Wireless Communication System” filed with the Korean Intellectual Property Office on Oct. 31, 2006 and assigned Serial No. 2006-106365, the contents of which are incorporated herein by reference.
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a wireless communication system, and more particularly to a method for transmitting signals in a wireless communication system.
BACKGROUND OF THE INVENTION
In a wireless communication system, base stations and mobile stations transmit signals in consideration of a channel coding scheme and a diversity gain in order to achieve reliable communication at a high speed.
Tarokh suggested space-time block coding for communication in a Rayleigh fading channel by means of multiple transmission antennas. Alamouti suggested a method capable of a diversity gain, with a system using two transmission antennas as a model.
Meanwhile, currently, an Orthogonal Frequency Division Multiple Access (OFDMA) scheme is being discussed as a wireless transmission scheme for the next-generation wireless mobile communication system.
According to the OFDMA scheme, a base station allocates a different number of subcarriers depending on data rates required by mobile stations, thereby efficiently distributing resources. In addition, the OFDMA scheme is suitable for a communication system using a large number of subcarriers, and can be efficiently used in a system having a wide area cell where a time delay spread is large.
However, since signals are mapped in units of symbols for each mobile station in a wireless communication system using the OFDMA scheme, it is impossible to obtain a diversity gain unless a channel coding is performed. Moreover, even though a channel coding is performed in the wireless communication system, only a small amount of diversity gain can be obtained. In order to maximize the diversity gain, it is necessary to use multiple antennas. However, when multiple antennas are used, there is a problem in that the configuration of a receiver is more complicated in order to remove interference between antennas.
SUMMARY OF THE INVENTION
To address the above-discussed deficiencies of the prior art, it is a primary object of the present invention to solve the above-mentioned problems occurring in the prior art, and the present invention provides a signal transmission method capable of maximizing a diversity gain without multiple antennas in a wireless communication system.
In addition, the present invention provides a signal transmission method capable of maximizing a diversity gain in a frequency selective channel through symbol sharing in a wireless communication system.
In accordance with an aspect of the present invention, there is provided a method for transmitting a signal in a wireless communication system, the method comprising the steps of: grouping two subcarriers having different channel characteristics; identifying a number of all cases occurring when either equal symbols or different symbols, among symbols determined upon applying a first modulation scheme, are mapped to the two subcarriers; and mapping two subcarriers corresponding to each of the number of all cases to one symbol according to a second modulation scheme, and transmitting the signal, wherein a modulation order of the second modulation scheme is two times higher than a modulation order of the second modulation.
In accordance with another aspect of the present invention, there is provided a method for transmitting a signal in a wireless communication system, the method comprising the steps of: grouping two subcarriers having different channel characteristics; identifying a number of all cases occurring when either equal symbols or different symbols among symbols determined upon applying a quadrature phase shift keying (QPSK) modulation scheme are mapped to the two subcarriers; when a phase difference between a first symbol mapped to a first subcarrier and a second symbol mapped to a second subcarrier according to the application of the QPSK modulation scheme is 90 degrees, transmitting a signal with no symbol mapped to the second subcarrier after shifting a phase of the first symbol by 45 degrees; and when a phase difference between the first symbol and the second subcarrier upon the application of the QPSK modulation scheme is 270 degrees, transmitting a signal with no symbol mapped to the first subcarrier after shifting a phase of the second symbol mapped to the second subcarrier by 45 degrees.
Before undertaking the DETAILED DESCRIPTION OF THE INVENTION below, it may be advantageous to set forth definitions of certain words and phrases used throughout this patent document: the terms “include” and “comprise,” as well as derivatives thereof, mean inclusion without limitation; the term “or,” is inclusive, meaning and/or; the phrases “associated with” and “associated therewith,” as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, or the like. Definitions for certain words and phrases are provided throughout this patent document, those of ordinary skill in the art should understand that in many, if not most instances, such definitions apply to prior, as well as future uses of such defined words and phrases.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present disclosure and its advantages, reference is now made to the following description taken in conjunction with the accompanying drawings, in which like reference numerals represent like parts:
FIG. 1 is a view illustrating a constellation of a conventional BPSK modulation scheme;
FIG. 2 is a view illustrating a constellation of a conventional QPSK modulation scheme;
FIG. 3 is a view illustrating a QPSK constellation used for a BPSK modulation according to a first embodiment of the present invention;
FIG. 4 is a view illustrating the 16QAM constellation used for QPSK modulation according to the first embodiment of the present invention;
FIG. 5 is a graph illustrating a performance comparison between the conventional BPSK modulation scheme and the modulation scheme according to the first embodiment of the present invention;
FIG. 6 is a view illustrating a constellation used for QPSK modulation according to a second embodiment of the present invention;
FIG. 7 is a graph illustrating a performance comparison between the modulation scheme according to the second embodiment of the present invention and the conventional QPSK modulation scheme;
FIG. 8 is a graph illustrating a performance comparison between the conventional QPSK modulation scheme and the modulation schemes according to the first and second embodiments of the present invention;
FIG. 9 is a graph illustrating a test result when channel coding according to the first and second embodiments of the present invention and the conventional scheme is performed; and
FIG. 10 is a graph illustrating a test result when channel coding according to the first and second embodiments of the present invention and the conventional scheme is performed.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 through 10 , discussed below, and the various embodiments used to describe the principles of the present disclosure in this patent document are by way of illustration only and should not be construed in any way to limit the scope of the disclosure. Those skilled in the art will understand that the principles of the present disclosure may be implemented in any suitably arranged wireless communication system.
The present invention provides a method for transmitting a signal in such a manner as to group at least two subcarriers into a group, and to apply a preset mapping rule, i.e., a new constellation, to each subcarrier according to each group in consideration of a case where a symbol is mapped to the subcarrier. Here, it is preferred that subcarriers having different channel states are grouped into a group.
The following description will be given about an example in which subcarriers having two different channel states are grouped into one group. The present invention can be applied to all communication systems which perform a modulation operation, and particularly can be preferably applied to a wireless communication system employing an Orthogonal Frequency Division Multiple Access (OFDMA) scheme.
Phase shift keying (PSK) and quadrature amplitude modulation (QAM) are the most widely used modulation schemes. The modulation schemes may be normalized as shown in equation 1.
S
i
(
t
)
=
2
E
T
exp
(
w
o
t
+
2
π
ⅈ
/
M
)
(
1
)
In equation 1, the “M” represents a modulation order.
When equation 1 is divided into a real component (Inphase) and an imaginary component (Quadrature), and the divided components are expressed by a constellation of binary phase shift keying (BPSK) and a constellation of quaternary phase shift keying (QPSK), the constellations are shown as FIGS. 1 and 2 , respectively.
FIG. 1 is a view illustrating a constellation of a conventional BPSK modulation scheme, and FIG. 2 is a view illustrating a constellation of a conventional QPSK modulation scheme. As shown in FIGS. 1 and 2 , the BPSK modulation scheme maps one 1-bit symbol to one subcarrier, and the QPSK modulation scheme maps one 2-bit symbol to one subcarrier.
However, as described above, the present invention groups two subcarriers having mutually different channel states into one group when each symbol is mapped to each subcarrier. Here, it is assumed that symbol “k” mapped to a j th subcarrier in Group i is defined as shown in equation 1.
S i,j,k : symbol k mapped to j th subcarrier in Group i
i
∈
I
,
I
=
{
n
1
≤
n
≤
total
subcarrier
2
}
j
∈
{
1
,
2
}
k
∈
{
n
1
≤
n
≤
2
modulation
order
}
(
2
)
When a symbol modulation scheme used for the group is the BPSK, the number of cases where a symbol is mapped to subcarriers in the group is four, as shown in Table 1 below.
TABLE 1
1 st subcarrier
2 nd subcarrier
in i th group
in i th group
Same information is loaded on
Case 1
S i,1,1
S i,2,1
1 st and 2 nd subcarriers
Case 2
S i,1,2
S i,2,2
Different pieces of
Case 3
S i,1,1
S i,2,2
information are loaded on 1 st
Case 4
S i,1,2
S i,2,1
and 2 nd subcarriers
FIG. 3 is a view illustrating a QPSK constellation used for a BPSK modulation according to a first embodiment of the present invention.
According to the present invention, the QPSK constellation is used as a constellation to be applied to the four cases shown in Table 1. That is, the QPSK constellation may be used for BPSK modulation.
When symbols loaded on subcarriers in the i th group correspond to Case 1 , both subcarriers in the group are mapped to symbol C i,1 in FIG. 3 . In the case of Case 2 , both subcarriers in the group are mapped to symbol C i,3 . In the case of Case 3 , both subcarriers in the group are mapped to symbol C i,4 . In the case of Case 4 , both subcarriers in the group are mapped to symbol C i,2 . A symbol mapping for each Case is based on a 2-bit Gray coding scheme.
That is, while a conventional BPSK modulation scheme maps one symbol to one subcarrier, the BPSK modulation scheme according to the present invention maps one symbol to one subcarrier, and maps such two subcarriers to one modulation symbol.
Meanwhile, when a symbol loaded on subcarriers in the i th group is based on the QPSK, the number of cases where a symbol is mapped to subcarriers in the group is sixteen. Therefore, a 16QAM constellation is used for symbol transmission for the 16 cases. That is, the 16QAM constellation may be used for QPSK modulation.
FIG. 4 is a view illustrating the 16QAM constellation used for QPSK modulation according to the first embodiment of the present invention.
A mapping method to the 16QAM constellation according to the 16 cases is based on a 4-bit Gray coding scheme. Table 2 shows cases where a symbol is mapped to subcarriers in a group, and a transmission symbol determined according to each case. Here, the symbol is two bits long.
TABLE 2
1 st
2 nd
subcarrier in
subcarrier in
transmission
i th group
i th group
symbol
Case where same
Case 1
S i,1,1
S i,2,1
C i,1
symbol is loaded
Case 2
S i,1,2
S i,2,2
C i,6
on 1 st and 2 nd
Case 3
S i,1,3
S i,2,3
C i,11
subcarriers
Case 4
S i,1,4
S i,2,4
C i,16
Case where phase
Case 5
S i,1,1
S i,2,2
C i,2
difference
Case 6
S i,1,2
S i,2,3
C i,7
between symbols
Case 7
S i,1,3
S i,2,4
C i,12
loaded on 1 st and
Case 8
S i,1,4
S i,2,1
C i,13
2 nd subcarriers is
90 degrees
Case where phase
Case 9
S i,1,1
S i,2,3
C i,3
difference
Case 10
S i,1,2
S i,2,4
C i,8
between symbols
Case 11
S i,1,3
S i,2,1
C i,9
loaded on 1 st and
Case 12
S i,1,4
S i,2,2
C i,14
2 nd subcarriers is
180 degrees
Case where phase
Case 13
S i,1,1
S i,2,4
C i,4
difference
Case 14
S i,1,2
S i,2,1
C i,5
between symbols
Case 15
S i,1,3
S i,2,2
C i,10
loaded on 1 st and
Case 16
S i,1,4
S i,2,3
C i,15
2 nd subcarriers is
270 degrees
Meanwhile, an error probability between symbols on a constellation is determined by the minimum distance between symbols. When it is assumed that power allocated for each symbol is “1,” the minimum distance between symbols in the conventional BPSK modulation scheme is “2.” However, the square of the minimum distance between symbols according to the first embodiment of the present invention is “2.” Therefore, when a coherent detection is applied to two subcarriers at the same time by means of a maximum likelihood scheme, the same performance as that of the conventional BPSK modulation scheme is obtained. The coherent detection may be defined as shown in equation 3 below.
C
^
i
=
arg
min
c
i
[
∑
k
=
1
2
{
(
R
k
-
H
k
·
C
i
)
}
2
]
(
3
)
In equation 3, the “R k ” represents a reception signal of a k th subcarrier, and the “H k ” represents a channel of the k th subcarrier.
However, in the frequency selective fading channel, channel states of subcarriers may be different. Therefore, as described with reference to the first embodiment of the present invention, it is possible to obtain a frequency diversity gain by grouping subcarriers outside a coherence band into one group, and transmitting symbols mapped to the grouped subcarriers as one modulation symbol by means of a new constellation.
FIG. 5 is a graph illustrating a performance comparison between the conventional BPSK modulation scheme and the modulation scheme according to the first embodiment of the present invention.
As test conditions, it is assumed that there are 1024 subcarriers, and that a multipath channel having 10 channel paths is used.
Meanwhile, according to the conventional QPSK modulation scheme, when the power per symbol is assumed to be “1,” the minimum distance between symbols is 1.414 (=√{right arrow over (2)}). However, according to the first embodiment of the present invention, when the power per symbol is assumed to be “1,” the minimum distance between symbols is 0.8994. Therefore, it can be understood that, in an Additive White Gaussian Noise (AWGN) channel, the modulation scheme according to the first embodiment of the present invention exhibits performance superior to the conventional QPSK modulation scheme.
However, in the frequency selective fading channel, the ranking of the performance is reversed. That is, in a channel with a high noise, the conventional QPSK modulation scheme exhibits performance superior to the modulation scheme according to the first embodiment of the present invention because the minimum distance between symbols used in the conventional QPSK modulation scheme is relatively longer. Moreover, even in a channel in which the number of multiple paths is too small to obtain a frequency diversity gain, the performance of the modulation scheme according to the first embodiment of the present invention, rather than that of the conventional QPSK modulation scheme, may be deteriorated.
Hereinafter, a second embodiment of the present invention for solving the above problem will be described.
FIG. 6 is a view illustrating a constellation used for QPSK modulation according to the second embodiment of the present invention.
According to the second embodiment of the present invention, when the same information is loaded on respective subcarriers in a group, that is, when the phase distance between symbols is 0 degree, the subcarriers are mapped to different modulation symbols and are then transmitted.
When the phase distance between symbols is 90 degrees, the phase of a modulation symbol corresponding to a first subcarrier is shifted by 45 degrees, and power increases to double, before the subcarriers are transmitted. In this case, no modulation symbol is mapped to a second subcarrier.
When the phase distance between symbols is 180 degrees, the subcarriers are mapped to different modulation symbols and are then transmitted, similarly to the case where the phase distance between symbols is 0 degree.
When the phase distance between symbols is 270 degrees, any modulation symbol is not mapped to a first subcarrier, the phase of a modulation symbol corresponding to a second subcarrier is shifted by 45 degrees, and power increases to double, before the subcarriers are transmitted.
Table 3 shows a symbol map determined for each subcarrier in a group according to the second embodiment of the present invention.
TABLE 3
1 st
2 nd
transmission
transmission
subcarrier
subcarrier
symbol for 1 st
symbol for 2 nd
in i th group
in i th group
subcarrier
subcarrier
Case where
Case 1
S i,1,1
S i,2,1
S i,1,1
S i,2,1
phase
Case 2
S i,1,2
S i,2,2
S i,1,2
S i,2,2
difference
Case 3
S i,1,3
S i,2,3
S i,1,3
S i,2,3
between
Case 4
S i,1,4
S i,2,4
S i,1,4
S i,2,4
symbols
loaded on 1 st
and 2 nd
subcarriers
is 0 degree
Case where phase
Case 5
S i,1,1
S i,2,2
2
S
i
,
1
,
1
exp
(
j
π
4
)
0
difference between
Case 6
S i,1,2
S i,2,3
2
S
i
,
1
,
2
exp
(
j
π
4
)
0
symbols loaded on 1 st and 2 nd
Case 7
S i,1,3
S i,2,4
2
S
i
,
1
,
3
exp
(
j
π
4
)
0
subcarriers is 90 degrees
Case 8
S i,1,4
S i,2,1
2
S
i
,
1
,
4
exp
(
j
π
4
)
0
Case where
Case 9
S i,1,1
S i,2,3
S i,1,1
S i,2,3
phase
Case 10
S i,1,2
S i,2,4
S i,1,2
S i,2,4
difference
Case 11
S i,1,3
S i,2,1
S i,1,3
S i,2,1
between
Case 12
S i,1,4
S i,2,2
S i,1,4
S i,2,2
symbols
loaded on 1 st
and 2 nd
subcarriers
is 180
degrees
Case where phase
Case 13
S i,1,1
S i,2,4
0
2
S
i
,
2
,
4
exp
(
j
π
4
)
difference between
Case 14
S i,1,2
S i,2,1
0
2
S
i
,
2
,
1
exp
(
j
π
4
)
symbols loaded on 1 st and 2 nd
Case 15
S i,1,3
S i,2,2
0
2
S
i
,
2
,
2
exp
(
j
π
4
)
subcarriers is 270 degrees
Case 16
S i,1,4
S i,2,3
0
2
S
i
,
2
,
3
exp
(
j
π
4
)
As shown in FIG. 7 , the modulation scheme according to the second embodiment of the present invention has the same performance as the conventional QPSK modulation scheme. In Table 3, transmission symbols in Cases 1, 2, 3, 4, 9, 10, 11, and 12 obtain diversity gains. Therefore, it can be understood that the modulation scheme according to the second embodiment of the present invention is superior to the conventional QPSK modulation scheme in terms of the overall performance, and does not show a deterioration in performance, even in a channel having a low Eb/No (i.e., in a high-noise environment).
FIGS. 9 and 10 are graphs illustrating test results when channel coding according to the first and second embodiments of the present invention and the conventional scheme is performed. The channel coding is performed in such a manner as to measure an error rate per frame, by means of a convolutional code (k=7, code rate=0.5) having an optimal polynomial.
Referring to FIG. 9 , it can be understood that the BPSK modulation scheme according to the first embodiment of the present invention exhibits performance superior to the conventional BPSK modulation scheme, even when a channel coding is performed.
However, the conventional QPSK modulation scheme and the QPSK modulation schemes according to the first and second embodiments of the present invention exhibit different performances depending on channel states. That is, referring to FIG. 10 , it can be understood that the modulation scheme according to the second embodiment of the present invention exhibits the best performance at a low Eb/No, while the modulation scheme according to the first embodiment of the present invention exhibits the best performance at a high Eb/No. This is because, as described above, in a channel having a low Eb/No, the minimum distance between symbols, rather than a diversity gain, exerts a large influence upon performance because of the effect of noise. Accordingly, the modulation scheme according to the second embodiment of the present invention, which can obtain a diversity gain while having the same minimum distance between symbols as the conventional QPSK modulation scheme, exhibits superior performance.
As described above, the present invention can enhance a diversity gain and can enhance the performance of the entire system, even without the addition of an antenna and/or a bandwidth.
Although the present disclosure has been described with an exemplary embodiment, various changes and modifications may be suggested to one skilled in the art. It is intended that the present disclosure encompass such changes and modifications as fall within the scope of the appended claims. | A method for transmitting a signal in a wireless communication system. The method comprises the steps of: grouping two subcarriers having different channel characteristics; identifying a number of all cases occurring when either equal symbols or different symbols, among symbols determined upon applying a first modulation scheme, are mapped to the two subcarriers; and mapping two subcarriers corresponding to each of the number of all cases to one symbol according to a second modulation scheme, and transmitting the signal, wherein a modulation order of the second modulation scheme is two times higher than a modulation order of the second modulation. | 7 |
BACKGROUND OF THE INVENTION
This invention relates to an valve for injection injecting chemicals and similar liquid substances into sub-surface formations being penetrated by an oil or gas well. Such wells are commonly provided with a casing and tubing means enabling operation of tools for downhole operations. The running and installation of a chemical injection valve may occasionally be desirable in order to inject fluids into a formation, for example a scale inhibitor at the outset of water breakthrough. The chemical injection valve is then installed in the appropriate sliding sleeve door or tubing port, thereby replacing for example a so-called concentric standing valve.
In many practical situations a chemical injection valve according to the present invention may be used in an arrangement as described for example in U.S. Pat. No. 4,441,558, FIGS. 1 and 2 of which illustrate somewhat schematically known principles of downhole operations by means of a pumpdown toolstring. This US patent, however, is directed to a particular dual valve being an improvement and replacement of the formerly well known ball-type check valve.
Reference is also made to U.S. Pat. No. 3,051,243 which describes a form of flow-control device which may perform the function of a sliding sleeve door as referred to above.
In a simultaneous and copending patent application, Ser. No. 07/689,547, the present applicants are also describing novel and specific toolstring methods and equipment which advantageously can be employed when running and installing the present injection valve. Thus, the chemical injection valve is well suited for installation and operation within a horizontal or highly-deviated well without, however, being restricted to such use.
OBJECTS AND SUMMARY OF THE INVENTION
It is an object of the present invention to provide a chemical injection valve of comparatively simple design and nevertheless being very reliable and secure in practical operations.
In analogy with other valves for downhole operation in a production tubing, the present chemical injection valve comprises a cylindrical housing with seals for co-operation with the surrounding tubing the housing encloses a cylindrical chamber in which a piston-like sleeve is movable in an axial direction, so as to cover or uncover one or more radial ports through a cylindrical wall of said housing. Spring means normally urge the sleeve to a position in which the port or ports is (are) covered.
During running of such an injection valve, and before an installed valve is ready for the intended chemical injection operation, it is important that the sleeve is securely restrained in a closed position covering the radial ports. An increased pressure applied from the surface through the tubing is then intended to move the sleeve within the chamber so as to uncover the ports for an injection operation.
The novel and specific features of the injection valve according to the invention, providing an advantageous solution in connection with the above, are stated in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
Further specific features and advantages of this invention will be apparent from the following detailed description of an exemplary embodiment as illustrated in the drawings, of which:
FIG. 1A schematical illustrate an axial section through an installation of a chemical injection valve together with a shifter unit and a lock unit within a tubing section including a sliding sleeve and a sleeve door or port unit,
FIG. 1B shows an activating rod element to be considered as an essential component of the chemical injection valve, and shown at approximately the same scale as the arrangement of FIG. 1A,
FIG. 2 shows in enlarged axial section an embodiment of the chemical injection valve according to the invention,
FIG. 3 shows the rod element of FIG. 1B in somewhat greater detail;
FIG. 4 shows the rod of FIG. 3 element partially inserted into the chemical injection valve, and
FIG. 5 shows the rod element of FIG. 3 completely inserted into the valve, thereby making possible injection of chemicals through the valve.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1A a section of tubing 100 is illustrated at a point where ports 20A have been formed in order to receive fluids from a corresponding production zone in the well. Thus, in cooperation with ports 20A there is provided a sliding sleeve 22 being operated by a shifter mandrel or unit 20 having conventional keys 21 mating with grooves in sliding sleeve 22. Further, according to common practice there is a lock unit positioned in tubing section 100 by means of dogs 31 projecting into corresponding recesses in the interior circumference of tubing 100. Conventional universal couplings interconnect lock unit 30 and shifter unit 20 and the latter is correspondingly coupled to an injection valve 10 installed for cooperation with ports 20A. Seals 24A and 24B around the circumference of valve housing 10 serve to connect valve 10 tightly into the sliding sleeve 22 for its intended function.
As will be explained further below with reference in particular to FIGS. 4 and 5, activating means 40 comprising a comparatively long rod element 41 is adapted to be run by means of suitable pumpdown methods through tubing 100 so as to be inserted through the central bore in lock unit 30, shifter unit 20 and into the injection valve 10. The activating rod means 40 should be considered as an integral component of the chemical injection system in which valve housing 10 is a main component. The forward (right) end of rod element 41 in FIG. 1B has a prong or nose member 42 with a first push member 43 behind it, and further behind there is a second push member 44, these members being all adapted to enter into an interior chamber of housing 10 in order to perform their intended functions. At the opposite or trailing end of rod element 41 there is shown a conventional coupling to a circulation valve 50 which may be of known type. Together with such a circulation valve 50 the complete activating rod means or unit 40 may be run by a toolstring when the same or a similar toolstring has installed the units as shown in FIG. 1A. At this point it should be noted that the length of rod element 41 is sufficient to pass through both units 20 and 30 in FIG. 1A and bring the inner or foremost end members 42, 43, 44 into the interior of valve housing 10 for cooperation therewith.
Turning now to FIG. 2 the main structure of the injection valve shall be described. As in FIG. 1A valve housing 10, which is of a substantially cylindrical shape, has two exterior seals bidirectional 24A and 24B and an interior cylindrical chamber 1. Through the housing wall there are provided a number of radial ports 10A which are normally closed by a sleeve 2 arranged to be slidable within chamber 1 against the force of a helical spring 3. In the position of sleeve 2 shown in FIG. 2 fluid communication from chamber 1 through ports 10A is blocked. Note in this connection seal 2A at the left or outer end of sleeve 2. An abutment or step 11 in the interior cylindrical surface defining chamber 1 serves to position sleeve 2 in its normal or rest position as shown in FIG. 2. The inner or right hand end portion of sleeve 2 protrudes into a chamber extension IA having preferably a reduced diameter in relation to the main chamber 1. At this inner end of sleeve 2 there is another seal 2B.
A slide or collet 4 provided in the chamber extension IA performs an important function in the chemical injection valve. Collet 4 may be displaced axially in chamber extension IA against a compression spring 5 and is formed with a projecting reduced diameter inner end portion which is split into expandable fingers 4F, the purpose of which is to be described further below. The collet 4 has an axial bore 4E extending also centrally through the finger portion 4F. At the opposite or outer end facing sleeve 2, the bore 4E has a widened opening in order to facilitate the inserting of the prong member 42 at the forward end of activating means 40 shown in FIG. 1B. The surrounding part of collet 4 has a reduced diameter for protruding into sleeve 2.
Activating means 40 in FIG. 1B is shown at an enlarged scale in FIG. 3 primarily in order to illustrate better the details at the forward or inner end of the rod element 41. Thus, it will be seen that nose or prong member 42 has a somewhat pointed end portion and has a slightly increased diameter in relation to the adjacent rod length running rearwardly to the second push or stop member 44. The first push member 43 is releasably attached to the innermost portion of this rod length by means of a shear pin 43A. In other words, when this shear pin is broken, member 43 may slide along the reduced diameter rod length between member 44 and the increased diameter prong member 42.
From the above it will be understood that this chemical injection valve is a normally closed valve. The radial ports 10A through the cylindrical walls or housing 10 are covered by the spring loaded sleeve 2, and this sleeve is itself backed by the spring loaded collet 4. The combination of the two springs 3 and 5 serves to hold the sleeve 2 closed against normal tubing pressure during installation of the valve and also during retrieval of the toolstring in which the valve is incorporated.
A first step during activation of this valve is illustrated in FIG. 4, where rod element 41 is inserted so that the forward members 42,, 43 and 44 thereof have entered into the interior of valve housing 10, i.e., both the main chamber 1 and the chamber extension IA. More specifically, the first push member 43 is seen to be just engaging the outer end of collet 4, whereas the prong member 42 has penetrated far into, but not quite through, the collet bore 4E. It is to be noted that the lateral dimensions of both push members 43 and 44 are just somewhat smaller than the interior diameter of sleeve 2, so as to be guided therein.
When the rod element 41 is pushed from the position shown in FIG. 4 further inwards (to the right), collet 4 will also be moved inwards during compression of spring 5 until collet 4 reaches the bottom of the chamber extension IA. In this bottom position, finger projections 4F will be positioned opposite an annular recess 9 in the end wall of housing 10.
Upon continued application of a push force through rod element 41, shear pin 43A will break and the first push member 43 will be released so as to permit further movement of rod element 41 and its prong member or tip 42 into a narrowed end portion of bore 4E at the level of finger projections 4F, so that these will be expanded into the recess 9.
This is the position illustrated in FIG. 5, in which the second push member has a position just behind the first push member 43, the latter having moved relatively backwards along the rod length between prong member 42 and the second push member 44. In moving its bottom position, collet 4 has compressed spring 5 substantially completely. The second push member 44 serves mainly to limit the inward movement of rod element 41 so as to bring finger projections 4F into the correct position with respect to recess 9.
During activation of the injection valve by means of rod element 41 with its functional members 42, 43 and 44, sleeve 2 maintains its position as shown in the upper half of FIG. 5 (as well as in FIGS. 2 and 4). A pressure increase applied through the toolstring will then be able to move sleeve 2 from the closed position to an open position uncovering port 10A as shown in the lower part of FIG. 5. Spring 3 is then compressed.
Referring again to FIG. 1B, circulation valve 50 will also be opened during this operation and the chemical to be injected is circulated down to the injection valve and out of the valve through ports 10A. The chemical or fluid to be injected is thereby allowed to enter into the surrounding formation. After injection of the required quantity of fluid, release of pumping pressure at the surface will allow the sleeve 2 to be retracted under the influence of spring 3, and ports 10A are again closed.
Reversed circulation through the tubing will serve to pull the activating rod element 41 out of the chemical injection valve, and the collet 4 therein will return to its normal position backing up the sleeve 2, as shown in FIG. 2. Further applications of pressure will then not be able to open the injection valve.
After retrieval of the rod element 41, the injection valve 10 is itself retrieved and the sliding sleeve door (20, FIG. 1A) is closed. Production units such as a concentric standing valve may then be installed immediately, or other intervals or zones in the well may be produced while the chemical injected is allowed to soak for days or weeks. Installation of a concentric standing valve is necessary before production backflow may commence.
As shown in FIGS. 2, 4 and 5 the chemical injection valve housing 10 is provided with high volume ports 10B in addition to radial ports 10A for the chemical injection flow. These additional ports 10B are very useful in the event that spring 3, which is comparatively weak, is not able to return sleeve 2 to its closed position by itself.
When the chemical injection valve is installed downhole as described above, it may still be possible to maintain production from well intervals above the point at which the valve is installed, but production from lower intervals will be restricted because of the comparatively small inner diameter of such a chemical injection valve.
Reverting again to the rod or prong element, generally denoted 40 in FIG. 1B, this component of the chemical injection system can be run and actuated by a toolstring method as described in the applicant's copending patent application No. 07/689,547 (Sak 18 - Coiled Tubing). Rod element 41 in practice may consist of a titanium rod being long enough to reach down through the lock unit 30, the shifter mandrel 20 and to the bottom of the chemical injection valve 10 (see FIG. 1A). The rod element should also be sufficiently flexible to be able to traverse a pipe bend of 1.5 m radius without permanent deformation. As shown in FIG. 1B the top or trailing end of the rod element 41 has a swivel socket for connection to a swivel ball on a circulation valve 50. At the opposite end of rod element 41, the smooth nose or prong 42 is shaped for entering into the collet 4 of the injection valve and more particularly for cooperation with the fingers 4F at the innermost end of this collet. | Injection valve for injecting chemicals into subsurface formations penetrated by an oil or gas well, comprising a cylindrical housing (10) with seals (24A, 24B) for cooperation with well tubing (100), said housing enclosing a cylindrical chamber (1) in which a piston-like sleeve (2) is movable axially so as to cover or uncover one or more radial ports (10A) through a cylindrical wall of said housing (10). A spring (3) normally urge the sleeve (2) to a position in which the ports (10A) are covered. A collet (4) is mounted for axial displacement in a chamber extension (1A) beyond an inner end of the sleeve (2), a compression spring (5) urging the collet against said inner end of the sleeve (2). A device (40) is provided for displacing the collet (4) to an inner end position in the chamber extension (1A) and for activating locking mechanism (4F, 9) for locking the collet (4) in the inner end position, whereby an increased pressure within the chamber (1) is able to move the sleeve (2) so as to uncover the ports (10A) for an injection operation. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority under 35 U.S.C. §119(a) of German Patent Application No. 10 2012 000 607.1 filed Jan. 16, 2012, the disclosure of which is expressly incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] Embodiments of the invention relate to a coupling element for a fluid line having a housing that has a receptacle region for receiving an insertion element. The receptacle region has a snap-in locking device for a locking connection with the insertion element, the snap-in device including at least one locking element that has an unlocking lever.
[0004] Embodiments of the invention further relate to an unlocking element for a coupling element of this type.
[0005] 2. Discussion of Background Information
[0006] Coupling elements of this type are used to connect fluid lines to nozzles, which for example are connected to a fuel tank. They can also be used to connect two lines for example in a vehicle. For example, a fluid-tight connection of so-called urea lines takes place via the coupling element.
[0007] The line to be connected using the coupling element has an insertion element that can be inserted into the seating region. The insertion element has a snap-in locking geometry, such as for example a circumferential flange which can interact with the snap-in locking device that is disposed in the receptacle region. The insertion element can thus be locked within the coupling element such that a secure connection is guaranteed.
[0008] To loosen the snap-in locking device, the locking element is provided with an unlocking lever; the locking element releases the insertion element upon actuation of the unlocking lever.
[0009] Coupling elements are often used in constricted spaces, for example in the automotive sector. For this reason, it is often relatively difficult to activate the unlocking lever. Loosening the coupling element becomes consequently complex.
SUMMARY OF THE EMBODIMENTS
[0010] Embodiments of the invention enable a simple loosening of the snap-in locking device.
[0011] This problem is inventively solved using a coupling element of the type described at the beginning, in that an unlocking element can be moved between a first position, in which it interacts with the unlocking lever, and a second position, in which the unlocking element releases the unlocking lever.
[0012] The unlocking levers of the locking device no longer need to be directly actuated, but rather are indirectly actuated by the unlocking element. The required actuating force is transferred via the movement of the unlocking element. In this manner, a transmission of force also results.
[0013] It is particularly preferable in this case that the unlocking element is mounted to be linearly displaceable. A linear displacement movement can be produced relatively easily, for example, by pulling or pushing on the unlocking element. Simultaneously, the unlocking element can be mounted relatively free of play, which is advantageous if the coupling element is exposed to vibrations.
[0014] The unlocking lever is preferably designed as one piece with the locking element. The locking element and the unlocking lever can be made of, for example, plastic. A one-piece design is thus relatively easily possible. The one-piece design also results in a very direct transmission of forces without additional connection points, which could be susceptible to dirt and/or temperatures.
[0015] The snap-in locking device has preferably at least two locking elements that are disposed on a circular path. The locking element can be moved radially outward by pressing the unlocking lever radially inward. In the case of two locking elements, these are disposed preferably on diametrically opposite sides of the housing of the coupling element. It is relatively easy to exert a compression force on the unlocking levers, in that, for example, the unlocking element is moved over an exterior side of the unlocking lever. In order that the locking element is then moved radially outward, the combination of the unlocking lever and locking element are mounted pivotably. A materially-bonded articulation is thus provided that is formed, for example, by the elasticity of the materials used and can be designed as one piece with the unlocking lever and the locking element.
[0016] The unlocking element preferably has a number of members disposed in parallel that correspond to the number of locking elements. The members each have an effective surface for interacting with one of the unlocking levers. A traction or compression force, which effects a displacement of the unlocking elements, can be applied relatively far removed from the snap-in locking device via the members. The members can also form relatively long guide surfaces for the unlocking element such that a relatively stable and in particular rattle-free mounting of the unlocking element is possible on the housing of the coupling element.
[0017] The effective surfaces are preferably disposed on projections directed radially inwardly that are in particular designed at the ends of the members. The effective surfaces can be spaced at a distance from the members due to the projections.
[0018] In this way, the effective surfaces can interact relatively easily with the unlocking levers. The projections increase a force directed radially inward, which affects the unlocking levers via the effective surfaces and thus affects an opening of the snap-in locking device. By simple displacement of the unlocking element, the effective surfaces can be brought in to cover with the unlocking levers and, due to the projections, automatically exert a force directed radially inward onto the unlocking levers, which thus effect an opening of the snap-in locking device.
[0019] The members are preferably connected to each other at the ends on which the projections are designed. The connection is, if necessary, designed in an arch-like shape, the curve of which runs in particular parallel to a curve of the housing in the receptacle region. The connection prevents the members from bending upwards, when the members transfer a force directed radially inward to the unlocking levers. In this manner, a relatively large force can be transferred without deforming the unlocking element. Due to an arch-shaped configuration of the connection, the curve of which runs parallel to a curve of the housing in the receptacle region, the connection runs so to speak along an exterior side of the housing, such that not much additional installation space is required. The coupling element can thus remain slim.
[0020] In a preferred embodiment, the members are connected to each other via a second connection at the second ends facing away from the projections. This second connection effects a stiffening of the unlocking element. It simultaneously ensures that all members are moved uniformly, such that all locking elements are simultaneously actuated.
[0021] The second connection preferably has an operation handle which is disposed in particular in the middle between the members. With the assistance of the operation handle, the handling is simplified. The operation handle can be designed for example in such a way that operation with gloves is easily possible.
[0022] The second connection preferably runs parallel to the first connection. The second connection is thus likewise designed as curved with a curve that runs parallel to the housing of the coupling element. A space-saving arrangement of the unlocking element at the housing of the coupling element is thus possible.
[0023] In another preferred embodiment, the second connection runs in a plane with the members and has in particular a curve that is directed away from the first ends. An embodiment of the unlocking element of this type lends itself in particular to coupling elements that are bent at 90°, in which the unlocking element has in particular only two members. The curve of the second connection can then likewise be adjusted to the housing of the coupling element, such that only a little additional installation space is required.
[0024] The members are displaceably guided in particular axially at the coupling element, for example, laterally outside on the housing of the coupling element. With regard to an embodiment of the unlocking element with two members, these members can be guided diametrically opposite with each respectively on one side of the housing of the coupling element. The coupling element can for example have a guide for this which is formed by two protrusions respectively for each member. It is also conceivable to provide a groove in which the members are guided.
[0025] More preferably, the locking elements can be displaced axially between a blocking position, in which a movement of the unlocking lever is blocked, and an unengaged position, in which the unlocking levers can be actuated. In this way, a blocking of an actuation of the unlocking levers is possible and thus an undesired opening of the snap-in locking device can be prevented. For example, it can be ensured thereby that the unlocking levers are positioned above raised points by the axial movement of the locking elements, so that the raised points prevent a compression of the unlocking levers.
[0026] It is thereby particularly preferred that the projections of the unlocking element interact with projections on the locking elements in such a way that, by applying a tractive force on the unlocking element, the locking elements can be moved from the blocking position into the unengaged position. With the assistance of the unlocking element, the unlocking levers are then actuatable, and the locking elements can be displaced from the blocking position into an unengaged position.
[0027] It is particularly preferred that, upon application of the tractive force, the projections of the unlocking element can slide over the projections of the locking elements, such that the effective surfaces interact with the unlocking levers. By a simple pulling movement, which is applied to the unlocking element, the locking elements can then be initially moved from the blocking position into the unengaged position, and then subsequently the unlocking levers are automatically actuated, such that the snap-in locking device opens. The increase of the tractive force results then automatically in this case in that the locking elements are prevented from a further movement upon reaching the unengaged position, in that for example the locking elements hit a stopper.
[0028] A serrated surface is provided preferably at the second ends of the members and/or on the handle. In this manner, the application of a tractive force on the unlocking elements is simplified in particular during damp conditions or during operation with gloves.
[0029] Preferably, the locking elements can be moved into the blocking position by pulling on the insertion element after the locking elements lock with the insertion element. This application of a tractive movement between the insertion element and the coupling element thus initially serves to move the locking elements into the blocking position, and thus to prevent loosening. Simultaneously, this also ensures that the insertion element is securely held in the snap-in locking device, thus it was properly guided into the receptacle region. In the case of an improper connection, the insertion element would otherwise be released again by the application of the tractive force.
[0030] In this way, an assembly indicator is preferably provided, which, after displacing the locking elements into the blocking position, can be displaced into a position that signals a secure connection. Simultaneously, the assembly indicator can then prevent a sliding back of the locking elements. The assembly indicator must then initially be removed or at least moved before the locking elements can be moved into the unengaged position. For example, for this purpose, the assembly indicator is moveable into a space which is released by moving the locking elements from the unengaged position into the blocking position.
[0031] Embodiments of the invention are directed to an unlocking element that includes at least two members disposed in parallel that are connected to each other at the respective ends thereof by a connection. The unlocking element is used to unlock a snap-in locking device of the above-described coupling element. The above-noted embodiments of the coupling element apply correspondingly.
[0032] The number of members disposed in parallel can, for example, correspond to a number of locking elements of the coupling element. In this manner, it is possible to assign a member to each locking element and thus guarantee a simultaneous actuation of all locking elements. Projections directed radially inward having effective surfaces can be provided on ends of the members. By the effective surfaces, a force directed radially inward is then exerted on the locking elements, which are opened thereby. In the region of the projections, the members can be connected to each other. This connection can be designed in an arch-like shape or in a curve that runs parallel to a curve of the housing in the receptacle region. The connection prevents a radial bending upward of the members. Simultaneously, the unlocking element can be adapted relatively well to the shape of the coupling element due to the curved design of the connection. In this manner, only a little additional installation space is required for the coupling element.
[0033] At a second end of the members, which end faces away from the projections, the members can likewise be connected via a connection. This second connection can run parallel to the first connection or have a curve that runs perpendicular to the curve of the first connection. By this means, an adaptation of the shape of the unlocking element to the shape of the coupling element is possible.
[0034] The unlocking element thus simplifies an unlocking of the coupling element and thus a removal of an insertion element connected to the coupling element. An unlocking is also possible without problems in constricted installation spaces, because, for example, the locking elements no longer have to be reached by hand, but instead can be actuated via the unlocking element. The locking elements are thus indirectly unlocked via the unlocking element. The point, which must be manually engaged, is extended by the unlocking element, specifically into a region that is more easily accessible than the region in which the locking elements are disposed. The insertion region of the coupling element is thus expanded, in particular in constricted installation conditions. Expected assembly work, for example in the case that a replacement due to repairs is necessary, is thereby shortened by the unlocking element.
[0035] Embodiments of the invention are directed to a coupling element for a fluid line. The coupling element includes a housing having a receptacle region structured and arranged to receive an insertion element, and a snap-in locking device in the receptacle region that is structured and arranged for a locking connection with the insertion element. The snap-in locking device includes at least one locking element having an unlocking lever and an unlocking element is movable between a first position, in which the unlocking element interacts with the unlocking lever, and a second position, in which the unlocking element releases the unlocking lever.
[0036] According to embodiments, the unlocking lever can be structured as one piece with the locking element.
[0037] In accordance with other embodiments, the snap-in locking device may have at least two locking elements that are disposed on a circular path, and the locking element can be movable radially outward by pressing the unlocking lever radially inward. The unlocking element may have a number of members, corresponding to a number of locking elements, which are disposed in parallel and have effective surfaces. The effective surfaces can be disposed on projections directed radially inward that are located at ends of the members. Further, a first connection may couple the ends of the members with the projections to each other. The first connection can have an arched shape with a curve corresponding to a curve of the housing in the receptacle region. A second connection can couple the members to each other at second ends of the members opposite the ends with the projections. The second connection may run parallel to the first connection. Further, the second connection can run in a plane with the members and can have a curve that is directed away from the ends with the projections.
[0038] According to further embodiments, the locking elements can be axially positionable between a blocked position, in which a movement of the unlocking levers can be blocked, and an unengaged position, in which the unlocking levers may be actuatable. The projections of the unlocking element can interact with projections on the locking elements so that in applying a traction force on the unlocking element, the locking elements can be movable from the blocking position into the unengaged position. Further, by increasing the traction force, the projections of the unlocking element can slide over the projections of the locking elements so that the effective surfaces interact with the unlocking levers. The locking elements can be movable into the blocked position by pulling on the insertion element after locking with the unlocking element.
[0039] Moreover, in embodiments are directed to an unlocking element to unlock a snap-in locking device of the above-described coupling element. The unlocking element includes at least two members disposed in parallel, and first and second connections structured and arranged at respective ends to connect the at least two members together.
[0040] In embodiments, the first and second connections can have an arcuate shape. Further, the arcuate shapes may be one of: arranged in non-parallel planes; and arranged in parallel planes.
[0041] Embodiments of the invention are directed to a method for one of engaging and disengaging an insertion tube from a coupling element of a fluid line. The coupling element has an unlocking device that is linearly movable parallel to the insertion tube. The method includes pulling the unlocking element relative to the coupling element in a direction away from an insertion tube receptacle, whereby projections on the unlocking element depress unlocking levers of a snap-in locking device to lift locking elements of the snap-in locking device; and moving at least one of the coupling element and the insertion tube relative to each other while the locking elements are lifted.
[0042] According to embodiments of the invention, for engaging, while the locking elements are lifted, the method can include relatively moving at least one of the coupling element and insertion tube toward each other until the insertion tube is seated in the coupling element, and pushing the unlocking element toward the insertion tube receptacle, whereby the locking elements engage the insertion tube.
[0043] In accordance with still yet other embodiments of the present invention, for disengaging, when the unlocking element is pulled relative to the insertion tube receptacle, the locking elements are lifted from engagement with the insertion tube, and while the locking elements are lifted from engagement with the insertion tube, relatively moving at least one of the coupling element and insertion tube away from each other until the insertion tube is removed from the coupling element.
[0044] Other exemplary embodiments and advantages of the present invention may be ascertained by reviewing the present disclosure and the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0045] The present invention is further described in the detailed description which follows, in reference to the noted plurality of drawings by way of non-limiting examples of exemplary embodiments of the present invention, in which like reference numerals represent similar parts throughout the several views of the drawings, and wherein:
[0046] FIG. 1 shows an unlocking element of a first embodiment;
[0047] FIG. 2 shows an unlocking element of a second embodiment;
[0048] FIG. 3 shows a coupling element having an unlocking element of the first embodiment;
[0049] FIG. 4 shows a coupling element having an unlocking element of the second embodiment;
[0050] FIG. 5 shows a cross-sectional view of the coupling element in the locked state; and
[0051] FIG. 6 shows a cross-sectional view of the coupling element in the opened state.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0052] The particulars shown herein are by way of example and for purposes of illustrative discussion of the embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the present invention. In this regard, no attempt is made to show structural details of the present invention in more detail than is necessary for the fundamental understanding of the present invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the present invention may be embodied in practice.
[0053] FIG. 1 shows an unlocking element 1 of a first embodiment. The unlocking element 1 has two members 2 , 3 disposed parallel to each another and which are connected to each another at first ends 5 , 6 thereof via a first connection 4 and at their second ends 8 , 9 via a second connection 7 . The first connection 4 and the second connection 7 are designed as curved and are disposed on an upper side of the members 2 , 3 . In this manner, the first connection 4 and the second connection 7 run parallel to each other.
[0054] The first connection 4 forms a rectangle with the second connection 7 and the members 2 , 3 . An actuation handle 10 disposed in the middle of the second connection 7 is arranged to extend in a direction facing away from the first connection 4 .
[0055] Projections 11 , 12 are designed at the ends 5 , 6 to be directed inward and thus at each other. Each projection 11 , 12 has an effective surface 13 , 14 is located on a radial inner side of the projections. The effective surfaces 13 , 14 can transition into inclined stopping areas in order to keep actuating forces low.
[0056] FIG. 2 presents an unlocking element 1 ′ according to a second embodiment which differs from the embodiment according to FIG. 1 ′ only in the arrangement of the second connection 7 ′. Accordingly, elements that correspond with each other are therefore provided with the same reference signs. In the embodiment according to FIG. 2 , the second connection 7 ′ runs in a plane with the members 2 , 3 .
[0057] A configuration of this type is particularly beneficial for coupling elements that are designed as 90° angled pieces, e.g., as depicted in FIG. 4 .
[0058] The members 2 , 3 can be produced from a plastic as one piece with the first connection 4 , the second connection 7 (or 7 ′), and the actuation handle 10 . It is also conceivable to connect several parts with one another, for example, by welding.
[0059] The unlocking element 1 (or 1 ′) is provided with a serrated surface at the ends 8 , 9 and at the handle 10 . This serves to simplify an actuation in damp environments or for example with gloves.
[0060] FIG. 3 shows the unlocking element of the first embodiment, i.e., as shown in FIG. 1 , in connection with a coupling element 15 . The coupling element 15 serves to fluid-tightly connect a nozzle-shaped insertion element 16 to a fluid line 17 . Instead of a nozzle-shaped insertion element 16 , a further fluid line can also be provided for connection. In this instance, it is advantageous when the fluid line includes, preferably as one piece, the insertion element 16 .
[0061] The members 2 , 3 of the unlocking element 1 are disposed laterally on a housing 18 of the coupling element 15 in such a way that they can be linearly displaced. Projections 19 , 20 are provided on the housing 18 to act as guides for members 2 , 3 . It is noted that only projection 19 is seen in FIG. 3 , but both projections 19 and 20 are depicted in FIG. 4 .
[0062] The unlocking element 1 has, between the members 2 , 3 , the first connection 4 and the second connection 7 , an open space through which a part of the housing 18 of the coupling element 15 extends. An arrangement of the unlocking element 1 at the coupling element 15 that is very space saving results from the shape of the connections 4 , 7 which is adapted to a curve or contour of the housing 18 .
[0063] FIG. 4 shows an embodiment of the coupling element 15 , in which the fluid line 17 and the insertion element 16 are not disposed aligned with each other, but are rather perpendicular to each other. Consequently, the coupling element 15 is designed to extend in a 90° angle. With regard to an embodiment of the coupling element 15 of this type, the second embodiment of the unlocking element 1 , as shown in FIG. 2 , is used. The connections 4 , 7 of the unlocking element 1 are also thereby designed parallel to the (e.g., contours of) housing 18 such that an installation space saving arrangement is possible. In the two embodiments, as well as in the embodiment according to FIG. 3 and also the embodiment according to FIG. 4 , the unlocking element 1 can be displaced linearly parallel to an axial direction of the insertion element 16 . The insertion element 16 is inserted in a receptacle region 21 (see FIGS. 5 and 6 ) which is formed in the housing 18 of the coupling element 15 .
[0064] FIG. 5 shows a cross-sectional view of the coupling element 15 according to FIG. 3 , wherein the coupling element 15 is connected to a insertion element 16 that is designed as one piece with a housing wall 22 , for example of a fuel tank.
[0065] As can be observed, only relatively little room is available for the coupling element 15 .
[0066] The coupling element 15 has a snap-in locking device 23 which comprises two locking elements 24 , 25 . The locking elements 24 , 25 are designed as one piece with the unlocking levers 26 , 27 . The locking elements 24 , 25 are disposed elastically pivotably at guide members 28 , 29 , and are designed as one piece with the guide members 28 , 29 and the unlocking levers 26 , 27 .
[0067] A part of the housing 18 of the coupling element 15 extends between the unlocking levers 26 , 27 and the guide members 28 , 29 . This part has raised points 30 , 31 which are disposed under the unlocking levers 26 , 27 at the position shown on the locking elements 24 , 25 , and thus prevent compression of the unlocking levers 26 , 27 .
[0068] The locking elements 24 , 25 are snapped onto a circumferential flange 32 of the insertion element 16 . The unlocking element 1 is displaced relatively far in the direction of the insertion element 16 , such that the projections 11 , 12 are located in front of projections or raised points 30 , 31 that are located in the initial region of the unlocking levers 26 , 27 . In this way, it is possible to exert an axial tractive force on the locking elements 24 , 25 via the unlocking element 1 such that the coupling element 15 can be pushed in the direction of the insertion element 16 while the locking elements 24 , 25 , with the assistance of the unlocking element 1 , are pulled in the opposite direction. In this way, a movement of the unlocking levers 26 , 27 is not further blocked by the raised points 30 , 31 . The locking elements 24 , 25 are then located in their unengaged position, as is shown in FIG. 6 .
[0069] In FIG. 6 , the unlocking element 1 is yet further axially displaced in a position such that the effective surfaces 13 , 14 of the unlocking element 1 interact with the unlocking levers 26 , 27 in such a way that the unlocking levers 26 , 27 are pushed radially towards each other. Due to the elastic design of the guide members 28 , 29 as well as the elastic connection thereof to the locking elements 24 , 25 , a pivoting movement and thus a radial removal of the locking elements 24 , 25 away from each other results from the radial compression of the unlocking levers 26 , 27 . The snap-in locking device 23 is thus loosened such that the insertion element 16 can be removed.
[0070] As long as the unlocking element 1 is located in the position shown in FIG. 6 , a renewed insertion of the insertion element 16 is possible without problem. To catch, the unlocking element 1 must only be displaced in the direction of the insertion element 16 . The unlocking element 1 enables a relatively simple actuation of the unlocking levers 26 , 27 without requiring a direct manual grasp at the unlocking levers 26 , 27 .
[0071] In this way, a simplified unlocking of the snap-in locking device 23 of the coupling element 15 occurs and thus a simplified disassembly.
[0072] It is noted that the foregoing examples have been provided merely for the purpose of explanation and are in no way to be construed as limiting of the present invention. While the present invention has been described with reference to an exemplary embodiment, it is understood that the words which have been used herein are words of description and illustration, rather than words of limitation. Changes may be made, within the purview of the appended claims, as presently stated and as amended, without departing from the scope and spirit of the present invention in its aspects. Although the present invention has been described herein with reference to particular means, materials and embodiments, the present invention is not intended to be limited to the particulars disclosed herein; rather, the present invention extends to all functionally equivalent structures, methods and uses, such as are within the scope of the appended claims. | Coupling element for a fluid line, an unlocking element, and a method of engaging and/or disengaging the coupling element with an insertion element. The coupling element includes a housing having a receptacle region structured and arranged to receive an insertion element, and a snap-in locking device in the receptacle region that is structured and arranged for a locking connection with the insertion element. The snap-in locking device includes at least one locking element having an unlocking lever and an unlocking element is movable between a first position, in which the unlocking element interacts with the unlocking lever, and a second position, in which the unlocking element releases the unlocking lever. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 13/886338, filed May 3, 2013, which claims priority to European Application No. 12166698.6, filed May 3, 2012, each of which is expressly incorporated herein by reference in its entirety.
BACKGROUND
[0002] The present invention relates to a process for manufacturing a waterproofing membrane comprising:
[0003] a preparation of a composition comprising an acrylic polymer and titanium dioxide dispersed in a solvent;
[0004] coating a reinforcement layer by application of said composition on one side of the reinforcement layer;
[0005] having the coated reinforcement layer dried; and
[0006] an application of a bituminous mass on another side of said reinforcement layer.
[0007] The present invention relates also to a composition for a waterproofing membrane.
[0008] A process for manufacturing such a waterproofing membrane is known from US2006/0110996. The coated waterproofing membrane, obtained by the known process, has the property to reflect the solar rays due to the presence of titanium dioxide and allows to avoid exudation problems of the membrane due to the presence of a coating with an acrylic polymer as binder which is less sensitive to solar rays. So the coating forms as if to say a barrier against the solar rays so that the latter heat less the bituminous mass and the building on which the membrane is placed as a roof covering.
[0009] A drawback of the known membrane is that its reflectivity decreases over time. Indeed, the colour of the coating on the membrane changes from white to yellow so that the coating on such a membrane loses its reflectivity property over the years. Consequently, in the known waterproofing membrane, the oil contained in the bituminous mass may migrate more easily to the upper side of the waterproofing membrane because the membrane heats more up due to the reflectivity decrease. This oil migration phenomenon is called exudation and it further reduces the long-term whiteness of the waterproofing membrane. Also, pollution could be provoked if the oil will not remain in the crystalline phase of the bituminous mass and mix with rain water.
SUMMARY
[0010] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
[0011] It is an object of the invention to provide a process for manufacturing a waterproofing membrane where the reflectivity decrease is reduced, thereby providing a long-term whiteness of said membrane.
[0012] A process for manufacturing a waterproofing membrane according to the invention is characterized in that, during the preparation of the composition, the acrylic polymer and the titanium dioxide are dispersed in a solvent chosen in the group consisting of a solvent other than water or water wherein the acrylic polymer, the titanium dioxide and additives, in particular a thickening agent, are mixed with cristobalite.
[0013] The invention thus provides two alternatives to solve the mentioned problem.
[0014] In the first alternative, the process is characterised in that the acrylic polymer and the titanium dioxide are dispersed in a solvent other than water before application of the composition.
[0015] It was established through researches that the viscosity of a composition comprising an acrylic polymer, titanium dioxide and additives, in particular a thickening agent, which are dispersed in an aqueous phase before application of the composition on the reinforcement layer, is non-Newtonian. Therefore, the viscosity of said composition does not remain constant during the application of the composition itself and the change of viscosity occurs when applying the coating on the reinforcement layer.
[0016] A surprising effect has now been noted when the solvent used in the composition was other than water. With the solvent other than water, the viscosity of the composition remains Newtonian, so it does not change during the application of the composition. Consequently, the acrylic polymer and the titanium dioxide anchor better to the reinforcement layer. So, the process using a solvent other than water during the dispersion step provides a waterproofing membrane which keeps its reflectivity property during a longer time in comparison with known membranes. Moreover, said process does not necessarily require the use of additives, in particular a thickening agent, to keep the viscosity of the composition constant during the application of said composition and allows to obtain a satisfactory application step.
[0017] In the second alternative, the process is characterized in that the acrylic polymer, the titanium dioxide and additives, in particular a thickening agent, are mixed with cristobalite and dispersed in aqueous phase before application of the composition.
[0018] Surprisingly, the presence of cristobalite in the composition provides a waterproofing membrane which keeps its reflectivity property for a longer time in comparison with known membranes. So, the yellowing of the membrane obtained by such a process is highly reduced. The particular choice of the cristobalite in the composition contributes substantially to obtain a more homogeneous dispersion of the additives, even when the solvent is water. Moreover, the mixture of cristobalite and titanium dioxide is synergistic. The presence of cristobalite in the composition increases the reflectivity properties of the titanium dioxide. The cristobalite contributes substantially to disperse more homogeneously the titanium dioxide when applying the composition on the reinforcement layer. Consequently, the amount of titanium dioxide can even be reduced as there is a better dispersion of it in the composition. Moreover, the sedimentation of titanium dioxide is also reduced by a better dispersion of it in the composition.
[0019] In a particular embodiment of the first alternative, the process for applying the composition according to the invention is characterized in that, when the solvent is other than water, the acrylic polymer and the titanium dioxide are mixed with cristobalite before application of the composition. Even when the solvent is not water, the use of cristobalite allows a further reduction of the yellowing for the waterproofing membrane obtained with the process according to the invention. The mixture of cristobalite and titanium dioxide in the composition is synergistic as mentioned above.
[0020] In another preferred embodiment according to the invention, the process for applying the composition is characterized in that the acrylic polymer and the titanium dioxide are mixed with talc, in a solvent other than water or in an aqueous phase, before application of the composition on the reinforcement layer. Talc is a suitable additive acting as a filler, which does not adversely affect the reflective properties of titanium dioxide.
[0021] In a particularly preferred embodiment according to the invention, the process for applying the composition is characterized in that the cristobalite has been obtained by heating quartz to substantially 1500° C. before it is mixed with acrylic polymer and titanium dioxide.
[0022] The thermal treatment of quartz to substantially 1500° C. allows to form extremely white cristobalite with a thermal conductivity of 8.5 W/mK, a thermal expansion of 20-300 C, a thermal capacity of 44.18 W/Mol C, a density of 2.32 g/cm 3 and an optical refraction index of 1.48.
[0023] The invention comprises, advantageously, the process for applying the composition according to the invention, characterized in that the acrylic polymer and the titanium dioxide are mixed with an additive composed by a core of titanium dioxide covered by calcium carbonate before application of the composition. The use of an additive composed by a core of titanium dioxide covered by calcium carbonate allows to use less titanium dioxide. The use of said additive is less expensive than pure titanium dioxide and does not hardly affect the reflectivity of the coated reinforcement layer.
[0024] Moreover, in a particular embodiment, the process for applying the composition according to the invention is characterized in that acrylic polymer and titanium dioxide are mixed with calcium carbonate before application of the composition. Calcium carbonate is a suitable additive which does not adversely affect the reflective properties of titanium dioxide.
[0025] The invention relates also to a composition for a waterproofing membrane characterized in that it comprises cristobalite.
[0026] Other characteristics and advantages of the invention will appear more clearly in the light of the following description together with the FIGUREs.
DESCRIPTION OF THE DRAWINGS
[0027] The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
[0028] FIG. 1 represents a device for a one-step application;
[0029] FIG. 2 represents a device for a multi-step application;
[0030] FIG. 3 illustrates the albedo in function of time of the compositions of a known coating and a coated reinforcement layer comprising cristobalite where the solvent is water;
[0031] FIG. 4 illustrates the yellowing in function of time of the compositions of a known coating and a coated reinforcement layer comprising cristobalite where the solvent is water;
[0032] FIG. 5 illustrates the albedo in function of time of the compositions of a known coating and a coated reinforcement layer comprising cristobalite where the solvent is other than water;
[0033] FIG. 6 illustrates the yellowing in function of time of the compositions of a known coating and a coated reinforcement layer comprising cristobalite where the solvent is other than water;
[0034] FIG. 7 illustrates an infrared analysis of the composition;
[0035] FIG. 8 represents a graph showing the absorbance in function of wavenumber (cm −1 ) of talc and the absorbance after removing of the coated reinforcement layer from the crystal. The graph comprises two spectra. Spectrum A corresponds to talc and spectrum B corresponds to the spectrum after removing of the coated reinforcement layer from the crystal;
[0036] FIG. 9 represents a graph showing the absorbance in function of wavenumber (cm −1 ) of the crystal, the coated reinforcement layer and after removing of the coated reinforcement layer from the crystal. The graph comprises three spectra. Spectrum A corresponds to the spectrum of the crystal, spectrum B corresponds to the spectrum of the coated reinforcement layer and spectrum C is the result after removing of the coated reinforcement layer from the crystal;
[0037] FIG. 10 represents a graph showing the absorbance in function of wavenumber (cm −1 ) of pure cristobalite and the coated reinforcement layer comprising cristobalite where the solvent was other than water. The graph comprises two spectra. Spectrum A is the spectrum of pure cristobalite and spectrum B is the spectrum of the coated reinforcement layer comprising cristobalite;
[0038] FIG. 11 represents a graph showing the absorbance in function of wavenumber (cm −1 ) of pure cristobalite and the coated reinforcement layer comprising cristobalite where the solvent was water. The graph comprises two spectra. Spectrum A is the spectrum of pure cristobalite and spectrum B is the spectrum of the coated reinforcement layer comprising cristobalite;
[0039] FIG. 12 represents the measurement method of a tint in a three dimensional model;
[0040] FIG. 13 illustrates three scales of values for the parameters “L”, “a” and “b”.
DETAILED DESCRIPTION
[0041] A process for manufacturing a known waterproofing membrane comprises an application of a composition which comprises an acrylic polymer and titanium dioxide on one side of a reinforcement layer (glass and/or polyester fibre) and is detailed in US 2006/0110996. The method for applying a bituminous mass on another side of the reinforcement layer is given in WO 97/24485. For details about the acrylic polymer and the titanium dioxide, as well as for the manufacturing process, reference is made to both referred patent applications.
[0042] The process according to the prior art comprises a preparation of a composition which will be applied on the one side of the reinforcement layer. Such a composition comprises a mixture of an acrylic polymer and titanium dioxide, which is a viscous composition. The viscosity of said composition is either non-Newtonian or Newtonian and depends on the composition itself In fact, when the solvent is water, additives are needed because the viscosity of said composition is non-Newtonian. It is not required to add additives in the composition where the solvent is other than water because the viscosity of said composition is Newtonian.
[0043] The viscosity of the composition comprising an acrylic polymer, titanium dioxide, additives, in particular a thickening agent, and talc, which are dispersed in an aqueous phase before application of the composition on a reinforcement layer, is non-Newtonian. The fact that the viscosity of the composition is non-Newtonian means that the viscosity changes while applying it on the reinforcement layer. When the solvent is water, it is required to add additives, in particular a thickening agent, otherwise the composition would not enough stabilize. It has also been noted that the use of said composition leads to the formation of a waterproofing membrane whose reflectivity decreases over time. A brief description of the process according to the prior art allows to highlight some factors and will make more clear why there is a link between the reflectivity decrease and the non-Newtonian viscosity.
[0044] Generally, a process for manufacturing a waterproofing membrane requires a preparation of a composition and an application of the composition on a reinforcement layer. When the solvent is water, the composition according to the prior art comprises the mixture of an acrylic polymer, titanium dioxide, additives and talc. The compounds of said composition are more susceptible to sediment during the mixing. Additives, in particular a dispersing agent, and high shear forces are needed to make a satisfactory dispersion and application on the reinforcement layer. Researches have however demonstrated that the dispersion of the known composition is still not sufficiently homogeneous and leads to reflectivity degradation of the coated reinforcement layer. Moreover, it has been observed that an additive like talc is present at the surface of the reinforcement layer (see FIG. 8 ), which indicated that the composition is not homogeneous within the coating. Therefore, the coated reinforcement layer looses its reflectivity properties in long-term as its composition changes due to the loss of some of the constituents.
[0045] In a composition according to the first alternative of the present invention, the composition comprises an acrylic polymer and titanium dioxide which are dispersed in a solvent other than water. In the second alternative, the composition is a mixture of an acrylic polymer, titanium dioxide, additives, in particular a dispersing agent, and cristobalite which are dispersed in water.
[0046] The method of application of a composition according to the invention is either a one-step application device or a multi-step application device.
[0047] The device provided for executing a one-step application is illustrated in FIG. 1 and comprises supply station for supplying a reinforcement layer ( 2 ) wound on a bobbin ( 1 ), a hopper ( 3 ) for supplying the composition, a rotatably driven carrier cylinder ( 4 ), a wiper blade ( 5 ), which is located just above the carrier cylinder and applies a pressure on it and on the coated reinforcement layer. A drying zone ( 7 ) is located after the cylinder. The reinforcement layer ( 2 ) is unrolled from the bobbin and moved towards the hopper ( 3 ), which supplies by gravity the composition to the layer ( 2 ). After supplying said composition, the reinforcement layer with the composition thereon reaches the carrier cylinder ( 4 ) and the wiper blade ( 5 ). The wiper blade will spread the composition on the reinforcement layer in order to adjust the thickness of the coating. Therefore, the layer with the applied composition is dried in the drying zone ( 7 ) in order to obtain the final coated reinforcement layer ( 6 ).
[0048] The device for the multi-step application is illustrated in FIG. 2 and distinguishes over the device provided for executing the one-step application in that it also comprises a second hopper ( 8 ), a second carrier cylinder ( 9 ), a second wiper blade ( 10 ) and a second drying zone ( 11 ), situated after the first drying zone ( 7 ). In this embodiment, the wiper blades are however no longer above the cylinders but offset and downstream from the cylinders. After drying in the drying zone ( 7 ) of the applied composition, the reinforcement layer is moved towards the second hopper ( 8 ) and the second carrier cylinder ( 9 ) in order to form an additional layer on the reinforcement layer. Then, the reinforcement layer is moved towards the second wiper blade to adjust the thickness of the layer. After drying ( 11 ) of the applied composition, the reinforcement layer is moved in the same way as described in the beginning of the description of the multi-step application. If more than two layers of composition are required, additional hoppers, cylinders, wiper blades and drying zone can be applied.
[0049] The one-step application or the multi-step application is used when the dispersion is realised either in a solvent other than water or in water. However, the multi-step application is preferably used when the dispersion is realised in a solvent other than water. When the solvent is other than water, the viscosity is Newtonian so it is not required to have the wiper blade directly located above the carrier cylinder, contrarily in an aqueous phase, because the viscosity is constant in that situation, and less shear forces is required for applying the composition.
[0050] FIG. 3 illustrates the albedo in function of time of a known coated reinforcement layer (comprising talc) and a coated reinforcement layer where an acrylic polymer, titanium dioxide, additives, in particular a thickening agent, and cristobalite are dispersed in an aqueous phase before application of the composition on the reinforcement layer. The albedo corresponds to the reflectivity of the coated reinforcement layer in the visible range of the solar spectrum. The reflectivity has been measured at different times (after 0 days (T=0), after 7 days (T+7) under ultra-violet rays and after 15 days (T+15) under ultra-violet rays).
[0051] The analysis of the results shows that the reflectivity of the coated reinforcement layer comprising cristobalite is higher in comparison with the known coated reinforcement layer after 0 days (T=0). This is due to the synergistic effect between the cristobalite and the titanium dioxide. Indeed, cristobalite allows a better dispersion of the titanium dioxide in the composition. Therefore, the reflectivity of the coated reinforcement layer is increased as the titanium dioxide is more uniformly spread.
[0052] FIG. 4 illustrates the yellowing in function of time of the coated reinforcement layers as mentioned above ( FIG. 3 ). The unit of the yellowing is expressed through the value of a “b” parameter defined by the method of measurement of a tint (CIELAB). The CIELAB method is a three-dimensional model of representation of colours and allows to characterize a tint according to three axis ( FIG. 12 ). The vertical axis (L) represents the brightness which varies from 0 to 100 corresponding to the black colour and to the white colour respectively. The horizontal axis (a) comprises a positive and a negative maximum values of the “a” parameter corresponding to the red colour (+127) and to the green colour (−127) respectively. The other horizontal axis (b) has a value of “b” which can be also positive or negative. The most negative value of the “b” parameter represents the blue colour (−127) and the most positive value of the “b” parameter (+127) corresponds to the yellow colour. FIG. 13 represents three scales of values for each parameter of the measurement method of a tint (0≦L≦100, −127≦“a”≦+127 and −127≦“b”≦+127).
[0053] In the known coated reinforcement layer of FIG. 4 , the yellowing increases over time. It is noted that the yellowing is reduced in the composition comprising cristobalite. So, the presence of cristobalite in the composition has two effects. Firstly, it allows the increase of the reflectivity properties of the titanium dioxide by a better dispersion in the composition. Secondly, it provides a coated reinforcement layer whose reflectivity remains more stable over the years.
[0054] FIG. 5 illustrates the albedo in function of time of a known coated reinforcement layer (comprising talc) and a coated reinforcement layer where an acrylic polymer, titanium dioxide and cristobalite are dispersed in a solvent other than water before application of the composition on the reinforcement layer.
[0055] It is noted that the reflectivity of the coated reinforcement layer comprising cristobalite remains stable over time in comparison with the known coating. This is also due to the synergistic effect between cristobalite and titanium dioxide.
[0056] FIG. 6 illustrates the yellowing of the coated reinforcement layers as described above ( FIG. 5 ) over time. It is noted that the yellowing is highly reduced in the coating comprising cristobalite where the solvent used is other than water.
[0057] The use of cristobalite in the composition thus allows to obtain a more homogeneous dispersion and a stability of the reflectivity of the coated reinforcement layer.
[0058] The solvent and the compounds in the composition are the elements which are determinant in obtaining a stable dispersion, leading to a waterproofing membrane whose reflectivity decrease over time is reduced.
[0059] In the first alternative of the present invention, the use of a solvent other than water, allows to keep a Newtonian viscosity in the composition. The fact that the viscosity remains Newtonian and thus stable allows that the shear forces described above do not constitute a limiting factor in the obtaining of a homogeneous dispersion.
[0060] In the second alternative of the present invention where the solvent is water, it has been noted that the addition of cristobalite in the composition comprising acrylic polymer, titanium dioxide and additives, in particular a thickening agent, leads to the formation of a homogeneous dispersion. Additives, in particular a thickening agent, have to be used in this embodiment because the process is realised in an aqueous phase which enables spreading and avoiding passing through the structure of the reinforcement layer while applying it. This surprising embodiment, where cristobalite is present in the composition, allows the manufacturing of a waterproofing membrane where its reflectivity decrease is reduced, even if the solvent is water.
[0061] The following tables illustrate some examples of compositions in order to manufacture a waterproofing membrane where its reflectivity remains longer over time in comparison with a known membrane.
[0062] The examples 1 to 4 illustrates compositions where the solvent is other than water and the example 5 illustrates a composition where the solvent is water (aqueous phase).
[0063] Table 1 illustrates a first example of composition according to the invention. The composition comprises an acrylic polymer and titanium dioxide which are dispersed in a solvent other than water before application of the composition on the reinforcement layer.
[0064] In each of the following tables, the first column of each table comprises the compounds of the composition. The second column gives an example of the composition according to the invention and the third column comprises ranges in weight percentage for each compound in the composition according to the invention.
[0065] The solvent used in the following examples is for example dimethylformamid, methyl ethyl ketone or toluene.
[0066] Table 1 illustrates the composition of the coated reinforcement layer without cristobalite in a solvent other than water.
[0000]
TABLE 1
Compounds of the
% in
Range (% in
composition
wet weight
wet weight)
Acrylic polymer dispersed
33
20-75
in solvent (40% solid)
TiO 2
5
0-20
Calcium carbonate
35
20-50
core of titanium dioxide
14
0-20
covered by calcium
carbonate
Solvent
9
0-20
Biocide
2
0.5-4
Optical brightener
2
0-5
[0067] It is also possible to have the composition according to table 1 without the presence of the core of titanium dioxide covered by calcium carbonate. In that case, the composition will comprise more titanium dioxide and calcium carbonate in the preferred embodiment.
[0068] Table 2 illustrates a second example of a composition according to the invention where cristobalite is mixed with acrylic polymer and titanium dioxide before application of the composition on the reinforcement layer. The dispersion step is realised in a solvent other than water.
[0000]
TABLE 2
Compounds of the
% in
Range (% in
composition
wet weight
wet weight)
Acrylic dispersed in solvent
33
20-75
(40% solid)
TiO 2
5
0-20
Calcium carbonate
35
20-50
Cristobalite
14
0-20
Solvent
9
0-20
Biocide
2
0.5-4
Optical brightener
2
0-5
[0069] Cristobalite is white and has reflective property with an optical refraction index of 1.48. Cristobalite is obtained by heating quartz to substantially 1500° C. and is preferably catalyzed by the addition of a sodium based flux additive. Cristobalite has a thermal conductivity of 8.5 W/mK, a thermal expansion of 20-300 C, a thermal capacity of 44.18 W/Mol C and a density of 2.32 g/cm 3 .
[0070] The mixture of cristobalite and titanium dioxide is synergistic and allows to use a reduced amount of titanium dioxide in the composition because cristobalite contributes to disperse more effectively the titanium dioxide in the obtained composition. Moreover, it has been noted that this embodiment allows to increase the reflectivity of the coated reinforcement layer, by the synergistic effect mentioned above. At the same time, it allows to reduce considerably the yellowing of said coated reinforcement layer in comparison with known coatings.
[0071] The percentage in wet weight of cristobalite in the composition is between 0-20%, 5-15% or in a preferential embodiment 14%.
[0072] Table 3 illustrates a third example of a composition according to the present invention where talc is mixed with acrylic polymer and titanium dioxide before application of the composition on the reinforcement layer. The dispersion step is realised in a solvent other than water.
[0000]
TABLE 3
Compounds of the
% in
Range (% in
composition
wet weight
wet weight)
Acrylic dispersed in solvent
33
20-75
(40% solid)
TiO 2
5
0-20
Calcium carbonate
35
20-50
Talc
14
0-20
Solvent
9
0-20
Biocide
2
0.5-4
Optical brightener
2
0-5
[0073] The percentage in wet weight of talc in the composition is between 0-20%, 5-15% or in a preferential embodiment 14%.
[0074] Table 4 illustrates a fourth example of a composition according to the invention where acrylic polymer and titanium dioxide are mixed with talc and cristobalite and dispersed in a solvent other than water before application of the composition on the reinforcement layer.
[0000]
TABLE 4
Compounds of the
% in
Range (% in
composition
wet weight
wet weight)
Acrylic dispersed in solvent
33
20-75
(40% solid)
TiO 2
5
0-20
Calcium carbonate
35
20-50
Talc and cristobalite
14
0-20
Solvent
9
0-20
Biocide
2
0.5-4
Optical brightener
2
0-5
[0075] The percentage in wet weight of cristobalite and talc in the composition is between 0-20%, 5-15% or in a preferential embodiment 14%.
[0076] Table 5 is a fifth example of a composition of a coating according to the invention where acrylic polymer and titanium dioxide are mixed with cristobalite and dispersed in an aqueous phase before application of the composition on the reinforcement layer.
[0000]
TABLE 5
Compounds of the
% in
Range (% in
compsoition
wet weight
wet weight)
Acrylic (emulsion in water
30
20-75
50% solid)
H2O
8.80
2-20
Dispersing agent
0.50
0.3-0.8
Anti-foaming agent
0.50
0.3.0.8
Biocide
1
0.5-4
TiO 2
5.00
0-20
TiO 2 covered by CaCO3
5.00
0-20
Cristobalite
7.00
0-20
Calcium carbonate
42.00
0-50
Thickener
0.20
0.1-0.5
[0077] The composition of table 5 where the dispersion step is realised in an aqueous phase requires the use of additives like a dispersing agent, an anti-foaming agent and a thickener. These additives are not necessarily needed when the dispersion step is realised in a solvent other than water. In a solvent other than water, the composition is less sensitive to sedimentation of the additives. When the solvent is water, it is preferred to use a dispersing agent, an anti-foaming agent and a thickener to avoid that the shear forces becomes a limiting factor during the dispersion step. Moreover, the addition of cristobalite in the composition allows to form a waterproofing membrane where its reflectivity decrease is reduced because cristobalite is homogeneously dispersed in the composition.
[0078] The percentage in wet weight of cristobalite in the composition is between 0-20%, 5-15% or in a preferential embodiment 14%.
[0079] It is also possible to add talc in the composition described in table 5.
[0080] Some infrared analyses were realised in order to show the difference between a known coated reinforcement layer and a coated reinforcement layer obtained by the present invention.
[0081] The test method of an infrared analysis ( FIG. 7 ) consists in pressing a coated reinforcement layer (a sample) on a crystal like zinc selenide (ZnSe) with a refraction index of around 2.4. The infrared beam ( 1 ) for example produced by a laser (not shown) penetrates into and travels through the crystal ( 2 ) and it is reflected on the crystal-sample interface and inside the crystal ( FIG. 7 ). At each reflection on the crystal-sample interface, beam penetrates a short distance (evanescent wave) in the sample ( 3 ) which causes absorptions by the coating present on the sample. In another words, this internal reflectance, located on the crystal-sample interface, creates an evanescent wave that extends beyond the surface of the crystal into the sample held in contact with the crystal. So, for each reflection the sample absorbs the evanescent wave which has been created. In regions of the infrared spectrum where the sample absorbs energy, the evanescent wave will be attenuated or altered. The alternated energy from each evanescent wave is passed back to the infrared beam, which then exits the opposite end of the crystal and is passed to a detector in an infrared spectrometer. The results are obtained through infrared spectrum. So, in the framework of the present invention, the infrared method is used to analyse a coated reinforcement layer.
[0082] The infrared analysis was carried out with a Horizontal Attenuated Total Reflexion (HATR), with a resolution of 4 cm −1 , 128 scans per spectra and 3 spectra per sample (FT-IR Spectroscopy, Attenuated Total Reflectance (ATR), 2005, technical note available on the following website: http://shop.perkinelmer.com/content/technicalinfo/tch_ftiratr.pdf)
[0083] Infrared analyses were realised for a known coated reinforcement layer comprising talc in order to analyse its surface.
[0084] Firstly, a coated reinforcement layer is placed on a crystal of zinc selenide (ZnSe) and pressed on the latter. Secondly, after removing of the coated reinforcement layer from the crystal, the infrared analysis is realised for the crystal without the presence of the coated reinforcement layer. The infrared analysis revealed traces of talc on the crystal. Consequently, it means that the coated reinforcement layer comprised talc at its surface. The loss of talc on the reinforcement layer leads to the reduction of the reflectivity of said coated reinforcement layer in long-term.
[0085] FIG. 8 illustrates two spectra (absorbance in function of wavenumber (cm −1 )) in the case of a known membrane as mentioned above.
[0086] Infrared spectrum B corresponds to the characteristics absorption peaks of talc and the infrared spectrum A is the result after removing of the coated reinforcement layer from the crystal. The comparison of both spectra allows to note that traces of talc are present on the crystal because spectrum B comprises some of the characteristics absorption peaks of talc (spectrum A). Therefore, the presence of these characteristics absorption peaks allows to conclude that talc was present on the surface of the crystal which could only come from the coating on the reinforcement layer. This is because, in a known coated reinforcement layer, talc was not impregnated sufficiently in the layer as described here before. Consequently, talc is present on the surface of the coated reinforcement layer because it does not adhere sufficiently in the obtained composition. The presence of talc on the surface of the known coated reinforcement layer is responsible of the reflectivity decrease of the waterproofing membrane.
[0087] Infrared analyses ( FIG. 9 ) were realised for the composition described in table 3 in order to analyse the coated reinforcement layer obtained by the process using a solvent other than water.
[0088] FIG. 9 illustrates three spectra. Infrared spectrum A corresponds to the spectrum of the crystal. Infrared spectrum B corresponds to the spectrum of the coated reinforcement layer. Infrared spectrum C corresponds to the result after removing of the coated reinforcement layer from the crystal.
[0089] On the basis of the comparison of spectrum C with A and B, it is noted that nearly no traces of talc are present on the surface of the coated reinforcement layer. Indeed, the characteristics absorption peaks of talc are nearly not present in spectrum C, but the latter looks more like spectrum A which corresponds to the crystal alone so without the presence of the coated reinforcement layer.
[0090] To conclude, these results tend to show that talc becomes impregnated sufficiently in the composition when the solvent is other than water in comparison to a known coated reinforcement layer when the dispersion step is realised in an aqueous phase.
[0091] Infrared analyses ( FIG. 10 ) were realised for the coated reinforcement layer where cristobalite is dispersed in a solvent other than water with the composition of table 2. Spectrum A of FIG. 10 represents the spectrum of pure cristobalite and spectrum B corresponds to the coated reinforcement layer comprising cristobalite. These results show that all the characteristics absorption peaks (spectrum A) of cristobalite are not present in spectrum B. That means that cristobalite remains in the coated reinforcement layer and not on the surface of the latter. However, it is noted from the comparison between spectrum A and B that some of the characteristics absorption peaks of cristobalite are present in spectrum B but these absorption peaks are weak in comparison to those in spectrum A. This is due to the manner to realise the measurement. In fact, during the infrared measurement, the coated reinforcement layer was present on the crystal so it is possible that the infrared rays penetrates into the coating in such a way that cristobalite contained in it absorbed an amount of the infrared rays. This is why all the characteristics absorption peaks of cristobalite are not present in spectrum B and in the same intensity as spectrum A. These analyses allow to conclude that cristobalite is not present on the coated reinforcement layer.
[0092] Infrared analyses were realised ( FIG. 11 ) in order to analyse a coated reinforcement layer obtained with the composition of table 5 where the dispersion is realised in an aqueous phase.
[0093] Spectrum A of FIG. 11 represents the spectrum of pure cristobalite and spectrum B corresponds to the coated reinforcement layer comprising cristobalite. These results show that all the characteristics absorption peaks (spectrum A) of cristobalite are not present in spectrum B. That means that cristobalite remains in the coated reinforcement layer and not on the surface of the latter. However, it is noted from the comparison between spectrum A and B that some of the characteristics absorption peaks of cristobalite are present as it was the case in the analysis of the results illustrated in FIG. 10 . So, the fact that the coated reinforcement layer was present on the crystal during the measurement involves the absorption of the infrared rays by the cristobalite which is present in the coated reinforcement layer. Consequently, the absorption peaks of low intensity noted in the spectrum b are due to the absorption of a small amount of infrared rays by cristobalite. These analyses allow to conclude that cristobalite is not present on the coated reinforcement layer.
[0094] While illustrative embodiments have been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention. | The present invention relates to a process for manufacturing a waterproofing membrane comprising:
a preparation of a composition dispersed in a solvent; coating a reinforcement layer by application of said composition on one side of the reinforcement layer; an evaporation of said solvent; having the coated reinforcement layer dried; and an application of a bituminous mass on another side of said reinforcement layer, characterized in that, during the preparation of the composition, the composition is dispersed in a solvent chosen in the group consisting of a solvent other than water or water.
The present invention relates also to a composition for a waterproofing membrane. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to a focus detecting device in a camera in which the image of an object is divided into two parts by means of a prism, a half mirror, and a mirror. Alternatively, the same image of an object is received at two places in accordance with a so-called range-finder system. By utilizing the fact the amount of mutual displacement of the two parts of the image becomes zero when correct focalization is obtained, the direction in which the photographing lens should be turned or moved for the correct focalization is informed to the photographer by display means such as light emission diodes or the like even if the initial focus position is remote from the correct focalization position.
A number of electrical focus detection methods have been proposed in the art, in which the same image of an object is processed in two optical paths according to variation of spatial frequency or variations in constrast of the image. The two images thus obtained are made to coincide with each other when the correct focalization is obtained. Among these conventional electrical focus detecting methods, the object of most methods resides in obtaining the correct focalization automatically. Accordingly, in these conventional methods, the photographer only knows that the correct focalization has been obtained. Thus, the conventional methods are still unsatisfactory to photographers in many respects.
Heretofore, the focalization can be achieved by moving a photographing lens in presently available camera systems. However, in the case of the aforementioned electrical focus detecting methods, it is necessary to move the photographing lens by means of, for instance, an electric motor. It is therefore a requirement of such systems to provide such an electric motor, a motor drive device and a battery, all of which leads to an increase in size of the camera. Thus, the use of such a camera is necessarily limited and cumbersome.
In addition, there are other factors to consider in the focalization process. At present, there are avilable a variety of optical focus detecting methods in which, for instance, a mat surface, a microprism or a split-prism are utilized. In any of these conventional optical focus detecting methods, the photographer recognizes the image of an object as an analog variation, or a continuous variation to thereby detect the correct focalization. Accordingly, the detection of correct focalization involves personal errors based on user skills. These are due to photographer's personal ability such as visual power, skill in focalization and sense of depth of field. The techniques are therefore not suitable for beginners, or children.
Since electrical focus detecting methods have been proposed in order to overcome this difficulty, completely automatic focalization is not necessarily required. That electrical lens movement is not always required. What is necessary is an indication as to how correct the focalization can be achieved. That is, if display indicating conditions of rear focalization, the front focalization and the correct focalization can be made during operation of the photographing lens as in present camera systems, then any photographer can obtain the correct focalization readily irrespective of his personal ability.
SUMMARY OF THE INVENTION
In view of the foregoing, an object of this invention is to provide a focus detecting device in a camera, in which the state of focalization is provided to a photographer by displaying it with a meter or light emission diodes so that any one can readily obtain the correct focalization.
It is another object of this invention to provide a focusing system in which the electronic focus detecting device is relatively simple in construction, and has no movable components.
It is yet another object of this invention to define a system useable in an automatic focus detecting device formed according to the technical concept of this invention.
These and other objects of this invention are accomplished by means of a novel focus detecting device.
The device comprises an optical member or an optical system for obtaining two images from an object and an optical member for displacing said two images in opposite directions or displacing one of said two images. Two minute photoelectric conversion element groups are employed for converting variation in light quantity of portions of the object into electrical signals. A photographing lens is used for projecting the image of said object onto the minute photoelectric conversion element groups. A circuit calculates outputs ##EQU2## from the outputs of minute photoelectric conversion elements forming the minute photoelectric conversion element groups. A circuit which has calculation circuits for calculating V out-3 =V out-1 +V out-2 and V out-4 =V out-1 -V out-2 so that when V out-3 becomes higher than a predetermined value, different outputs are produced under conditions that V out-4 >ε 1 , ε 1 ≧V out-4 ≧ε 2 , and ε 2 >V out-4 . A display effectuates different outputs according to the different outputs, where n is the number of the minute photoelectric conversion elements forming each of the two minute photoelectric conversion element groups, m is a number of a minute photoelectric conversion element, i is the output of a minute photoelectric conversion element in one of the two minute photoelectric conversion element groups, i' is the output of a minute photoelectric conversion element in the other minute photoelectric element group.
This invention will be discribed in greater detail with respect to the accompanying drawings and the description of the preferred embodiment that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an explanatory diagram showing one example of an optical system according to an electrical focus detecting method of this invention;
FIG. 2(a) is a diagram showing the images of an object on photoelectric conversion element groups 5 and 5' in the case where the focus position is in front of (or in the rear of) the correct focalization position;
FIG. 2(b) is a diagram showing the images of the object on the photoelectric conversion element groups 5 and 5' in the case where the correct focalization is obtained;
FIG. 2(c) is a diagram showing the images of the object on the photoelectric conversion element groups 5 and 5' in the case where the focus position is in the rear of (or in front of) the correct focalization position;
FIG. 3(a) is a graphical representation indicating variations of focus detecting outputs V out-1 , V out-2 and V out-3 with respect to positions of extension of a photographing lens;
FIG. 3(b) is a graphical representation indicating variation of an focus detecting output V out-4 with respect to positions of extension of the photographing lens;
FIG. 4 is a block diagram showing one example of a processing circuit in an electrical focus detecting device according to the invention;
FIG. 5 shows one example of a display in a finder utilizing the focus detecting outputs according to the invention; and
FIG. 6 is a block diagram showing one example of a control circuit shown in FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENT
One preferred embodiment of this invention will now be described with reference to the accompanying drawings.
FIG. 1 shows an optical system according to an electronic focus detecting method of this invention, which is incorporated in a single lens reflex (SLR) camera. In this optical system, a half mirror 2 is employed as an optical member for dividing the image of an object into two parts, and wedge-type prisms are employed as optical means for displacing the image of the object in the opposite directions.
Referring to FIG. 1, reference numeral 1 designates a photographing lens for forming the image of the object in the vicinities of wedge-type prisms 3 and 3'. Reference numeral 2 is a half mirror and reference numeral 2' is a total reflection mirror having a half mirror in the central portion (the arrow indicating the motion thereof). Reference numeral 2" is a total reflection mirror; and reference numeral 2'" is the surface of film in the camera.
The wedge-type prisms 3 and 3' are disposed at positions optically equivalent to the position of the film surface 2"' in the camera having the electronic focus detecting device. Upon focalization of the image of the object, the image of the object is formed on the wedge-type prisms 3 and 3'. Reference numerals 4 and 4' designate image forming lenses for projecting the object image formed on the prisms 3 and 3' onto minute photoelectric conversion element groups 5 and 5', respectively. Each of the minute photoelectric conversion element groups 5 and 5' is used to convert the optical variation of the object image into an electrical signal. Reference numeral 6 designates a processing device adapted to calculate the outputs of the minute photoelectric conversion element groups 5 and 5' (hereinafter referred to merely as "the photoelectric conversion element groups 5 and 55'") thereby to carry out the electrical focus detection. The block diagram of the processing device 6 is shown in FiG. 4 and will be described herein in detail.
The arrow A for the photographing lens indicates the direction of movement of the photographing lens 1. While the lens 1 is moved either inward or outward in the direction of the arrow, focalization is obtained. Reference characters d 1 through d n , and d 1' through d n' designate photoelectric conversion elements forming the above-described photoelectric conversion element groups 5 and 5'. These elements are equal to each other in photoelectric characteristics and in light receiving area. This is shown in FIG. 2. The elements d 1 and d 1' , the elements d 2 and d 2' and so on optically correspond to each other.
FIG. 2 shows the images of the object (the hatched circles) formed on the photoelectric coversion element groups 5 and 5'. FIG. 2(a) shows the case where the focus position is in front of (or in the rear of) the photoelectric conversion element group. FIG. 2(b) shows the case where focalization is obtained on the photo-electric conversion element group. As shown, the image is centered in the array. FIG. 2(c) shows the case where the focus position is in the rear of (or in front of) the photoelectric conversion element group.
FIG. 3 is a graphical representation indicating variation of focus detection output with amount of extension of photographing lens 1. FIG. 3(a) indicates the following outputs: ##EQU3## FIG. 3(b) indicates the following output:
V.sub.out-4 =V.sub.out-1 -V.sub.out-2
In FIG. 3, ε 0 is the voltage for determining a range in which the output V out-4 is detected, and ε 1 and ε 2 are the voltages which meet an expression ε 1 ≧V out-4 ≧ε 2 and at which a focalization signal is provided. In the above-described expressions, i is the output corresponding to the incident light quantity of each photoelectric conversion element and the suffix m is the element number of each photoelectric conversion element.
FIG. 4 is a block diagram of the processing circuit (shown in FIG. 1) of the focus detecting device according to the invention. The processing circuit, as shown in FIG. 4, comprises: a differential circuit 7 recieving the output from the conversion element groups 5 and 5' and an absolute value circuit 8. An integrating circuit 9 provides inputs to sample hold circuits 10 and 10'. An addition circuit 11, a comparator 12, a differential circuit 13, and a sample hold circuit 14 are shown in serial connections. Comparators 15 and 16 receive the output of circuit 14 and inverters 17 and 18 provide parallel inputs to a NOR circuit 19, AND circuits 20 and 21. Display elements 22, 23 and 24 can be light emission diodes or other display devices. A control circuit 25 is employed for controlling the aforementioned various circuit elements. In the control circuit 25, reference symbols 1 through 5 designate various control signals. FIG. 4 shows switches, S 1 , S 2 , S 3 and S 4 . These may be 3-terminal analog switches (see S 1 ) and it is assumed that the terminals 2 and 3 are short-circuited when the terminal 1 is at a logical high level (hereinafter referred to merely as "H", when applicable.) The terminals 2 and 3 are in open state when the terminal 1 is at a logical low level (hereinafter referred to merely as "L", when applicable.) In FIG. 4, reference characters R O and R O' designate resistors either input or feed-back types.
FIG. 5 shows on example of a technique for displaying a focus detection state according to the invention in a view finder 26. In this view finder, a shutter speed displaying section is provided on the left-hand side and a focalizing section utilizing a split-prism shown in the central position. This is conventional in SLR cameras. Furthermore, however in the upper right portion of the view finder 26 there is provided a front focalization displaying element (or a rear focalization displaying element) 23, a correct focalization displaying element 22, and a rear focalization displaying element (or a front focalization displaying element) 24, which are, for instance, light emission diodes. Elements 23 and 24 would, by arrow instruct the user which way to rotate the barrel of the lens.
FIG. 6 shows one example of the control circuit 25 in FIG. 4. The control circuit comprises ring counters A and A'; J-K flip-flops F 1 through F n , F 1' through F n' , F 0 , F 0' , FF 1 , FF 2 ; switches s 1 through s n , and s 1' through s n' such as analog switches; OR circuits A 1 and A 2 , an AND circuit A 3 ; inverters A 4 and A 5 , an oscillator 27 and a focus detection start switch SW 1 . In FIG. 6, reference characters R and C designate a resistor and capacitor elements respectively. Furthermore, a supply voltage Vcc is at "H", and the ground is at "L". In FIGS. 4 and 6, like parts are designated by like reference numerals or characters.
It will be noted that the operation and symbols for digital logical elements in this specification are similar to those of a C-MOS manufactured by RCA company.
The operation of the focus detecting device according to the invention will now be described with reference to FIGS. 1 through 6.
Referring to FIG. 1, in order to perform the electronic focus detection, the image of the object passes through the photographing lens 1 and the total reflection mirror 2' having the half mirror in the central portion and is then reflected by the total reflection mirror 2". The image thus reflected is divided by the half mirror 2 into two images, which are formed in the vicinities of the wedge-type prisms 3 and 3'. At the time of the correct focalization, the images on the wedge-type prisms 3 and 3' are passed through the image forming lenses 4 and 4', so that identical images are projected onto the photoelectric conversion element groups 5 and 5', respectively. That is, the same portions of the object image are projected onto the photoelectric conversion elements d 1 and d 1' , d 2 and d 2' , . . . , d n and d n' , respectively.
When correct focalization is not obtained (such variation in focus position being due to the movement, in the direction of the arrow A of the photographing lens 1) the image of the object is not on the wedge-type prisms 3 and 3'. Since the prisms 3 and 3' are inclined in the opposite directions, the object images on the photoelectric conversion element groups 5 and 5' are displaced in the opposite directions. Furthermore, because the image forming lenses 4 and 4' are arranged so that they will project the object images formed on the prisms 3 and 3' onto the photoelectric conversion element groups 5 and 5', respectively, the object images on the photoelectric conversion element groups 5 and 5' become more unclear as the deviation from the correct focalization position is increased.
FIG. 2 is a diagram showing variations of the object images on the photoelectric conversion element groups 5 and 5'. FIGS. 2(a) and (c) show the cases where the focus position is remote from the correct focalization position, but the image is not particularly unclear. A common method of reducing the degree of image lack of clarity is to adjust the depth of field of the image forming lenses 4 and 4'.
FIG. 2(a) illustrates the case where the focus position is in front of (or in the rear of) the correct focalization position. If the output ##STR1## and the output ##EQU4## are considered with respect only to the vicinity of the (K-1)th, K'th and (K+1)th elements of the photoelectric conversion element groups 5 and 5', then i 0 >i 00 , where i 0 is the output of an element having the hatched circle which is the object image. i 00 is the output of an element having no hatched circle. (In this case, the output of each of the remaining photoelectric conversion elements is i 00 ). In this case, the output V out-1 is the sum of the outputs of the photoelectric conversion elements:
|d.sub.k-2 -d'.sub.k-1 |+|d.sub.k-1 -d'.sub.k |+|d.sub.k -d'.sub.k+1 |+|d.sub.k+1 -d'.sub.k+2 |.
That is,
V.sub.out-1 =|i.sub.00 -i.sub.00 |+|i.sub.0/2 -i.sub.0/2 |+|i.sub.0/2 -i.sub.0/2 |+|i.sub.00 -i.sub.00 |=0
on the other hand, the output V out-2 is the sum of the difference outputs of the photoelectric conversion elements:
|d'.sub.k-2 -d.sub.k-1 |+|d'.sub.k-1 -d.sub.k |+|d'.sub.k -d.sub.k+1 |+|d'.sub.k+1 -d.sub.k+2 |
That is, ##EQU5##
Since, V out-3 =V out-1 +V out-2' V out-3 =4|i' 0/2 -i 00 |>0.
Since V out-4 =V out-1 -V out-2 , then V out-4 =-4|i 0/2 -i 00 |<0.
FIG. 2(b) shows the case where the correct focalization is obtained. As in the above-described case, the outputs V out-1 , V out-2 , V out-3 and V out-4 can be obtained as follows: ##EQU6##
FIG. 2(c) illustrates the case in contrast to FIG. 2(a) where the focus position is in the rear of (or in front of) the correct focalization position. As in the above-described cases, the outputs can be obtained as follows: ##EQU7##
The outputs V out-3 and V out-4 in FIGS. 2(a)-(c) will be subjected to comparison. Since i 0 >i 00 , with respect to the output V out-3 , part (b)>part (a)>0 and part (b)>part (c)>0. In addition, if the object image becomes unclear when the correct focalization is not obtained, the difference in each of the above-described expression is increased. With respect to the output V out-4 , part (a)<0, part (b)=0, and part (c)>0.
FIGS. 3(a), (b) and (c) indicate variations of the aforementioned outputs with respect to various positions of extension of the photographing lens 1. FIG. 3(a) indicates variations of the outputs V out-1 , V out-2 and V out-3 (the focus detection output ratio of V out-1 or V out-2 to V out-3 being 1:1.) The results of FIGS. 2(a) and (c) described above indicate the outputs at the points a 4 and a 2 , while the result of FIG. 2(b) indicates the output at the point a 3 . FIG. 3(b) shows a variation of the output V out-4 .
The output V out-2 in FIG. 3(a) will now be described. On the left-hand side of the point a 1 , the object image becomes unclear because the focus position is remote from correct focalization position a 3 , and therefore the output V out-2 approaches zero (0). In the vicinity of the point a 1 , the degree of image uncleaness is reduced, and therefore the output is increased. However, when the two object images begin to coincide with each other gradually, the output is decreased. The sum of these two outputs has an external value at point a 2 . The output becomes zero (0) as described with reference to FIG. 2, however, it does not become completely zero (0) because there are involved errors such as the fluctuation in characteristic of the elements. The correct focalization is obtained at the point a 3 .
At this point, the contrast is maximum, and therefore the sum V out-1 of the difference outputs of the adjacent elements becomes maximum. As the position of extension of the photographing lens is moved beyond the point a 3 , the object images are displaced in the opposite directions and becomes unclear. Thus, the output is decreased gradually as the position of extension of the photographing lens is advanced to the points a 4 , a 5 and so on.
The variation of the output V out-2 is as described above. The V out-1 is symmetrical with the V out-2 with respect to the point a 3 , and carries out the variation as indicated in FIG. 3(a). On the other hand, the output V out-3 varies to be a maximum value at point a 3 because V out-3 =V out-1 +V out-2 . FIG. 3(b) shows the variation of the output V out-4 . The value of the output V out-4 is positive on the left-hand side of the point a 3 , zero (0) at the point a 3 , and negative on the right-hand side of the point a 3 . In other words, as described with reference to FIG. 2(b), the output V out-4 =0 at the point a 3 that is, the correct focalization position. The variations of the outputs V out-1 through V out-4 according to the invention are as described above. Now, the value ε 1 and ε 2 will be described with reference to FIG. 4.
In addition, the processing circuit adapted to carry out the focus detection, according to this invention, by utilizing the various outputs will be also described with reference to FIG. 4.
As was described before, FIG. 4 is a block diagram of the processing circuit 6 shown in FIG. 1. First, the output differences of the elements in the photoelectric conversion element groups 5 and 5' are obtained by the differential circuit 7, and then the output ##STR2## is obtained by means of the absolute value circuit 8 and the integrating circuit 9. Thereafter, the output thus obtained is applied to the sample hold circuit 10 such as IH5110 made by Intersil Inc.
Similarly as in the above-described case, the output ##EQU8## is applied to the sample hold circuit 10'. The outputs of the sample hold circuits 10 and 10' are applied to the addition circuit 11. As a result the output V out-3 is obtained. At the same time, the output V out-4 is obtained by the differential circuit 13. If, in this case, the output V out-3 is greater than the value ε 0 in FIG. 3(a), the output of the comparator 12 is raised to "H". This output is applied, as a sample signal, to the sample hold circuit 14 through the switch S 1 . As a result the output V out-4 is obtained at the output of the sample hold circuit 14, while the switches S 2 , S 3 and S 4 are placed in short-circuit state by the application of the "H" output of the comparator 12.
When the output of the sample hold circuit 14, i.e., the outpput V out-4 is greater than the value ε 1 in FIG. 3(b), the output of the comparator 15 is raised to "H", while the output of the comparator 16 is set to "L". As a result, the output of the AND circuit 20 is raised to "H" with the aid of the inverter 18, whereby the display element 23 such as a light emission diode is turned on (emitting light).
When the output V out-4 is defined by an expression ε 1 >V out-4 >ε 2 , the outputs of the comparators 15 and 16 respectively set to "L". Therefore, the output of the NOR circuit 19 is raised to "H" to operate the light emission element 22 such as a light emission diode.
These operations are controlled by the control circuit 25. That is, the control circuit 25 applies various control signals to the various circuit elements. The control signal (2) is employed to combine the elements in the photoelectric conversion element groups 5 and 5', namely, the elements d 1 -d 2' , . . . , d n-1 -d n' . The control signal (3) is used to combine the elements d 1' -d 2' , . . . , d n-1' -d n . The control signal (1) causes integration of the difference outputs of the elements combined by the control signals (2) and (3). That is, it is used to obtain ##EQU9##
The control signal (4) is a sample signal which, after the output V out-1 is obtained, holds the value thereof. The control signal (5) is a sample signal which, after the output V out-2 is obtained, holds the value thereof. In the case where V out-3 is less than ε 0 the switches S 2 , S 3 and S 4 are not short-circuited, and therefore the display elements 22, 23 and 24 emit no light.
If the incident luminous fluxes of the photoelectric conversion elements are represented by F 1 through F n , and F 1' through F n' , then the outputs i 1 through i n and i 1' through i n' of the photoelectric conversion elements described above can be expressed as follows:
i.sub.1 =K.sub.1 ·F.sub.1, i.sub.2 =K.sub.2 ·F.sub.2, . . . i.sub.n =K.sub.n ·F.sub.n, i'.sub.1 =K'.sub.1 ·F'.sub.1, . . . i'.sub.n =K'.sub.n ·F'.sub.n.
Alternatively, i 1 =L 1 log e F 1 +α 1 . . . i n =L n log e F n +α n , i' 1 =L' 1 log e F' 1 +α 1 . . . i' n =L' n log e F' n +α' n , where, K 1 ˜K n , K' 1 ˜K' n , L 1 ˜L n , L' 1 ˜L' n , α 1 ˜α n , and α' 1 ˜α' n are the constants.
Thus, the state of the focalization position can be given to the photographer according to the invention.
FIG. 5 shows one example of a system where the focalization position state is displayed in the view finder 26. When the lens extending position is sufficiently remote from the correct focalization position in FIG. 3 (V out-3 <ε 0 ), no focalization display is made in the view finder. In the case of V out-3 >ε 0 and V out-4 >ε, the display element 23 emits light. If, in this case, the display element 23 is designed in the form of an arrow so that the focus position will approach the correct focalization position (V out-3 >ε 0 and ε 1 ≧V out-4 ≧ε 2 ). By turning the photographing lens 1 in the direction of the arrow, the direction in which the photographing lens 1 the correct focalization can be readily detected. When the correct focalization is obtained, the display element 22 emits light, but the remaining display elements 23 and 24 in the form of arrows do not emit light. Therefore, it can be ascertained that the correct focalization has been obtained. When the correct focalization position is passed, the display element 24 emits light. Since the direction of the arrow of the display element 24 is opposite to the direction of the arrow of the display element 23, the photographing lens 1 should be rotated in the opposite direction. If the display elements are arranged as described above, the correct focalization can be readily obtained. In the embodiment of the invention described above, only three kinds of display are used. However, the invention is not limited thereto or thereby. That is, the display may be designed to display the case where the current focus position of the lens is considerably remote from the correct focalization. Also, other forms of display may be used to indicate near or far focal positions.
FIG. 6 shows one example of the control circuit 25 in FIG. 4 in detail. The theoretical operation of the control circuit 25 will first be described. When the focus detection start switch SW 1 is in open state, the J-K flip-flops in the groups A and A' and the J-K flip-flops FF 1 and FF 2 are in reset state, and their terminals Q are at "L". The signal from the oscillator circuit 27 is at "L" because the remaining input of the AND circuit A 3 is at "L". When the switch SW 1 is closed, the reset states of the J-K flip-flops are released and the output of the OR circuit A 2 is set to "L". This "L" output is applied through the inverter A 5 to the terminal CL of the J-K flip-flop FF 1 .
Thus, the terminal CL of the J-K flip-flop FF 1 is raised to "H" from "L". Therefore, the terminal Q of the J-K flip-flop FF 1 is raised to "H". The terminals S of the J-K flip-flops F 1 and F 2' are momentarily raised to "H" with a slight delay because of the capacitor C 3 and the resistor R 3 . Therefore their terminals Q are also raised to "H". The switches s 1 and s 2' are closed, and an output i 1 -i 2' is provided by the differential circuit 7.
On the other hand, at the same time, the terminal Q of the J-K flip-flop FF 2 is set to "H", the integrating circuit 9 is therefore operated to start its integration, and the signal of the oscillator circuit 27 is applied to the terminals CL of the J-K flip-flops in the ring counters A and A'. As a result, the switches s 2 and s 3' are closed and an output i 2 -i 3' is provided by the differential circuit 7. Thus, outputs i 3 -i 4' , . . . , i n-1 -i n' are successively provided by the differential circuit 7 in response to the pulse signal from the oscillator circuit 27.
Next, when the terminal Q of the J-K flip-flop F O ' is set to "H" in response to the pulse signal from the oscillator circuit 27, the terminal Q of the J-K flip-flop FF 2 is set to "L" with the aid of the OR circuit A 1 . As a result, the operation of the integrating circuit 9 is suspended. When application of the pulse signal from the oscillator circuit 27 is suspended, the control signal 4 is provided. Since the control signal 4 is applied through the OR circuit A 2 to the J-K flip-flops in the groups A and A' to reset these flip-flops. Thus, the terminal Q of the J-K flip-flop FF 1 is set to "H" with the aid of the inverter A 5 .
Therefore, the terminals Q of the J-K flip-flops F 2 and F 1' are set to "H" with a slight delay due to the operation of the resistor R 2 and the capacitor C 2 . The switches s 2 and s 1' are closed and therefore an output i 1' -i 2 is provided by the differential circuit 7. At the same time, the terminal Q of the J-K flip-flop FF 2 is set to "H" and the integrating circuit 9 starts its operation. The pulse signal from the oscillator circuit 27 is applied to the terminals CL of the J-K flip-flops in the groups A and A'. Thus, outputs i 2' -i 3 , . . . , i n-1' -i n are successively produced by the differential circuit 7. In response to the next pulse, the terminal Q of the flip-flop F 0 is set to "H", the sample control signal 5 is generated, the J-K flip-flops in the groups A and A' are reset and the terminal Q of the J-K flip-flop FF 2 is set to "L". Also, the operation of the integrating circuit 9 is suspended and application of the pulse from the oscillator circuit 27 is suspended (the operation up to this being one focus detection). At the same time, the terminal Q of the flip-flop FF 1 is set to "H", and the terminals Q of the flip-flops F 1 and F 2' are set to "H". Thus, the above-described operation is repeated.
The control signals 2 and 3 are employed to control the switches s 1 -s n and s 1' -s n' , respectively. In FIG. 6, the supply voltage V cc is at "H", while the ground is at "L". The electronic focus detection can therefore be effectively controlled by the circuit as described above.
Thus, as was described briefly in the introductory part herein according to this invention, the electronic focus detection and display device is made up of the relatively simple optical system and circuit to readily permit the photographer to detect and obtain the correct focalization. This technique is a considerable improvement when compared with a focus detecting device employing the conventional method in which the focus is optically detected. Also, this system eliminates the need for drive motors and the like by allowing manual operation of the lens.
Also, instead of the image forming lenses 4 and 4', lens systems (such as cylindrical lenses) whose magnifications are greater in the direction perpendicular to the direction of the photoelectric conversion element group 5 or 5' than in the said direction of the photoelectric conversion element group 5 or 5' can be employed and the detection performance can be improved as much. Self-scanning type image sensors, photodiodes or photo-transistors may be used for the photoelectric conversion element groups 5 and 5'.
In the above description, ##EQU10## however, it may be modified into ##EQU11## Of course, in this case, V out-2 should be modified similarly.
It is also apparent that other modification may be made without departing from the scope of this invention. | A focus detecting device in a camera having an optical member or an optical system for obtaining two images from an object and an optical member for displacing said two images in opposite directions or displacing one of said two images. Two minute photoelectric conversion element groups are used for converting variations in light quantity of portions of the object into electrical signals. A photographing lens projects the image of the object onto the minute photoelectric conversion element groups. A circuit calculates outputs ##EQU1## from the outputs of minute photoelectric conversion elements forming the minute photoelectric conversion element groups. A circuit which has a first calculation function for calculating V out-3 =V out-1 +V out-2 and a second calculation function for calculating V out-4 =V out-1 -V out-2 so that when V out-3 becomes higher than a predetermined value, different outputs are produced under conditions that V out-4 >ε 1 , ε 1 ≧V out-4 ≧ ε 2 , and ε 2 >V out-4 . A display produces different displays according to the different outputs where n is the number of the minute photoelectric conversion elements forming each of the two minute photoelectric conversion element groups, m is a number of a minute photoelectric conversion element, i is the output of a minute photoelectric conversion element in one of the two minute photoelectric conversion element groups, i' is the output of a minute photoelectric conversion element in the other minute photoelectric conversion element group, ε 1 and ε 2 are predetermined constants. | 6 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims the filing benefit under 35 U.S.C. § 119(e) of U.S. Provisional Application No. 60/383,554, filed May 24, 2002, which is included herein by reference.
TECHNICAL FIELD
This invention relates generally to multi-axle transport vehicles for moving heavy loads, and more particularly to a method and apparatus for steering the transport vehicle.
BACKGROUND OF THE INVENTION
Heavy hauling vehicles for moving transformers, cranes, boats, industrial equipment, and other heavy objects are well known in the art. An example of such a vehicle is shown in U.S. Pat. No. 4,943,078 which discloses a heavy load hauler for traveling on conventional roadways for moving heavy construction equipment such as cranes or the like from one work site to another. The hauler includes a front tractor drawn carriage, a rear carriage, and a load unit between and carried by the carriages. The front carriage is supported upon a multiplicity of independent wheel and axle units. There is a first fifth wheel coupling at the leading end of the front carriage for connecting to the fifth wheel coupling of a tractor. A second fifth wheel coupling is spaced rearwardly. The load carrying rear carriage is also supported upon a multiplicity of independent wheel and axle units. There is a fifth wheel coupling intermediate the leading and trailing ends of the carriage. The load unit has forwardly and rearwardly projecting goosenecks. Each gooseneck has a fifth wheel coupling. The one on the forwardly projecting gooseneck connects to the fifth wheel coupling on the front carriage. The one on the rearwardly projecting gooseneck connects to the fifth wheel coupling on the rear carriage. The load unit may be either the crane itself or a flatbed upon which the crane is carried. At least some of the independent wheel and axle units are steerably mounted on their carriages. Each wheel and axle unit has its wheels supported by a hydraulic suspension. Hydraulic circuitry interconnects all of the suspensions so as to equally distribute the load among all of the wheel units. Steering of the independent wheel and axle units is interphased for the front and rear carriages by a pair of operatively associated interrelated inline valve cylinder units. FIG. 12A shows a valve 718 used in a power steering system which is coupled to a connecting link 703 .
Other heavy hauling vehicles are sold by Goldhofer Fahrzeugwerk G.m.b.H. of Memmingen, Germany; Nicolas of Champs Sur Yonne, France; and, Talbert of Renssclaer, Ind.
Improved systems having automatic steering at all speeds and suspension systems that respond rapidly to the varying road conditions imposed by higher speeds would greatly reduce the time and effort required to move the vehicle to the load, move the load, and return the vehicle to storage.
SUMMARY OF THE INVENTION
The present invention is directed to a method and device for steering a heavy load transport vehicle. The invention combines a conventional hydraulic power steering valve with a variable length strut to effect steering control. The power steering valve is placed in “parallel” across the variable length strut so that as the variable length strut expands and contracts a small distance due to the movement of a tow bar, the power steer valve changes switching states, and though mechanical linkages, causes the transport vehicle to turn in the desired direction. In essence the variable length strut serves as a direction sensor which communicates the desired direction of turn to the power steering valve.
The present invention has a distinct advantage over prior art systems in the event of power steering system failure. The variable length strut will turn the steering system without hydraulic power. When this happens, the variable length strut absorbs the mechanical stresses of turning, thereby protecting the power steering valve. This is in contrast to prior art systems where the power steering valve is installed in series with the strut and is thereby exposed to large mechanical stresses if the power steering system fails.
Additionally, because of the small displacement of the variable length strut, the present invention provides rapid and continuous steering corrections as the transport vehicle is towed down a highway.
In accordance with a preferred embodiment of the invention, a device for steering a transport vehicle having a rotatable tow bar and a front dolly having front wheels is provided and includes:
a variable length strut connected between the tow bar and the front dolly, the variable length strut having a first section and a second section, the first and second sections longitudinally movable with respect to one another;
a hydraulic power steering valve having a first end and a second end;
the first end of the power steering valve connected to the first section of the variable length strut, and the second end of the power steering valve connected to the second section of the variable length strut; and,
wherein when the tow bar is rotated, the first and second sections of the variable length strut longitudinally move with respect to one another causing the power steering valve to assume a hydraulic switching state, the switching state including one of (a) a left state which causes the front wheels of the front dolly to turn in a left direction, and (b) a right state which causes the front wheels of the front dolly to turn in a right direction.
In accordance with an aspect of the invention, when the rotation of the tow bar is stopped, the power steering valve assumes a neutral hydraulic switching state wherein further turning in a left direction or right direction ceases.
In accordance with an aspect of the invention, the first and second sections are longitudinally movable a distance of about 0.13 inches with respect to each other.
Other aspects of the present invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation view of a prior art multi-axle transport vehicle for moving heavy loads;
FIG. 2 is a top plan view of the vehicle of FIG. 1;
FIG. 3 is a side elevation view of a second prior art transport vehicle;
FIG. 4 is a partial enlarged top plan view of the vehicle of FIG. 3;
FIG. 5 is a top plan view of a multi-axle transport vehicle which includes a system for steering the transport vehicle in accordance with the present invention;
FIG. 6 is an enlarged view of area 6 of FIG. 5;
FIG. 7 is an enlarged view of area 7 of FIG. 6;
FIG. 8 is a top plan view of the transport vehicle turning to the left;
FIG. 9 is an enlarged view of area 9 of FIG. 8;
FIG. 10 is an enlarged view of the device for steering the vehicle in accordance with the present invention;
FIG. 11 is an enlarged partial cross sectional view of area 11 of FIG. 10, showing the device in a neutral state;
FIG. 12 is an enlarged partial cross sectional view of area 11 of FIG. 10, showing the device in a turn left state;
FIG. 13 is an enlarged partial cross sectional view of area 11 of FIG. 10, showing the device in a turn right state;
FIG. 14 is an enlarged view of area 14 of FIG. 11;
FIG. 15 is an enlarged view of area 15 of FIG. 12;
FIG. 16 is an enlarged view of area 16 of FIG. 13;
FIG. 17 is a hydraulic flow diagram with the device in a neutral hydraulic state;
FIG. 18 is a hydraulic flow diagram with the device in a turn left hydraulic state;
FIG. 19 is a hydraulic flow diagram with the device in a turn right hydraulic state; and,
FIG. 20 is a hydraulic flow diagram of a second embodiment with the device in the neutral hydraulic state.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 and 2 illustrate side elevation and top plan views, respectively, of a prior art multi-axle transport vehicle 500 for moving heavy loads. The vehicle 500 has a front dolly 502 and a pair of rear dollies 504 upon which a load 506 rests. A towing vehicle 508 such as a tractor pulls transport vehicle 500 using a tow bar 510 .
FIGS. 3 and 4 are side elevation and partial enlarged top plan views respectively of a second prior art transport vehicle 600 . Transport vehicle 600 includes a front hauling carriage 602 and a rear hauling carriage 604 . Each hauling carriage has a plurality of dollies 606 (six in the shown embodiment). Each dolly 606 includes two rotatable axles 608 each having four wheels 610 . Axles 608 are rotatably mounted to an axle beam 612 . The dollies 606 are mechanically linked together by turning struts 615 which cause the axles 608 to rotate in a desired manner as transport vehicle 600 turns (refer also to FIG. 8 ). A load bed 614 is attached to two goosenecks 616 which rotatably connect to hubs 618 of hauling carriages 602 and 604 . A heavy load 700 such as a large transformer is carried by load bed 614 .
FIG. 5 illustrates a top plan view of a multi-axle transport vehicle 800 which includes a system 20 for steering the transport vehicle 800 in accordance with the present invention. As with FIG. 4, only the front hauling carriage is depicted. System 20 includes a rotatable tow bar 22 which is connected to a towing vehicle 802 and a front dolly 24 . Front dolly 24 includes rotatable axle 25 having wheels 27 . In the shown embodiment, there are both right and left front dollies 24 . A hydraulic cylinder 26 (also refer to FIG. 6) is mechanically connected by a steering crank 28 and a steering strut 30 to front dolly 24 . In the shown embodiment, there are two hydraulic cylinders 26 which are connected in push pull relationship. A variable length strut 32 is connected between tow bar 22 and front dolly 24 . In the shown embodiment, variable length strut 32 is connected to left front dolly 24 . However, it may be appreciated that it could alternatively be connected to right front dolly 24 . Variable length strut 32 has a first section 34 and a second section 36 (refer to FIG. 10 ). First section 34 and second section 36 are longitudinally movable with respect to one another (refer to FIGS. 11 - 16 ). In an embodiment of the invention, first section 34 and second section 36 longitudinally move apart a total distance of about 0.13 inches as variable length strut 32 contracts and expands.
A hydraulic power steering valve 38 (also refer to FIG. 10) is coupled along strut 32 . Hydraulic power steering valve 38 has a first end 40 and a second end 42 . Hydraulic power steering valve 38 is of a type available from Garrison Manufacturing of Santa Ana, Calif. First end 40 of power steering valve 38 is connected to first section 34 of variable length strut 32 , and second end 42 of power steering valve 38 is connected to second section 36 of variable length strut 32 . That is, power steering valve 38 is attached in parallel across variable strut 32 . Again referring to FIG. 10, power steering valve 38 is hydraulically connected by hydraulic lines to pair of front hydraulic cylinders 26 and to a hydraulic pump and a hydraulic fluid reservoir (also refer to FIG. 17 ).
Now also referring to FIGS. 9, 11 , 12 , and 13 , when tow bar 22 is rotated, such as when towing vehicle 802 turns, first section 34 and second section 36 of variable length strut 32 longitudinally move with respect to one another causing power steering valve 38 to assume a hydraulic switching state. The hydraulic switching state is communicated to the pair of front hydraulic cylinders 26 which in turn, via steering crank 28 and steering strut 30 , cause front axle 25 and wheels 27 of front dolly 24 to turn in one of (a) a left direction as shown, and (2) a right direction.
When the rotation of tow bar 22 is stopped, power steering valve 38 assumes a neutral hydraulic switching state wherein further turning in the left direction or the right direction ceases. That is, the axle 25 and wheels 27 of dolly 24 stop turning (rotationally moving). However, the axle 25 and wheels 27 remain in the turned configuration. FIGS. 17-20 discussed below provide a description of the flow of hydraulic fluid in system 20 .
Again referring to FIG. 5, system 20 also has a rear dolly 44 (actually two rear dollies 44 ) which is mechanically linked to front dolly 24 via a series of linkage struts 46 as is well known in the art. A pair of rear hydraulic cylinders 48 are also arranged in push pull relationship, and are mechanically connected to rear dolly 44 via a rear steering crank 50 and rear steering strut 52 . Power steering valve 38 is also hydraulically connected to the pair of rear hydraulic cylinders 48 (refer also to FIG. 20 ).
FIG. 6 is an enlarged view of area 6 of FIG. 5 showing various components of steering system 20 .
FIG. 7 is an enlarged view of area 7 of FIG. 6 showing pair of hydraulic cylinders 26 , steering crank 28 , and steering struts 30 . It is noted that steering crank 28 pivots about pivot point 31 . Hydraulic cylinders 26 include pistons rods 23 which are driven back and forth by hydraulic pressure exerted upon a piston.
FIG. 8 is a top plan view of transport vehicle 800 turning to the left. Through the action of tow bar 22 , variable length strut 32 , power steering valve 38 , hydraulic cylinders 26 , steering crank 28 , and steering struts 30 , axle 25 and wheels 27 of dollies 24 have steered to the left. This steering motion has been coupled to other dolly 24 axles and wheels via linkage struts 46 . Rear hydraulic cylinders 50 have been similarly activated by power steering valve 38 to assist in the turning action.
FIG. 9 is an enlarged view of area 9 of FIG. 8 showing various components of steering system 20 in a turned configuration.
FIG. 10 is an enlarged view of a device 100 for steering a transport vehicle 800 in accordance with the present invention. Referring also to FIG. 8, transport vehicle 800 has a rotatable tow bar 22 and a front dolly 24 . Device 100 includes a variable length strut 32 which is connected between tow bar 22 and front dolly 24 . Variable length strut 32 has a first elongated section 34 and a second elongated section 36 , wherein first section 34 and second section 36 are longitudinally movable with respect to one another. That is, first section 34 and second section 36 may be longitudinally moved toward one another (contracted, refer to FIG. 12 ), or move away from one another (expanded, refer to FIG. 13 ). Device 100 further includes a hydraulic power steering valve 38 having first end 40 and second end 42 . First end 40 of power steering valve 38 is connected to first section 34 of variable length strut 32 , and second end 42 of power steering valve 38 is connected to second section 36 of variable length strut 32 . Because of this connection, as sections 34 and 36 longitudinally move with respect to one another, their relative position is directly coupled to power steering valve 38 . Power steering valve 38 is hydraulically connected to a pump, a reservoir, and hydraulic cylinders 26 (refer also to FIGS. 17 through 20 ).
Referring also to FIG. 9, when tow bar 22 is rotated with respect to transport vehicle 800 , such as when towing vehicle 802 turns, first section 34 and second section 36 of variable length strut 32 longitudinally move with respect to one another. The relative longitudinal movement of first section 34 and second section 36 causes powering steering valve 38 to assume a hydraulic switching state. That state can be one of (a) a left state which causes the front wheels 27 of front dolly 24 to turn (move) in a left direct, (b) a right state which causes the front wheels 27 of front dolly 24 to turn in a right direction, and (c) a neutral state which causes turning motion to cease, but leaves wheels 27 pointing in their last ordered direction.
FIG. 11 is an enlarged partial cross sectional view of area 11 of FIG. 10 showing device 100 in a neutral hydraulic switching state (also refer to FIG. 17 ). In this state the first section 34 and second section 36 of variable length strut 32 are neither moved together (contracted) nor moved apart (expanded). This relative longitudinal position of the two sections is mechanically coupled to power steering valve 38 which resultantly assumes a neutral hydraulic switching state. That is, front wheels 25 are neither ordered to turn to the left nor the right. It is noted that in an embodiment of the invention, first section 34 of variable length strut 32 is longitudinally received by second section 36 , and the two sections are connected by a bolt and flange arrangement. Self-lubricating bearings 43 are installed between first section 34 and second section 36 of variable length strut 32 .
FIG. 12 is an enlarged partial cross sectional view of area 11 of FIG. 10 showing device 100 in a turn left hydraulic switching state (also refer to FIG. 18 ). Referring also to FIG. 8, tow bar 22 has been rotated to the left as towing vehicle 802 turns left. This motion causes variable length strut 32 to contract. That is, first section 34 and second section 36 move together. This relative longitudinal position of the two sections is mechanically coupled to power steering valve 38 which, through an internal ball stud device, resultantly assumes a left hydraulic switching state which causes front wheels 27 of front dolly 24 to turn in a left direction.
FIG. 13 is an enlarged partial cross sectional view of area 11 of FIG. 10 showing device 100 in a turn right hydraulic switching state (also refer to FIG. 19 ). Tow bar 22 is rotated to the right as towing vehicle 802 turns right. This motion causes variable length strut 32 to expand. That is, first section 34 and second section 36 move apart. This relative longitudinal position of the two sections is mechanically coupled to power steering valve 38 which resultantly assumes a right hydraulic switching state which causes front wheels 27 of front dolly 24 to turn in a right direction.
FIG. 14 is an enlarged view of area 14 of FIG. 11 showing the relative longitudinal position of first section 34 and second section 36 of variable length strut 32 which results in a neutral hydraulic switching state of power steering valve 38 . Flange 37 of first section 34 and flange 39 of second section 36 are held together by a bolt 41 and reside in a spaced apart relationship wherein a distance D (about 0.065 inches) exists between the two flanges. This spaced relationship of first 34 and second 36 sections is mechanically coupled to power steering valve 38 (refer to FIG. 10 ), and causes power steering valve 38 to assume a neutral hydraulic switching state. Flange 37 has a through hole 51 and flange 39 has threads 53 . Bolt 41 is fed through hole 51 and threaded into flange 39 until proper relative movement of flanges 37 and 39 has been achieved. Then a lock nut 55 is used to retain bolt 41 in a fixed position within threaded flange 39 .
FIG. 15 is an enlarged view of area 15 of FIG. 12 showing the relative longitudinal position of first section 34 and second section 36 of variable length strut 32 which results in a turn left hydraulic switching state of power steering valve 38 . As tow bar 22 is turned to the left, variable length strut 32 contracts thereby forcing first section 34 and second section 36 together so that flanges 37 and 39 come into contact. In an embodiment of the invention, the motion between first section 34 and second section 36 is small, being a total distance 2D of about 0.13 inches. That is, the difference between the contracted and expanded lengths of variable length strut 32 is 0.13 inches. The contracted relationship of first section 34 and second section 36 is mechanically coupled to power steering valve 38 (refer to FIG. 10 ), and causes power steering valve 38 to assume a left hydraulic switching state which causes front wheels 27 of front dolly 24 to turn in a left direction.
FIG. 16 is an enlarged view of area 16 of FIG. 13 showing the relative longitudinal position of first section 34 and second section 36 of variable length strut 32 which results in a turn right hydraulic switching state of power steering valve 38 . As tow bar 22 is turned to the right, variable length strut 32 expands thereby forcing first section 34 and second section 36 apart. This expanded relationship of first section 34 and second section 36 is mechanically coupled to power steering valve 38 (refer to FIG. 10 ), and causes power steering valve 38 to assume a right hydraulic switching state which causes front wheels 27 of front dolly 24 to turn in a right direction.
FIG. 17 is a hydraulic flow diagram with device 100 in a neutral hydraulic state. Hydraulic fluid from a reservoir is pumped via hydraulic lines into power steering valve 38 . In the neutral state, the fluid circulates through power steering valve 38 and is routed back to the reservoir. As has been previously discussed, the neutral hydraulic state of power steering valve 38 is controlled by the relative longitudinal motion of variable length strut 32 .
FIG. 18 is a hydraulic flow diagram with device 100 in a turn left hydraulic state. Hydraulic fluid from a reservoir is pumped via hydraulic lines into one side of cylinders 26 and pushes upon a piston within cylinder 26 . It may be appreciated that cylinders 26 are physically arranged so that the piston of one cylinder 26 moves in an opposite direction from the piston in the other cylinder 26 . Fluid from the other side of cylinders 26 is routed back through power steering valve 38 to the reservoir. This turn left hydraulic configuration will be maintained as long as variable length strut 32 is being contracted by the turning action of tow bar 22 .
FIG. 19 is a hydraulic flow diagram with device 100 in a turn right hydraulic state. Hydraulic fluid from a reservoir is pumped via hydraulic lines into one side of cylinders 26 . It is noted that the fluid is delivered to the opposite side of cylinders 26 from the left hydraulic state of FIG. 18 . Fluid from the other side of cylinders 26 is routed back through power steering valve 38 to the reservoir. This turn right hydraulic configuration will be maintained as long as variable length strut 32 is being expanded by the turning action of tow bar 22 .
FIG. 20 is a hydraulic flow diagram of a second embodiment with device 100 in the neutral hydraulic state. The only difference in this configuration is that hydraulic fluid is also delivered to a second pair of rear cylinders 48 (refer to FIGS. 5 and 8 ).
It may be appreciated that the terms left and right can vary depending upon the specific arrangement of the mechanical elements of the present invention.
In terms of use, a method for steering a transport vehicle 800 , includes:
(a) providing a transport vehicle 800 having a rotatable tow bar 22 and a front dolly 24 having front wheels 25 ;
(b) providing a device 100 for steering the transport vehicle 800 , device 100 including:
a variable length strut 32 connected between tow bar 22 and front dolly 24 , the variable length strut 32 having a first section 34 and a second section 36 , the first section 34 and second section 36 longitudinally movable with respect to one another;
a hydraulic power steering valve 38 having a first end 40 and a second end 42 ;
first end 40 of power steering valve 38 connected to first section 34 of variable length strut 32 , and second end 42 of power steering valve 38 connected to second section 36 of variable length strut 32 ; and,
(c) rotating tow bar 22 thereby causing first section 34 and second section 36 of variable length strut 32 to longitudinally move with respect to one another, the motion causing power steering valve 38 to assume a hydraulic switching state, the hydraulic switching state including one of (a) a left state which causes front wheels 27 of front dolly 24 to turn in a left direction, and (b) a right state which causes front wheels 27 of front dolly 24 to turn in a right direction.
The method may further include:
(d) ceasing to rotate tow bar 22 wherein power steering valve 38 assumes a neutral hydraulic switching state and further turning in the left direction or right direction ceases.
The method may further include:
in step (b), the first section 34 and second section 36 longitudinally movable a distance of about 0.13 inches.
The preferred embodiments of the invention described herein are exemplary and numerous modifications, variations, and rearrangements can be readily envisioned to achieve an equivalent result, all of which are intended to be embraced within the scope of the appended claims. | A method and device for steering a heavy load transport vehicle includes a variable length strut which cooperates with a power steering valve. The length of the variable length strut changes as a function of tow bar rotation. This length variation is mechanically coupled to the power steering valve, which in turn controls an automatic steering system. The present invention permits mechanical steering of the transport vehicle even in the event of failure of the automatic steering system, and does so without placing mechanical stress upon the power steering valve. | 1 |
FIELD OF THE INVENTION
This invention relates to level shifting circuits.
BACKGROUND OF THE INVENTION
A level shifting circuit is used to shift the logic levels of a signal to higher voltages. For example, in a circuit where the logic levels are 0 volts for a “low” logic level and +5 volts for a “high” logic level, a level shifting circuit can be used so that those logic levels are 0 volts for the “low” logic level and +10 volts for the “high” logic level, in one example.
Typically, level shifting circuits are used in non-volatile memories that require the controlled and selective application of a large voltage to program, write or erase portions of the non-volatile memory, such as memory cells.
For example, in a non-volatile memory device which operates with supply voltages of 5 volts, a programming voltage of the magnitude of approximately 10 volts is typically used. For non-volatile memory devices which operate using supply voltages of 3.3 volts, a programming voltage of approximately 10 volts in magnitude is also typically used.
FIG. 1 illustrates an example of a level shifting circuit which shifts the logic levels for an input or data signal IN to higher voltage levels. The signal VNEG is a negative reference signal which can be generated by another circuit (not shown) so that VNEG goes from 0 volts to −5 volts in order to provide a −5 volt reference for the level shifting circuit of FIG. 1 .
In overall operation and as shown in Table 1, node A and B are output nodes, wherein node A follows the value of the input or data signal IN, while node B is the complement of the input or data signal IN. When the VNEG reference signal is driven to a negative voltage level, such as −5 volts, then an output signal can be taken across node A with respect to the VNEG signal. If the input signal IN is at a low logic level of 0 volts, then the output measured across the (A to VNEG) node is 0 volts. When the input signal IN is at a high logic level of +5 volts, the voltage at the (A to VNEG) node is +10 volts, meaning that the high logic level for the IN signal has been shifted to +10 volts.
TABLE 1
IN
VNEG
NODE A
NODE B
(A-VNEG)
(B-VNEG)
0
0
0
+5
0
+5
+5
0
+5
0
+5
0
0
−5
−5
+5
0
+10
+5
−5
+5
−5
+10
0
As recognized by the present inventors, such a circuit shown in FIG. 1 is problematic in that n-channel transistors 20 and 22 —which act as a high voltage switch to drive the output to the higher voltages—may degrade over time due to the fact that the gate to source voltages across these transistors may be 10 volts when the VNEG reference signal is at −5 volts. As the transistors 20 , 22 are subjected to numerous programming voltages of, for example, 10 volts between the gate and the source of each transistor, the transistors may degrade over time. If the transistor degrades, the functionality of the integrated circuit incorporating the transistor may not perform in its expected manner, and may even possibly fail due to the degradation of the transistor subjected to the high gate to source voltage.
FIG. 2 illustrates an example of a level shifting circuit wherein p-channel transistors 24 , 26 are used for the high voltage output switches. The reference voltage VPOS is generated by a circuit (not shown) which generates a voltage from +5 volts to +10 volts in order to generate an output signal measured across node (A to VPOS), or node (B to VPOS). As recognized by the present inventors, the circuit of FIG. 2 may also be subjected to degradation issues when a −10 volt gate to source voltage is applied to transistors 24 and 26 during level shifting operations.
As recognized by the present inventors, what is needed is a circuit for shifting the voltage levels of an input signal to higher voltage levels, while reducing the gate to source voltages on the high voltage output switching transistors. In this way, due to the reduced bias voltage applied to the gate of the high voltage switching transistors, degradation of the transistors due to the high programming voltages is reduced, thereby improving the performance of the transistors and any device in which the transistors are used.
It is against this background that various embodiments of the present invention were developed.
SUMMARY
According to one broad aspect of one embodiment of the invention, disclosed herein is a circuit for shifting a signal from a first voltage level referenced to a first voltage reference, to a second voltage level referenced to a second voltage reference. In one embodiment, the circuit includes six switches. A first switch receives the signal; a second switch receives an inverted representation of the signal; a third switch receives the output of the first switch; a fourth switch receives the output of the second switch; a fifth switch, referenced to the second voltage reference, has an input coupled with the output of the first switch and a control coupled with the output of the fourth switch; and a sixth switch, referenced to the second voltage reference, has an input coupled with the output of the second switch and has a control coupled with the output of the third switch. In one embodiment, when the third switch and the fourth switch are on, the signal is shifted to the second voltage level measured between the input of the fifth switch and the second voltage reference. The third and fourth switches act to prevent the gate to source voltage on the fifth and sixth switches from reaching a high voltage level, such as 10 volts as shown in FIG. 1 .
In one embodiment, the second voltage reference is a high voltage signal of approximately −5 volts, and the first and second switches may be p-channel transistors; the third, fourth, fifth and sixth switches are n-channel transistors. In this embodiment, the circuit can shift an input signal at logic levels, such as 0 to +5 volts, to higher voltage levels of −5 to +5 volts.
In another embodiment, the second voltage reference is a high voltage signal of approximately +10 volts, and the first and second switches may be n-channel transistors; the third, fourth, fifth and sixth switches are p-channel transistors. In this embodiment, the circuit can shift an input signal at logic levels of, for example, 0 to +5 volts, to higher voltage levels of 0 to +10 volts.
The circuit can further include a means for generating a control signal responsive to the level of the second voltage reference. The control signal may be coupled with the third switch and the fourth switch in order to activate the third and fourth switches when the second voltage reference has reached a particular level outside of the logic levels of the circuit (i.e., below 0 volts, or alternatively, above 5 volts).
Also disclosed herein is a method for reducing a voltage applied between a gate and a source of a transistor in a level shifting circuit. The method includes providing a first switch receiving the signal, and providing a second switch receiving an inverted representation of the signal. A first high voltage switch is provided and is referenced to the second voltage reference, and the first high voltage switch has an input coupled with the output of the first switch. A second high voltage switch is provided and referenced to the second voltage reference, the second high voltage switch has an input coupled with the output of the second switch. A third switch is coupled with the output of the first switch and with the control of the second high voltage switch, wherein the third switch responsive to the second reference voltage. A fourth switch is coupled with the output of the second switch and the control of the first high voltage switch, wherein the fourth switch responsive to the second reference voltage. In this manner, when the third switch and the fourth switch are on, the signal is shifted to the second voltage level measured between the input of the first high voltage switch and the second voltage reference, while preventing a high voltage from being applied across the gate and source of the first and second high voltage switches.
The features, utilities and advantages of the various embodiments of the invention will be apparent from the following more particular description of embodiments of the invention as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a level shifting circuit for shifting the level of the input signal IN to a greater level across n-channel transistors 20 and 22 referenced to a VNEG voltage reference.
FIG. 2 illustrates an example of a level shifting circuit for shifting an input signal IN to a greater voltage value across the p-channel transistors 24 and 26 referenced to the VPOS voltage.
FIG. 3 illustrates a level shifting circuit in accordance with one embodiment of the present invention.
FIG. 4 illustrates a circuit for detecting a change in the value of the reference voltage VNEG, in accordance with one embodiment of the present invention.
FIG. 5 illustrates an alternative embodiment of a level shifting circuit in accordance with one embodiment of the present invention, wherein p-channel transistors are used on the output of the circuit with reference to a VPOS voltage reference.
FIG. 6 illustrates a circuit for detecting a change in the value of the VPOS reference voltage, in accordance with one embodiment of the present invention.
FIG. 7 illustrates an example of a memory device incorporating an embodiment of the present invention.
DETAILED DESCRIPTION
FIG. 3 illustrates a circuit 30 for shifting a signal from a first voltage level to a second voltage level, referenced to a second voltage reference, in accordance with one embodiment of the present invention. In one example, the first voltage level can be 0 volts or +5 volts, representing logic low and logic high, respectively, referenced to a first voltage reference such a ground. The second voltage level may be −5 volts to +5 volts, in one example, representing logic low and logic high, respectively, when referenced to a second voltage reference of, for example, −5 volts.
As will be explained below, the circuit 30 of FIG. 3 provides the level shifting function while reducing the gate-to-source voltage applied to transistors (Q 5 ) and (Q 6 ), in one example. FIG. 5 illustrates a complementary circuit for performing the level shifting function while reducing the gate-to-source voltage applied to transistors (Q 14 ) and (Q 15 ), in one example.
As used herein, the term “transistor” or “switch” includes any switching element which can include, for example, n-channel or p-channel CMOS transistors, MOS-FETs, FETs, JFETS, BJTs, or other like switching element or device. The particular type of switching element used is a matter of choice depending on the particular application of the circuit, and may be based on factors such as power consumption limits, response time, noise immunity, fabrication considerations, etc. Hence while embodiments of the present invention are described in terms of p-channel and n-channel transistors, it is understood that other switching devices can be used.
Further, embodiments of the present invention are described in terms of a circuit which utilizes logic levels of 0 volts (logic low) and +5 volts (logic high), where a high voltage signal can include voltages such as −5 volts or +10 volts. It is understood that embodiments of the present invention can be utilized in circuits wherein the logic levels and high voltage levels are different, such as in a circuit which utilizes logic levels of 0 volts (logic low) and +3 volts (logic high), where a high voltage signal can include voltages such as −7 volts or +13 volts, in one example.
Referring to FIG. 3, an input signal IN acts as an input to the circuit 30 and can be at a low logic level (such as 0 volts) or a high logic level such as +5 volts.
The signal VNEG is a high voltage reference signal, which in this example goes from ground (0 volts) to its high voltage level of −5 volts. VNEG is initially at zero volts and is driven below ground to −5 volts, in one example, by a circuit (not shown) such as a pump circuit, a driver circuit, or an external supply.
The input signal VDROP is a control signal which indicates that the VNEG signal has reached a voltage level of outside of the logic levels of the circuit. In one example, the VDROP signal is active when the VNEG signal is below 0v, such as at a level of −2VTN (where VTN is the threshold voltage for an n-channel transistor). In one example, the VDROP signal is provided by the circuit of FIG. 4 . FIG. 5 shows a complementary circuit for generating the VDROP signal to detect the level of a VPOS high voltage reference signal when VPOS has reached a voltage level of outside of the logic levels of the circuit, such as above +5 volts.
Referring again to FIG. 3, the output signals are taken across the (A to VNEG) node, which will be 10 volts in one example; or across the (B to VNEG) node, wherein the B node has a logic state which is the complement of the A node, in one example. The A node follows the logic state present at the input IN, while the B node is the inverted state of the input signal IN. The output signal of this circuit can be used to program or erase one or more cells in a non-volatile memory.
Transistor (Q 1 ) has the source coupled with the logic level input IN, the gate coupled with ground, and the drain coupled with the output A node. Transistor (Q 2 ) has the source coupled with the inverted logic level input IN (through inverter Il), the gate coupled with ground, the drain coupled to output node B. Transistor (Q 3 ) has its gate coupled with the VDROP control signal, the drain coupled with the output node A, and the source coupled with the gate of transistor (Q 6 ). Transistor (Q 4 ) has its gate coupled with the VDROP control signal, the drain coupled with the output node B, and the source coupled with the gate of transistor (Q 5 ).
Transistor (Q 5 ) has the drain coupled with output node A, the gate coupled with the source of transistor (Q 4 ), and the source coupled with the VNEG signal. Transistor (Q 6 ) has the drain coupled with output node B, the gate coupled with the source of transistor (Q 3 ) and the source of transistor (Q 6 ) is coupled with the VNEG signal. The transistors (Q 5 ) and (Q 6 ) form a high voltage output switch of the level shifting circuit of FIG. 3 . In one example, the P-well connections of transistors (Q 3 ), (Q 4 ), (Q 5 ), and (Q 6 ) are coupled with the VNEG line.
In overall operation, the circuit 30 of FIG. 3 limits the maximum gate to source voltage on transistors (Q 5 ) and (Q 6 ) to the magnitude of the VNEG signal (i.e., 5 volt magnitude), while still providing a 10 volt swing between the output nodes A, B and the VNEG signal so that this 10 volt output swing can be used to program a non-volatile memory cell. In this manner, degradation of transistors (Q 5 ) and (Q 6 ) during level shifting operations is reduced.
Generally, the signal VNEG begins at a voltage ground level and the input signal IN is at a desired logic input level. Initially, the control signal VDROP is at a high level such as +5 volts. The VNEG signal is then driven below ground, and after VNEG is adequately below ground, the VDROP signal can be switched to a low logic level (which will be shown in the circuit of FIG. 4 ). The signal VNEG continues to its final low voltage (i.e., −5 volts). The circuit outputs are taken across node A and VNEG, wherein node A will maintain the voltage applied at the logic level input and wherein node B maintains the complement thereof.
When the input signal IN is +5 volts and VNEG is −5 volts, the value measured across the (A-VNEG) node is 10 volts. Hence, it can be seen that the circuit of FIG. 3 shifts the input signal to a higher voltage. Conversely, if the input signal IN goes low, (i.e., to 0 volts), the circuit of FIG. 3 would provide an output voltage shifted to a higher level voltage (i.e., −5 volts) measured between output node A and VNEG. The gate to source voltage on transistor (Q 5 ) is approximately 5 volts, instead of 10 volts in the circuit of FIG. 1 .
The operations of the circuit 30 of FIG. 3 will be described with reference to Table 2.
TABLE 2
Q1
Q2
Q3
Q4
Q5
Q6
Time T0
ON
OFF
ON
ON
OFF
ON
Time T1
ON
OFF
ON
ON
OFF
ON
Time T2
ON
OFF
Weakly ON
ON
OFF
ON
Time T3
ON
OFF
Weakly ON
ON
OFF
ON
Assume that the logic level input signal IN is at +5 volts at time T 0 . At time T 0 , VNEG begins at 0 volts, and VDROP is inactive at a high level such as +5 volts. Since the input signal IN is at +5 volts, then the source of transistor (Q 1 ) is at 5 volts and the source of transistor (Q 2 ) is at 0 volts. As shown in Table 2, transistor (Q 1 ) is on so that its drain is at +5 volts, and transistor (Q 2 ) is off so that its drain is at ground. Since the control signal VDROP is at +5 volts, transistors (Q 3 ) and (Q 4 ) are on, so that the +5 volts at the drain of transistor (Q 3 ) are present at its source which is coupled with the gate of transistor (Q 6 ). Because the gate of transistor (Q 6 ) is high, transistor (Q 6 ) is on. Similarly, transistor (Q 4 ) has the VDROP control signal applied to its gate, and accordingly transistor (Q 4 ) is on. Because the drain of transistor (Q 4 ) is at 0 volts (low logic level), the source of transistor (Q 4 ) is also low which is applied to the gate of transistor (Q 5 ), and therefore transistor (Q 5 ) is off.
The output of the circuit 30 of FIG. 3 is taken across node A and VNEG, or across node B and VNEG, wherein the output voltage at node A is +5 volts, and the output voltage at node B is the complement of node A. The voltage difference across node A and VNEG is 5 volts in magnitude.
At time T 1 , VNEG begins to be driven from 0 volts to −5 volts, indicating that a control signal has been passed to the VNEG generator enabling the VNEG generator to transition its VNEG voltage from 0 to −5 volts. At time T 1 , VNEG is therefore at some negative potential between 0 and −5 volts. The VDROP signal is at +5 volts and accordingly, at time T 1 and as shown in Table 2, transistor (Q 1 ) is on, transistor (Q 2 ) is off, transistor (Q 3 ) is on, transistor (Q 4 ) is on, transistor (Q 5 ) is off, and transistor (Q 6 ) is on, and therefore the voltage at output node A is +5 volts. Hence, >5 volts magnitude is present across the A to VNEG node, while the gate to source voltage on transistor (Q 6 ) is ( 5 −VTN−VNEG) volts, while the gate to source voltage on transistor (Q 5 ) is 0 volts.
At time T 2 , assume that VDROP goes from +5 volts to 0. When VNEG reference signal goes to a voltage of −V2, wherein −V2 is more negative than −V but more positive than −5 volts. In this instance, and assuming that the logic level input IN is still at +5 volts, the transistors are in the state indicated in Table 2. Transistor (Q 1 ) is on and transistor (Q 2 ) is off, while transistor (Q 3 ) is weakly on, transistor (Q 4 ) is on, and transistor (Q 5 ) is off, and transistor (Q 6 ) is on.
At time T 3 , when VDROP is 0 volts and VNEG reaches a voltage of −5 volts (still assuming the logic level input IN is at +5 volts), transistor (Q 1 ) is on, transistor (Q 2 ) is off, and transistor (Q 3 ) is weakly on. Transistor (Q 4 ) turns on because its gate is at VDROP (0 volts) and its source is at VNEG (−5 volts), thus its gate to source voltage is 5 volts. Transistor (Q 5 ) remains off, and transistor (Q 6 ) remains on. On transistor (Q 6 ), the maximum gate to source voltage is equal to 5 volts minus the threshold voltage VTH, which provides a reduction in the gate to source voltage seen by transistor (Q 6 ) when compared with the circuit of FIG. 1 . In this manner, transistor (Q 6 ) is subjected to less potential for degradation due to high gate to source voltages applied thereto. As to transistor (Q 4 ), the maximum gate to source voltage is equal to 0 minus 5 volts.
Referring now to FIG. 4, FIG. 4 illustrates a circuit 40 for generating a voltage drop control signal VDROP based on a control input (CONTROL) and a generated negative voltage VNEG, in accordance with one embodiment of the present invention. The circuit 40 provides the VDROP signal to switch from +5 volts to 0 volts when the VNEG input signal reaches a voltage level of −V2. In this manner, the circuit of FIG. 4 provides the VDROP signal to controllably indicate the occurrence of this event.
Referring to FIG. 4, transistor (Q 7 ) has its gate coupled with the control signal through inverter I 2 , while its source is coupled with the sources of transistors (Q 8 ) and (Q 9 ). The drain of transistor (Q 7 ) is coupled with the drain of transistor (Q 8 ), which is also coupled to the source of transistor (Q 10 ). Transistor (Q 8 ) has its gate coupled with the control signal, while transistor (Q 9 ) has its gate coupled with the output VDROP, and its drain coupled with the output of inverter I 3 . Inverter I 4 is coupled between the drain and-the gate of transistor (Q 9 ).
Transistor (Q 10 ) has its gate coupled with ground, and its drain coupled to the input of inverter I 3 and to the drain of transistor (Q 11 ). Transistor (Q 11 ) has its gate coupled with the control signal, and its source coupled with the gate and the drain of transistor (Q 12 ). Transistor (Q 12 ) has its source coupled with both the gate and the drain of transistor (Q 13 ). Transistor (Q 13 ) has its source coupled with the VNEG generated signal. In one embodiment, the P-well connections for transistors (Q 11 ), (Q 12 ), and (Q 13 ) are coupled with the VNEG generated signal. In operation, the circuit 40 of FIG. 4 provides the VDROP signal to switch from +5 volts to 0 when the VNEG generated signal goes from 0 volts to a level such as −V2, which in one example is at least −2VTN.
The control signal is an input signal which is the same signal that instructs the VNEG generator (not shown) to begin generating a voltage of −5 volts. Therefore, when the control signal is active, the VNEG generator begins to generate a negative voltage, and as the VNEG voltage signal reaches the level of minus V2, the VDROP signal accordingly indicates the occurrence of this event. Hence, the VDROP signal can be viewed as a signal which indicates the detection that the VNEG generated signal has reached a particular desired level.
The operations of circuit 40 in FIG. 4 will now be described with reference to Table 3.
TABLE 3
Q7
Q8
Q9
Q10
Q11
Q12
Q13
Time T0
OFF
ON
OFF
ON
OFF
OFF
OFF
Time T1
ON
OFF
OFF
ON
OFF
OFF
OFF
Time T2
ON
OFF
ON
ON
ON
ON
ON
Time T3
ON
OFF
ON
ON
ON
ON
ON
At time T 0 , the control voltage is assumed to be at 0 volts, and the VPWR signal illustrated is at a logic level of +5 volts, the VNEG signal begins initially at 0 volts, and the VDROP signal is at +5 volts. Because the control signal is at 0 volts, transistor (Q 7 ) is off, transistor (Q 8 ) is on. Since transistor (Q 10 ) is on, and the source of transistor (Q 10 ) is at 5 volts, the output voltage VDROP is also at 5 volts (since transistors (Q 11 ), (Q 12 ), and (Q 13 ) are all off).
At time T 1 , assume that the control signal is now +5 volts and accordingly, VNEG is at a voltage of −V which is between 0 and −V2 volts. Since the control signal is at +5 volts, transistor (Q 7 ) is on and transistor (Q 8 ) is off. Since transistor (Q 10 ) is on, the VDROP output signal remains at +5 volts since transistors (Q 11 ), (Q 12 ), and (Q 13 ) are off.
At time T 2 , assume that the control signal remains at 5 volts, but the VNEG voltage has reached −V2 which is more negative than V1 but not yet at −5 volts. Because the control signal is at +5 volts, transistor (Q 7 ) is on and transistor (Q 8 ) is off. Transistor (Q 9 ) and (Q 10 ) are on, and accordingly the VDROP signal goes from +5 volts to a low logic level of 0 volts.
At time T 3 , assuming the control signal remains at +5 volts, and VNEG has now moved more negative to −5 volts, the state of the transistors is the same as at time T 2 , in one embodiment, and the output signal VDROP remains at a logic low level of 0 volts.
Accordingly, the output signal VDROP generated by the circuit of FIG. 4 can be used to enable the operation of a level shifter with reduced transistor bias voltages, as shown in FIG. 3, according to one embodiment of the present invention.
FIGS. 5 and 6 illustrate alternative embodiments of the invention, wherein P-channel transistors are used to provide the level shifted high voltage output signals across either the node between A and VPOS or between B and VPOS. The circuit 50 of FIG. 5 operates in a manner similar to the circuit 30 of FIG. 3, in that the switching transistors (Q 14 ) and (Q 15 ) are not subjected to a high voltage gate to source voltages during level shifting operations due to the introduction of the P-channel series transistors (Q 16 ) and (Q 17 ) controlled by the VDROP signal, in one embodiment.
FIG. 6 illustrates a circuit 60 for generating a VDROP signal to the series transistors (Q 16 ) and (Q 17 ) of FIG. 5 in accordance with one embodiment of the present invention. Circuit 60 of FIG. 6 operates in a manner similar to circuit 40 of FIG. 4 described above. In FIG. 6, the VDROP control signal is generated when the VPOS high voltage reference signal reaches a level such as between +5 and +10 volts, or more specifically, when VPOS is higher than VCC+2VTP volts.
Embodiments of the present invention can be used in a variety of circuits where level shifting may be used, such as in non-volatile memory circuits, or programmable logic devices. For instance, in a non-volatile memory circuit, embodiments of the present invention may be used to control the application of high voltage write or erase signals to one or more portions of the non-volatile memory.
FIG. 7 illustrates one example of a non-volatile memory 70 having a plurality of memory cells 72 and level shifters 74 according to embodiments of the present invention. In one embodiment, the memory device 70 has a plurality of memory cells, and associated with each row or column of cells is one or more level shifting circuits 74 . Under the control of the one or more select lines, the level shifting circuits provide high voltages signals to the memory cells to perform a write or erase operations. One example of a non-volatile memory device is described in commonly owned U.S. Pat. No. 5,506,816, entitled “Memory Cell Array Having Compact Word Line Arrangement,” issued on Apr. 9, 1996, the disclosure of which is expressly incorporated herein by reference in its entirety.
While the methods disclosed herein have been described and shown with reference to particular operations performed in a particular order, it will be understood that these operations may be combined, sub-divided, or re-ordered to form equivalent methods without departing from the teachings of the present invention. Accordingly, unless specifically indicated herein, the order and grouping of the operations is not a limitation of the present invention.
While the invention has been particularly shown and described with reference to embodiments thereof, it will be understood by those skilled in the art that various other changes in the form and details may be made without departing from the spirit and scope of the invention. | A circuit for shifting a signal from a first voltage level referenced to a first voltage reference, to a second voltage level referenced to a second voltage reference, while reducing the gate to source voltages on the output transistors. In one embodiment, the circuit includes six switches. A first switch receives the signal; a second switch receives an inverted representation of the signal; a third switch receives the output of the first switch; a fourth switch receives the output of the second switch; a fifth switch, referenced to the second voltage reference, has an input coupled with the output of the first switch and a control coupled with the output of the fourth switch; and a sixth switch, referenced to the second voltage reference, has an input coupled with the output of the second switch and has a control coupled with the output of the third switch. In one embodiment, when the third switch and the fourth switch are on, the signal is shifted to the second voltage level measured between the input of the fifth switch and the second voltage reference. The third and fourth switches act to prevent the gate to source voltage on the fifth and sixth switches from reaching a high voltage level, such as 10 volts. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an apparatus and process for delivering a pulsed fluid jet that can be used to extinguish a fire, launch a projectile and/or perform other useful work.
2. Description of Prior Art
It is a well known fact that rapidly extinguishing uncontrolled fires can be a very difficult task due to the complex nature of present day fires and the associated urgency of saving lives or minimizing economic loss and environmental damage. Many different types of fire occur today because of a presence of many man-made materials that combust with unusual characteristics and extinguishing such fire rapidly requires unusual approaches. Worldwide cities are now more crowded than ever and more people are living inside high-rise buildings which also contributes to the problem. And yet, the available fire-fighting technologies have not appreciably changed over the years and are known to be inadequate in many ways. There is a demanding need for improved fire extinguishing processes.
One most common process for extinguishing fires is to pour water over a burning object. The basic scientific principle involved in extinguishing fire with water is to reduce a temperature of the burning object as each combustible material has its unique flammability temperature. A flame can be extinguished if the temperature of the burning object is reduced below a threshold temperature by wetting and cooling the burning object with water. However, the flame can resume when the water is evaporated and the object is again raised above this flammability threshold temperature. There are many materials, such as plastics, that are not water absorbent and that combust at very high temperatures or that combust in vapor form; water has very limited usefulness in extinguishing a fire of such materials.
Current water-based fire fighting processes also have shortcomings because of the delivery method. As a fluid, water flows down due to gravity such that its contact time with materials in a vertical, flowing downward, and inclined position is usually very short unless the spray is continuously applied over a period of time. The water spray is also often not powerful enough to travel a long distance, to reach a considerable height, or to break through common barriers such as windows, doors, roofs, and walls. In many cases, most of the water flows downward and is wasted. A good example is forest and bush fires in which a long contact time between the water and the burning branches is literally impossible to maintain, except by rain. Extinguishing common house fires within a house can be troublesome because of difficulties with pouring water into a house interior and onto burning surfaces. Fire can exist between the exterior walls and the interior walls or on ceilings, where water cannot be easily delivered into such space and onto such surfaces. As a result, much of the water consumed in fighting house fires causes water damage to the extent that even if a house is saved it is frequently damaged beyond repair.
A fire which occurs in a high-rise building is also a difficult fire to extinguish because of the difficulty in reaching the fire with water. Common sprinkler systems can be ineffective for various reasons. Likewise, fire which occurs at locations where water is scarce, or where fire equipment cannot be transported to the site, can be a problem where effective portable fire extinguishing equipment is unavailable. There are many other examples of ineffective currently available water-based fire fighting processes. Fires on oil storage tanks and on oceangoing oil tankers are very difficult to extinguish with conventional water processes. Airplane fires are another example of difficult fires to extinguish because of the presence of jet fuels and the large quantity of plastics materials. In some unusual cases, the water consumed in fighting fire can result in very severe environmental damage if it is not properly contained, as evidenced years ago in a fire that occurred in a chemical plant in Switzerland, in which the fire fighting water dissolved a large quantity of toxic chemicals and then flowed into the Rhine River and severely impacted the ecosystem of the Rhine River.
Since water is ineffective against certain types of fire and under certain conditions, more effective fire retardants have been developed and made available in various forms and packages over the years. These fire retardants, when released from their containers, can be in the form of a powder, a foam, or a liquid. They function in different ways and therefore should be used differently. Some produce inert gas such as carbon dioxide and nitrogen when they are heated, thus suffocating the fire; examples include sodium bicarbonate and azodicarbonamide. Others produce vapors that act as diluent and heat sinker to combusting gases or as a free radical trap that stops or slows flame propagation; examples include halogenated flame retardants. Still other fire retardants function on solid phase by forming a protective layer on combusting substances to inhibit heat transfer; examples include many phosphorous compounds. Then there are many common materials that are very effective fire retardant when they are spread over a burning object by isolating the burning object from the ambient air; examples include many earth minerals such as clay, alumina, and sand. These earth minerals are particularly effective when they are wet and impervious. There are also materials that are very absorbent to water and can swell to form a gel that can be very useful for extinguishing fires by acting as a wet blanket; examples include polyacrylamide polymers and copolymers, and some natural gums. All these materials have some very useful features that can be used to fight fires.
Unfortunately, the currently available processes involving the use of various fire retardants have a common shortcoming, namely poor delivery distance, accuracy, and coverage. For example, powders and foams are very light and they cannot be pumped easily or blown in air over a distance with any accuracy. Once delivered, powder and foam may have difficulty remaining on top of a burning object. For example, powder fire retardants are currently used to fight forest fires and are dropped from an airplane, with questionable effectiveness. Hand-operated fire extinguishers are effective only on small fires and in confined space because of limited delivery distance and light weight characteristics of the retardants. Sand is a good fire retardant, but there is no good way to throw sand over a distance. The currently available fire extinguishing processes based on fire retardants are also not powerful enough for breaking through barriers to reach interior fires. For example, the current practice of fighting ship fires is to spray water on the ship until it is virtually sunk. Therefore, to take advantage of the positive features of available fire retardants requires a more effective retardant delivery method. Further, a synergistic approach must be adopted to combine one or more materials to fight fires. For example, water can be used in conjunction with another fire retardant to create a slurry that can smear and stick to burning surfaces like a wet blanket rather than merely touch it which then flows downward.
SUMMARY OF THE INVENTION
One object of this invention is to provide an improved fire extinguishing process that combines the positive features of water and selected fire retardants with other suitable materials and devices to form a combination that can more effectively fight various types of fire, under a wide range of conditions.
Another object of this invention is to provide a process and apparatus that are useful for performing many other work tasks.
Another object of this invention is to provide an improved process and apparatus for extinguishing fire of many types.
Another object of this invention is to provide a process that uses a high-speed pulsed waterjet or other fluid jet to extinguish fires either by the fluid jet alone or in combination with selected fire retardants in various forms.
Another object of this invention is to provide an instant on-off valve useful in many fluid jet processes.
Still another object of this invention is to incorporate other selected materials or devices into the process to assist delivery of pulsed fluid jets and/or selected fire retardants and/or other materials that are useful in many other applications.
The process of this invention uses pressurization of a selected system fluid by a suitable pump or a source of compressed gas that is used to pressurize a system fluid inside a cylinder. The pressurized fluid is transported with a tube or hose into one or more energy storage devices in the form of a spring-powered or a gas-powered accumulator. The system fluid is stored inside an energy accumulator fluid chamber to a prescribed volume. The stored system fluid is ejected or discharged through one or more suitable instant on-off valves and nozzles to generate high-speed fluid jets on demand, and directing and delivering the fluid jet to a target. The selected system fluid can be water or other fluids, such as a pure liquid, an emulsion, a slurry, or a soft gel. The pump can be large or small, low pressure or high pressure, depending on the desired characteristics of the fluid jet. The pulsed fluid jet of this invention can be generated at a wide range of pressures, power input, frequency, and pulse durations by operating the energy accumulators and the on-off valves. The system equipment involved can be large and heavy, which of ten require mounting on a suitable chassis or carriage, or can be very portable that can be carried by a person, such as on a backpack. There can be multiple energy accumulators to a single pump, multiple on-off valves to a single energy accumulator, or multiple nozzles to a single on-off valve. The on-off valve used in this process is one important part of this invention. The nozzles on this process can be a simple fluid jet nozzle commonly used in water jetting applications or a compound nozzle that has components for introducing other substances into the fluid jet or to assist a fluid jet, such as during flight in air. The nozzles of the process of this invention may also be attached with a source of optical light or laser light, for the purpose of illuminating the fluid jet.
The process of this invention also uses a fluid jet to carry selected additives to assist extinguishing fire or doing other work. The additives can be added to the fluid prior to pressurization to form a mixture, a colloid, a soft gel, or a slurry and then introduced into the system equipment and eventually discharged or ejected out of the nozzle as a pulsed fluid jet. In an alternative embodiment of this invention, selected additives are introduced into the pulsed fluid jet in the nozzle chamber by utilizing a venturi effect generated by the fluid jet, or by loading the additives into the nozzle chamber by gravity, by pressure, or by other suitable mechanical means. The additives are preferably formed as a liquid, a slurry, a soft gel, a powder, or pellets that can be introduced into the fluid jet nozzle, preferably in a simple manner. In one embodiment of the pulsed fluid jet process of this invention, selected additives are time loaded into a nozzle chamber prior to issuing a pulsed jet. The fluid jet passes through the nozzle chamber and carries additives through a secondary nozzle to be shaped into a high-speed slurry jet. Thus, in this process there is proper energy transfer from the fluid jet to the additives. Such energy transfer is not proper or possible with a setup that uses continuous fluid jet. In fighting fires, the fluid jet of this invention can act as a carrier for the additives.
The process of this invention also use a special-effect device that is introduced into or onto the nozzle and ejected with or propelled by the pulsed fluid jet, for various suitable purposes. This device may be in the form of a ball, a bullet, a cap, a capsule, a cartridge, a shell, a tube or the like. This added device can be for shielding the pulsed fluid jet and/or the additives against the air during flight so that the fluid jet can travel much further, particularly with less dispersion. The added device can be packed with fire retardants and can be used or manufactured with fire retardants, to play an active role in fighting fires when propelled into a fire by the pulsed fluid jet. The added device of this invention can also be used as a piercing tool, allowing the retardants to be delivered into a closed space, such as a house, by breaking through barriers. The added device of this invention can also be installed with a valve or another material-releasing mechanism to perform special effects, such as releasing fire retardants to cover a large area.
The pulsed fluid jet of this invention is an ideal tool for propelling fire retardants because of the following reasons.
Water or another suitable liquid alone is or can be made to be an effective fire retardant. For example, carbon tetrachloride is a non-conductive and non-flammable liquid that can be useful in fighting an electrical fire, particularly when it is used in conjunction with conventional Halon powder. Water can be converted into a sticky soft gel with various additives such that it will smear a surface instead of flowing quickly down the surface.
Water or another suitable liquid can be pressurized to a high level and ejected or discharged through a nozzle to generate a pulsed jet that can be very fast and can pack considerable power which is particularly suitable for carrying additives. Air or gases, in contrast, cannot be used to generate a very fast jet and cannot be readily pressurized, due to its compressible nature.
Liquid having a specific gravity not too different from that of solid fire retardants allows a pulsed liquid jet to transfer energy more effectively to additives when compared to an air jet or a gas jet.
Waters and other selected liquid jets do not generate much heat in repeated operations and thus do not interfere with fire retardants. Explosives, on the other hand, cannot be used to propel many fire retardants due to the heat generated inside a tube, and the heat can set off the fire retardants.
The process of this invention also includes the use of a light source, such as laser light or other suitable optical lights, to illuminate a pulsed fluid jet issued from the nozzle for various purposes.
The process of this invention can be used also for delivering selected materials for other purposes, such as agricultural, environmental, and construction applications. For example, seeds, fertilizers, insecticides, and bioremediation reagents can be delivered effectively with the process and equipment of this invention. Soil stabilization materials can be blown over or injected into earth embankment, slopes, and ground with the process of this invention. Even seedlings can be propelled by pulsed fluid jet according to the process of this invention, and planted over a distance by using special capsules.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the apparatus and process according to this invention will be better understood when taken in view of the drawings, wherein:
FIG. 1 is a schematic view of an apparatus or a system for generating a pulsed fluid-jet, according to one preferred embodiment of this invention;
FIG. 2A is a graph showing an energy level versus time as related to the power according to a conventional pulsed fluid jet process;
FIG. 2B is a graph showing energy level versus time as related to the power of one preferred embodiment of this invention;
FIG. 3 is a cross-sectional view of an on-off valve, according to one preferred embodiment of this invention;
FIG. 4 is a cross-sectional view of a combination actuator and on-off valve, according to another preferred embodiment of this invention;
FIG. 5A is a cross-sectional view of a manually-operated actuator and on-off valve, according to another preferred embodiment of this invention;
FIG. 5B is a schematic view of a portable manually-operated apparatus, according to one preferred embodiment of this invention;
FIG. 6 is a cross-sectional view of a conventional venturi-effect fluid-jet nozzle, according to the prior art;
FIG. 7 is a cross-sectional view of a capsule or projectile, according to one preferred embodiment of this invention; and
FIG. 8 is a cross-sectional view of a capsule or projectile, according to another preferred embodiment of this invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIG. 1, one embodiment of this invention concerns a process for generating a pulsed fluid jet such as one that is useful for extinguishing fires and for many other tasks. The fluid can be water or any other suitable fluid, including slurries. The fluid is pressurized either by pump 1 that is powered by a motor or engine, or by a gas powered piston inside cylinder 2 , and is transported by a conduit, such as a tube or hose 3 through control valve 4 to accumulator 5 . Accumulator 5 is preferably, but not necessarily a cylindrical device having fluid chamber 6 and gas chamber 7 which is separated by piston 8 or straddled by piston-plunger assembly or plunger 9 that can slide within the chambers. Gas chamber 7 is filled with a pressurized gas, such as air or nitrogen, to a prescribed precharge pressure. Fluid chamber 6 is normally occupied by plunger 9 . When the pressurized system fluid enters into fluid chamber 6 , it forces plunger 9 against piston 8 to further compress the gas and to fill fluid chamber 6 . Fluid chamber 6 has outlet 10 leading to on-off valve 11 that is normally closed by valve poppet 12 . Valve 11 has outlet port 13 leading to fluid jet nozzle 14 .
In one preferred embodiment of this invention, valve 4 is an on-off valve comprising actuator 15 that can be operated by electrical, compressed air, hydraulic oil, or manual trigger power. Valve 11 comprises actuator 16 that is powered by electrical, compressed air, hydraulic fluid, or manual trigger power. When valve 4 is open and valve 11 is closed, the pressurized system fluid flows into fluid chamber 6 of the energy accumulator 5 and is stored there to a predetermined capacity. As a result, piston 8 inside gas chamber 7 is moved to compress the gas to a higher pressure, thus storing the energy. One or more piston position sensors 17 can be mounted inside or outside the cylinder of accumulator 5 , for example to monitor the exact location of piston 8 and to inform the controller if valve 11 should be opened. When valve 11 suddenly opens and valve 4 closes, the pressurized fluid inside fluid chamber 6 flows out valve port 13 and nozzle 14 to generate a high-speed fluid jet until fluid chamber 6 is emptied as plunger 9 pushes all fluid out of outlet 10 . Plunger cushion 18 which is preferably mounted inside fluid chamber 6 provides a fluid cushion to decelerate plunger 9 . Then, valve 11 closes and valve 4 opens to start another cycle. The presence of multiple piston position sensors 17 permits the variation of pulsejet duration and frequency. The valve operation can be handled manually or by means of controller 19 . On-off valve 4 protects pump 1 and can be omitted in some applications and the fluid will flow directly from the source to the energy accumulator 5 without interruption. Nozzle 14 of this invention can be a simple fluid nozzle or a complex nozzle, such as shown in FIG. 1, comprising additive inlet 20 for introducing to the fluid jet selected additives from storage hopper 21 , magazine 22 for storing and introducing special-effect devices 23 into nozzle chamber 24 , and/or a source of laser or optical light 25 attached to or near nozzle 14 .
In one preferred embodiment of this invention, the system fluid is water or a water-based liquid mixture, a soft gel, or a slurry. However, in other preferred embodiments the fluid is ethylene glycol, carbon tetrachloride, or other fluids that possess special properties advantageous to the applications. In large systems, the system fluid can be pressurized by suitable pumps and the valves operated with a controller. In portable systems, the system fluid can be pressurized with a manual pump or stored inside a cylinder that is pressurized by compressed air or gas and the valves can be operated by hand. The system fluid can be pressurized to a modest level of less than one hundred pounds per square inch (psi) or to tens of thousand psi, depending on the intended application. For systems operating at a modest pressure, accumulator 5 can comprise a simple cylinder having piston 8 inside for separating the system fluid from the compressed gas. In high-pressure systems, accumulator 5 is preferably constructed as a pressure vessel and has gas piston 8 and an attached fluid plunger 9 ; the diameter of piston 8 and plunger 9 is of a prescribed ratio, which determines a force relationship across the two components. The force generated by the system fluid inside fluid chamber 6 needs to overcome the force exerted on piston 8 by the compressed gas, in order to move piston 8 and to store the fluid energy. When valve 11 opens, the fluid jet is powered by the compressed gas pushing against piston 8 and plunger 9 and thus has power instantly and the power is continued until fluid chamber 6 is emptied and valve 11 closes. By manipulating or varying design and/or operating parameters of valves 4 and 11 and accumulator 5 , the pulsed fluid jet can vary in pulse duration and frequency. If pump 1 has variable pressure and flow control, then the power of the pulsed fluid jet can be varied as well.
For the pulsed fluid jet of this invention to function properly, it should have instant power and its power vs. time profile should follow a step curve rather than a bell curve, as shown in FIGS. 2A and 2B. In a bell-shaped curve profile as shown in FIG. 2A, the pulsed fluid jet would have fluid dripping at the beginning and end of a pulse due to a lack of energy. The dripping fluid does no work and is wasted. In a step-shaped curve profile as shown in FIG. 2B, the pulsed fluid jet, on the other hand, has instant power at the beginning of a pulse and plentiful power at the end of a pulse, thus wasting no fluid power. To produce such fluid jet pulse requires a suitable valve that provides instant on-off operations with a reasonably large outlet and with a fluid passage that is free of flow obstacles. Otherwise, a significant pressure drop and flow turbulence can occur which prevents the formation of a coherent high-speed fluid jet. In one preferred embodiment of this invention, an instant on-off valve is ideally suited for this process.
Referring to FIG. 3, instant on-off valve 100 of this invention comprises valve body 101 having central in-line cylindrical cavities 102 and 103 separated by partition 104 and seal 105 . Valve plunger 106 straddles across partition 104 and has front end 107 in chamber 102 and rear end 108 in chamber 103 . Valve seat 109 comprises a central valve port 1 10 shaped to mate with plunger front end 107 and in communication with valve outlet 111 . Valve inlet 112 passes through valve body 101 in communication with chamber 102 . Compression spring 113 around valve plunger 106 urges valve plunger 106 to move away from valve seat 109 . Valve actuating pin 114 has internal end 115 positioned inside chamber 103 and external end 116 positioned outside valve body 101 . Valve actuator 117 is attached to valve body 101 through adapter 118 . Valve plunger 106 has central through fluid passage 119 , check valve assembly 120 in line with fluid passage 119 that allows fluid to flow only from rear end 108 to front end 107 , and a smaller side fluid passage 121 linking chamber 102 to chamber 103 . Fluid passage 119 is in line with valve actuating pin 114 and can be closed or opened by internal end 115 of actuating pin 114 . Valve actuator 117 provides a necessary force to external end 116 of actuating pin 114 , directly or indirectly.
Still referring to FIG. 3, valve 100 in a normally-closed mode has an external force from valve actuator 117 pushing against actuating pin 114 , which in turn engages fluid passage 119 and pushes valve plunger 106 down to close valve port 110 . As pressurized fluid enters into valve chamber 102 , it is stopped by valve plunger 106 and a portion of this fluid flows through fluid passage 121 and fills chamber 103 , thus exerting force on plunger end 108 to close valve port 110 . In the meantime, the fluid force inside chamber 102 urges valve plunger 106 to part from valve seat 109 is comparably smaller due to the conical mating surface between plunger front end 107 and valve seat 109 , such that the fluid does not contact the central portion of valve plunger front end 107 .
To open valve 100 , actuator 117 is activated to allow actuating pin 114 to move away from chamber 103 and to expose fluid passage 119 , thus allowing pressurized fluid inside chamber 103 to flow through fluid passage 119 and into valve outlet 111 . As a result, the fluid force on plunger end 108 ceases and the fluid force inside chamber 102 pushes valve plunger 106 upward to expose valve port 110 . Being relatively smaller, fluid passage 121 delays the pressure equalization of chambers 102 and 103 , and check valve assembly 120 blocks the reverse flow of fluid from chamber 102 to chamber 103 , thus assuring that valve plunger 106 rapidly moves all the way up. Compression spring 113 also helps the upward motion of valve plunger 106 and keeps it at its highest position. Without check valve assembly 120 , valve plunger 106 may move up only part the way and then stop as the fluid pressure in chambers 102 and 103 equalizes, unless a powerful compression spring 113 is used to overcome seal friction around valve plunger 106 . In some embodiments of this invention, such powerful spring is not desired inside valve 100 . In normally-open mode of operation, valve 100 is identical except that actuator pin 114 is normally in disengaged position and the system fluid flows freely through valve 100 . To close valve 100 , actuator 117 is powered to push actuating pin 114 against valve plunger 106 and to close valve port 110 . Actuator 117 can have a piston-and-rod arrangement to provide the necessary force and can be powered by compressed air or gas and by pressurized oil. Actuator 117 can also be an electrical solenoid capable of push-pull operations. Actuator 117 can also be manually operated in which the required valve closing or opening force is provided either by a compression spring or by a hand-operated lever working against the spring.
Referring to FIG. 4, another instant on-off valve 200 of this invention comprises valve plunger 206 that serves dual purposes. Valve 200 comprises valve body 201 having three in line cylindrical chambers 202 , 203 and 204 , separated by partitions and seals. Valve plunger 206 straddles across the three chambers 202 , 203 and 204 and has front end 207 in chamber 202 and rear end 208 in chamber 204 . Valve seat 209 has valve port 210 in communication with valve outlet 211 . Valve inlet 212 passes through valve body 201 and is in communication with chamber 203 . Compression spring 213 around valve plunger 206 urges it to move away from valve seat 209 . Valve actuating pin 214 is in line with valve plunger 206 and has internal end 215 inside chamber 204 and external end 216 outside valve body 201 and in contact with valve actuator 217 . Side valve port 224 is in communication with chamber 202 to an external accumulator 205 . Valve plunger 206 has a central through fluid passage 219 with check valve assembly 220 near valve plunger front end 207 . A smaller side fluid passage 221 of valve plunger 206 is in communication with chambers 203 and 204 . Cutout area 222 around the middle portion of valve plunger 206 straddles across seal assembly 223 . The cutout area 222 serves as fluid passage from chamber 203 to chamber 202 , with a function similar to that taught in U.S. Pat. No. 5,297,777.
Still referring to FIG. 4, valve 200 of this invention combines two valves in one and represents the combination of valve 4 and valve 11 as shown in FIG. 1 . In normally-closed operation, valve 200 is closed and the system fluid flows through inlet 212 , chamber 203 , cutout area 222 , chamber 202 , valve port 224 , and into the fluid chamber of energy accumulator 205 and is stored there. In this closed position, cutout area 222 of valve plunger 206 is positioned across seal 223 , thus allowing the fluid to pass through cutout area 222 . When actuator 217 is energized to retract valve actuating pin 214 , valve plunger 206 moves away from valve seat 209 to open valve port 210 so that cutout area 222 moves to the right, as shown in FIG. 4, of seal 223 and into chamber 203 , thus preventing fluid flow from chamber 203 to chamber 202 . In the meantime, valve port 210 opens and the fluid stored inside accumulator 205 flows into chamber 202 and out of valve outlet 211 until the fluid chamber of accumulator 205 is emptied and valve 200 is closed again. Valve 200 allows separation of fluid flow so that clean pulsed fluid jets can be produced and the pump function not disturbed. If piston position sensor 227 is mounted on accumulator 205 and is connected to actuator 217 , valve 200 can be operated on an automatic repeat mode so that it will open as soon as the fluid chamber of accumulator 205 is filled to a prescribed volume and closes when the fluid chamber is empty.
The pulsed fluid jet process of this invention can be applied with a portable and manually-operated apparatus, such as shown in FIGS. 5A and 5B. The apparatus of this invention combines a relatively small energy accumulator with a manually-operated dual-function valve and a nozzle to form a complete pulsejet applicator 300 . With applicator 300 in a normally-closed position, hand lever 301 is pulled toward handle 302 to compress valve-actuating spring 303 and to move valve plunger 304 to open valve port 305 . When hand lever 301 is released and applicator 300 is closed, a pressurized system fluid flows from a pump or a pressurized tank through a hose to inlet 306 of applicator 300 . From inlet 306 , the fluid flows into valve chamber 307 , through cutout area 308 of valve plunger 304 , valve chamber 309 , side port 310 , fluid passage 311 , and into valve chamber 312 and fluid chamber 313 of energy accumulator 314 , which can be a separate unit or conveniently attached to the valves. Applicator 300 can have two valves, and front pulsejet valve 315 that controls valve port 305 in a way similar to valve 100 shown in FIG. 3, and rear valve 316 controls the inflow of system fluid to the energy accumulator. Together, valves 315 and 316 function as valve 200 shown in FIG. 4 . Applicator 300 has nozzle 317 in line with valve port 305 . Nozzle 317 can be a conventional fluid-jet nozzle employed in water jetting applications, or a complex fluid-jet nozzle having additive inlet 318 and detachable capsule magazine 319 for special-effect devices. Applicator 300 can provide a very compact hand-held pulsejet generator which can be used with a compact pump system or a pressurized fluid supply system.
When used in fighting fires, the system fluid such as water can be stored in a pressurized cylinder and can be carried on a backpack or on a small cart, and the selected fire retardants can be prepared in capsules and packed in magazines to be delivered by the pulsejets, or stored in another cylinder and delivered into the nozzle via a conduit, such as a hose. A venturi-effect fluid-jet nozzle allows energy to be transferred from the pulsejet to the additives and ejected together through a secondary nozzle. A suitable nozzle is taught by U.S. Pat. No. 4,666,083, and is illustrated in FIG. 6 of this invention. As shown in FIG. 6, this nozzle assembly has a high-pressure fluid-jet nozzle on the left and a secondary slurry nozzle on the right and therebetween a mixing chamber. The selected additives enter the mixing chamber through a feed tube in a side port and are often drawn or sucked into the nozzle by a vacuum generated by the very high speed fluid jet. The cited prior art taught the use of multiple orifices strategically positioned to provide superior energy transfer from the fluid jets to the additives and to generate a high-speed slurry jet. This prior art nozzle can be advantageously used in this invention.
The process of this invention also includes the use of a pulsed fluid jet to propel a selected object placed inside or outside a nozzle for various purposes. This object can be in many forms such as balls, bullets, caps, capsules, cartridges, cups, shells, and tubes, and is preferably loaded into a nozzle cavity by various means such as gravity, spring force, pneumatic power, mechanical means, or manual loading. The objects can be soft or hard, and made of various materials. FIG. 7 shows one preferred embodiment of the object wherein capsule 400 of this invention is shaped like a hollow bullet having an outer surface 401 , inner surface 402 , front head 403 , and interior cavity 404 . Capsule 400 can be molded from selected powder, formed from a gel, or can have an outer skin and an inner skin with other materials in between a powder and a gel. When the process of this invention is used to fight fires, capsule 400 can be made of fire retardants and be ejected out of a nozzle by a pulsed waterjet. Capsule 400 can deflect air resistance during flight and actively participate in extinguishing the fire. When capsule 400 is made of water absorbing polymers such as polyacrylamide, a pulsed waterjet swells the capsule further upon contact and together can be effective in blanketing a fire. Capsule 400 can be formed in so many ways such that they can be coded for use against fire of various types and under various conditions.
A pulsed fluid jet of this invention can generate so much force that capsule 400 can be made into a shell or bomb and shot or lopped into a fire by a pulsed fluid jet. Referring to FIG. 8, one embodiment of this invention is a fire-extinguishing shell 500 that has a cylindrical body 501 made of metal, glass, ceramic, or a hard plastic that can be propelled by a pulsejet of this invention. Shell 500 comprises rear cavity 502 for accepting a pulsed fluid jet, front cavity 503 containing liquid carbon dioxide or liquid carbon dioxide and other selected fire retardants, front impact valve 504 for releasing the contents of cavity 503 , and stabilizing fins 505 for improved air flight. Shell 500 is preferably loaded inside a cylindrical cavity in a pulsejet nozzle of this invention and is to be propelled by one pulsejet. Impact valve 504 opens rapidly upon impact, to release the fire retardants. Shell 500 can be made in various sizes and with different specialties to tackle fires of different natures. Shell 500 can also be made with very hard metal, so that it can pierce through barriers such as steel plate and deliver the fire retardants to the interior of vessels and tanks. Such capabilities are also very useful in fighting fire in high-rise buildings with a system mounted on a helicopter.
Referring back to FIG. 1, the apparatus of this invention may comprise more than one energy accumulator for each pump system to handle high flow of a system fluid, so that the flow is almost continuous. There can be multiple nozzle assemblies operating at a high frequency for each energy accumulator to deliver a large quantity of system fluid and additives to a target. Such capabilities are advantageous in fighting large fires with limited supply of water. The incorporation of water absorbing materials, in particular, will further improve the effectiveness of the process as the evaporation of water will be slowed down and nearly none of the water will be wasted. Once the flame is extinguished, the spread of fire will be arrested and cooling can begin. Bush and forest fires are examples of situations in which this invention will be useful.
The pulsed fluid-jet process of this invention has many applications other than fighting fires. A pulsed waterjet can find applications in display fountains and is particularly aesthetically pleasant if optical or laser light is incorporated to illuminate it at night. An acoustic effect of a powerful pulsed waterjet and the ability of this process in programming the pulsejet generation are other advantages in fountain applications. A high-power pulsed waterjet can be useful in many concrete demolition work and in mining/tunneling applications, even under submerged conditions. The process of this invention is also useful in many agricultural applications. For example, capsule 400 can contain seeds, plant nutrients, and water absorbents, and be delivered over a distance by pulsed waterjets. The water can be absorbed into capsule 400 and be used by seeds for germination. Such remote seeding process can be very beneficial in land reclamation and desert control. Even seedlings can be delivered over a distance and planted into ground by this process using a specially designed double-barreled capsule in which one barrel is for the seedling and the other barrel is for water and nutrients. A hand-held apparatus of this invention can be useful in such seedling planting operation. | An apparatus and process for generating a pulsed high-speed fluid jet that can be used to extinguish fires and/or to launch a projectile. A valve, such as an instant on-off valve, preferably operates in combination with a pressure accumulator. In a controlled manner, a pulsed fluid jet is generated and directed through a nozzle. The nozzle can draw into the fluid-jet an additive. The nozzle may also be used to launch a projectile using the fluid jet as a propellant. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to a fuel injection timing control apparatus for a diesel engine, whereby the timing of fuel injection into the cylinders of the engine is controlled on the basis of injection time phase difference deviations and firing time deviations.
There have been various proposals in the prior art for a fuel injection timing control apparatus having similar objectives to those of the present invention. For example Japanese patent No. 58-70029 describes an apparatus in which an actual firing time sensor is employed to detect the points in time at which firing (i.e. combustion of fuel being injected into a cylinder) actually occurs. This sensing is performed by detecting light which is emitted by the firing, e.g by an opto-electric sensing element disposed outside a viewing window. A target firing time is established, and feedback control is applied by a fuel injection timing control means such as to vary the timing of fuel injection into the cylinders until the actual firing time is made coincident with the target firing time. However, such an apparatus presents problems due to the fact that under some engine operating conditions, for example during intervals in which the engine is run without fuel being injected into the cylinders, or when the engine is idling with only very small amounts of fuel being injected into the cylinders, or when the viewing window is obscured by soot, etc, satisfactory signals will not be produced from the firing time sensor.
In order to overcome this problem, it has been proposed, for example in Japanese patent No. 59-153942, to switch over to an open-loop control of the fuel injection timing when satisfactory signals cannot be obtained from the sensor means used to detect the actual firing times. However such open-loop control cannot provide precise control of the fuel injection timing. Another attempt to overcome this problem is proposed in Japanese patent No. 58-20935, in which changeover to control of the fuel injection timing on the basis of a rotational phase difference is performed, when the firing time sensor means becomes inoperative as described above. However such control cannot provide a sufficiently high degree of accuracy, due to errors which arise from the mechanical tolerances of the fuel injection pump and engine components, inaccuracies resulting from component wear over a long period of use, etc.
It can thus be understood that prior art types of apparatus for controlling the fuel injection timing of a diesel engine based on firing times do not provide a highly accurate control over the entire range of engine operating conditions.
SUMMARY OF THE DISCLOSURE
With a fuel injection timing control apparatus for a diesel engine according to the present invention, control is basically performed on the basis of a phase difference between an actual fuel injection and a commanded fuel injection, which precisely expresses a timing at which fuel is injected into a cylinder of the engine. A feedback signal based on this phase difference is derived, and the feedback signal is then corrected by a correction factor, to provide compensation for the effects of mechanical tolerances of the fuel injection pump and the diesel engine and errors resulting from component wear over a long period of use, etc. This correction factor is periodically updated, i.e. a new value for the factor is computed, based on an engine firing signal consisting of pulses which are generated by detection of firing occurring within a cylinder of the diesel engine. It is a basic and novel feature of the present invention that this updating of the correction factor is performed only when it is judged that the diesel engine is running within a specific range of operating parameters, for example when the degree of accelerator pedal actuation is within a specific range while at the same time the engine speed of rotation is within a specific range. This range of operating conditions of the engine is determined such as to ensure the feasibility of obtaining a signal indicating the actual times of firing within a cylinder of the diesel engine in a stable and reliable manner, with this signal being employed in computing an updated value for the correction factor. So long as the engine continues to operate within the above range, then closed-loop control of the fuel injection time will be performed, with the correction factor being regularly updated in accordance with successively obtained firing time values. When it is judged that the engine has ceased to operate within that range, so that there is no longer any assurance of obtaining an accurate signal indicating the fuel firing times, then updating of the correction factor is terminated, with closed loop control of the fuel injection time being continued, employing the phase difference described above and utilizing the most recently updated value of the correction factor for correction purposes. When the engine subsequently again enters the range of operation within which correction factor updating is feasible, then this updating is resumed.
In this way, accurate closed-loop control of fuel injection timings is attained over the entire range of engine operating conditions.
More specifically, a fuel injection timing control apparatus for a diesel engine according to the present invention comprises operating status sensing means for sensing a current operating status of the engine and producing output data indicative thereof, reference position sensing means for detecting a reference time point at which a crankshaft of the engine attains a reference angular position and producing a corresponding output signal, phase difference sensing means for detecting a phase angle representing a time at which fuel is injected into a cylinder of the engine and for producing data indicative thereof, firing time sensing means for detecting firing of fuel within a cylinder of the engine and producing a signal indicative thereof, target firing time computation means for computing a target firing time at which the latter firing should occur with respect to the reference time point, based on output data from the operating status sensing means, actual firing time computation means for computing an actual firing time with respect to the reference time point, based on output data from the reference position sensing means and the firing time sensing means, compensation factor computation means for computing a correction factor based on a difference between output data from target firing time computation means and actual firing time computation means, injection time adjustment means controllable for varying the time of injection of fuel into the cylinders of the engine, output value computation means for computing an output data value, based on data produced from phase difference sensing means and operating status sensing means, with this output data value being applied to the injection time adjustment means and being such that the injection time adjustment means acts to bring the actual fuel injection time into coincidence with the target fuel injection time, the output value computation means also acting to modify the output data value computed thereby, in accordance with the correction factor, such as to modify the fuel injection time to bring the actual firing time into coincidence with the target firing time, and updating feasibility judgement means for performing computations, based on output data from the operating status sensing means, to judge whether a current operating status of the diesel engine is suitable for obtaining actual firing time data from the firing time sensing means, and for respectively enabling and inhibiting computation of a new value of the compensation factor, in accordance with the result of this judgement.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a general block diagram for illustrating the basic configuration of a fuel injection timing control apparatus according to the present invention;
FIG. 2 is a block diagram showing an embodiment of the present invention;
FIG. 3 is a cross-sectional view illustrating fuel injection timing adjustment means for the embodiment of FIG. 2;
FIG. 4 is a cross-sectional view of a firing time sensor element;
FIG. 5 is a cross-sectional view for illustrating the manner of mounting the sensor element of FIG. 4 in a diesel engine;
FIG. 6 is a partial cross-sectional view showing an actual injection quantity sensor;
FIG. 7 is a circuit diagram of an input circuit for use with the sensor element of FIG. 4;
FIG. 8 is a circuit diagram of a configuration for a reference position sensor and for a fuel injection phase difference sensor together with an input circuit;
FIGS. 9(a) to 9(d) are waveform diagrams of signals produced by the circuits of FIG. 7 and FIG. 8;
FIG. 10 to FIG. 16 are flow charts for illustrating the program flow sequence of control operation by a microcomputer in the embodiment of FIG. 2;
FIG. 17 is a diagram for graphically illustrating a range of engine operating conditions within which correction factor updating is judged to be feasible;
FIG. 18 is a cross-sectional view illustrating the physical configuration of a fuel injection phase sensor;
FIG. 19 shows an alternative example of a toothed wheel for a phase sensor of the form shown in FIG. 18, and;
FIG. 20 is a waveform diagram for illustrating output signal pulses produced by a phase sensor employing the toothed wheel shown in FIG. 19.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a general block diagram for assistance in describing the basic features of the present invention. In FIG. 1, reference numeral 101 denotes actual phase difference sensing means for detecting a time difference which corresponds to an actual fuel injection timing of a fuel injection pump. Reference numeral 102 denotes operating condition sensing means for producing output signals that are input to target phase difference computation means 105. The target phase difference computation means 105 computes a target phase difference, corresponding to a target fuel injection time. Compensation amount computation means 108 serves to compute a correction factor, and tis factor, together with the value of target phase difference and actual phase difference is applied to output value computation means 109. The output value computation means 109 computes an output value which is applied to control injection timing adjustment means 110.
Reference numeral 104 denotes correction factor updating feasibility judgement means for performing computations to judge whether the current operating condition of the diesel engine is suitable for performing updating of the correction factor, with this updating computation being carried out on the basis of output signals which are produced from engine operating condition sensing means 102 and from firing time sensing means 103 and reference position sensing means 100. The output signals from the engine operating condition sensing means can represent for example the current speed of rotation of the engine and current amounts of fuel being injected in each fuel injection operation. More specifically, the correction factor updating judgement means judges whether the engine is functioning within a certain range of operating parameter values such that data representing the precise timings of fuel firing within the engine cylinders can be accurately obtained, since the updating of the correction factor is essentially based on this data. Such data can for example be obtained by signals produced from an opto-electric probe mounted to protrude within the combustion chamber of a cylinder. The target firing time computation means 106 computes target firing times for the engine, based on signals which are output from the operating condition sensing means 102. Actual firing time computation means 107 compute the actual times at which firing occurs in the cylinders, based on output signals from the firing time sensing means 103 and from reference position sensing means 100. The compensation factor computation means 108 produce output signals representing the correction factor described above, which are input to output value computation means 109, together with data from the phase difference sensing means 101 and the target phase difference computation means 105. Output data from the output value computation means 109 based on these inputs is applied to injection timing adjustment means 110, which acts to successively increase or decrease the timings at which fuel is injected into the cylinders until the actual firing times are brought into coincidence with the target firing times. When these times coincide, then the corresponding compensation factor is held fixed until another computation to obtain a new value of compensation factor is performed i.e. the data representing the most recently updated value of compensation factor is retained. The process of successively acquiring new values of compensation factor is periodically repeated until it is detected that the engine is no longer operating in a suitable condition for acquisition of data to be used in acquiring a new value of the compensation factor. When this occurs, the most recently obtained value of compensation factor is held fixed, until the engine again enters an operating condition which is suitable for acquisition of new values of compensation factor. However closed-loop control of the fuel injection timings, based on the latest value of the compensation factor and the fuel injection phase difference data continues to be performed, ensuring maximum accuracy of injection timing control even when the engine is operating under conditions in which updating of the correction factor is not possible.
An embodiment of the present invention will now be described, referring first to FIG. 2 and the waveform diagrams of FIGS. 9(a) to 9(d). In FIG. 2, reference numeral 1 denotes a diesel engine. A distributor type of fuel injection pump 2 injects fuel under high pressure through each of a set of fuel injection nozzles 7 into respective cylinders of diesel engine 1. The timings of fuel injection operations by pump 2 are controlled by an injection time adjustment unit 3, which in this embodiment consists of an electrohydraulic timer. A reference position sensor 4 serves to detect when the crankshaft of diesel engine 1 has reached a reference angular position, and is made up of a toothed wheel which is mounted coaxially with the crankshaft of diesel engine 1 and a fixed electromagnetic pick-up which is fixedly mounted opposite this toothed wheel. The reference position sensor 4 is utilized to measure the speed of rotation of diesel engine 1.
Reference numeral 5 denotes a firing time sensor, for detecting the timings at which firing occurs within one of the cylinders of diesel engine 1. An example of a suitable configuration for the firing time sensor 5 is shown in FIG. 4. Here, numeral 58 denotes a housing which is of semi-hollow construction and is formed of a heat-resistant material. A rod-shaped member 59 is formed of a heat-resistant optically transparent material such as quartz glass, and is mounted within the hollow portion of housing 58, held fixedly retained therein by suitable attachment means. The transparent rod 59 is mounted such as to protrude outward from the tip of housing 58 by approximately 3 to 5 mm. A photoelectric sensing element such as a phototransistor 61 is mounted in housing 58 facing the opposite end of rod 59 to the outwardly protruding end of that rod and concentric with the axis of elongation of rod 59. Light which is generated by firing within a cylinder of diesel engine 1 is transmitted from the protruding end portion of rod 59, along rod 59 and hence directed onto phototransistor 61 to generate a sensing signal.
FIG. 5 is a partial cross-sectional view of diesel engine 1 illustrating the manner in which firing time sensor 5 is mounted. In this embodiment, the diesel engine is of turbulent flow type. Reference numeral 62 denotes a cylinder head, numeral 64 an exhaust valve, numeral 63 a piston, and numeral 65 a turbulence chamber into which fuel is injected through the fuel injection nozzle 7. The firing time sensor 5 is fixedly mounted in cylinder head 62 by being screwed into an aperture communicating from the interior of turbulence chamber 65 to the exterior of the engine. With this arrangement, while the engine is operating within a specific range of parameters as mentioned above, the light flash generated upon the occurrence of firing within turbulence chamber 65 will be of sufficient intensity to result in an output signal from phototransistor 61 which will be of suitable magnitude for indicating the precise timing at which the firing occurred.
It should be noted that the present invention is not limited to the use of photo-electric sensing means for detecting the firing timing. It is equally possible for example to use a device which senses changes in fuel pressure, ion flow, or other suitable parameter.
Referring again to FIG. 2, an injection quantity sensor 6A serves to detect an actual amount of fuel which is injected by fuel pump 2 in each fuel injection operation. With the present embodiment, the injection quantity sensor 6A acts to sense the position of a spill ring of the fuel pump, as described hereinafter.
A temperature sensor 6B serves to sense the operating temperature of diesel engine 1. An accelerator position sensor 6C senses the amount of actuation of an accelerator pedal.
A phase sensor 6D senses an actual phase difference, which is the difference in phase occurrence between the fuel injection timing (which is variable by means of injection time adjustment unit 3) and a time point represented by a reference position of the engine crankshaft, which is detected by the reference position sensor 4.
Reference numeral 10 denotes an electronic control unit, which includes an analog/digital converter 11, waveform shaping circuits 12 and 13, a microcomputer 14, and an output circuit 15. The microcomputer 14 is preferably capable of processing 8-bit or 12-bit data, and includes a CPU, memory, timers, etc. The electronic control unit 10 supplies output pulses to the injection time adjustment unit 3, through output circuit 15. The injection time adjustment unit 3 functions such as to control the timings of fuel injection operations in accordance with the duty ratio of the output pulses applied thereto from output circuit 15.
FIG. 3 shows an example of a suitable configuration for the injection time adjustment unit 3. In FIG. 3, a timing piston 30 is coupled to a roller ring 32 by a pin 31. The angular position of the roller ring 32 determines the precise timings at which fuel is injected into each of the cylinders of diesel engine 1. As the timing piston 30 is moved to the left (as seen in FIG. 3), the roller ring 32 is rotated clockwise, and vice versa. In this way, the fuel injection timing (as represented by an amount of lateral displacement of the timing piston 30) is converted into an amount of angular displacement of the roller ring 32. This degree of angular displacement can be converted into an electrical signal by various means, which are well known i the art and will therefore not be described. The data represented by this electrical signal will be referred to as the fuel injection phase difference. Numeral 33 denotes a vane-type fuel pump which is rotated by a drive shaft (not shown in the drawings) to send fuel under pressure from a fuel tank to a pressure chamber 34 within the body of fuel injection pump 2. When fuel from pressure chamber 34 is injected into a cylinder of diesel engine 1, then during this injection process fuel is also passed through a narrow-bore restriction into a timer piston high-pressure chamber 35. Numeral 36 denotes a return spring, which is contained within a low-pressure chamber 38. The timing piston 30 becomes set at a position where there is a balance between the pressure force applied to the piston from high-pressure chamber 35 and the reaction force produced by return spring 36, and this position determines the injection timing, as well as the angular position of roller ring 32. Reference numeral 37 denotes an electromagnetic valve for pressure control, i.e. which controls the level of pressure within the high-pressure chamber 35. This is performed by valve 37 being periodically and alternately opened and closed, in response to a drive pulses applied thereto from output circuit 15 of electronic control unit 10 as describe above, with the duty ratio of successive opening and closing of valve 37 (i.e. the ratio of the duration of a time interval in which the valve is open to the duration of a succeeding time interval in which the valve is closed) being determined by the duty ratio of these drive pulses. In this way, the duty ratio of the output signal from electronic control unit 10 controls the position of the timing piston 30, and hence the timing of fuel injection by pump 2, while the timing which is actually set in this way is indicated by an amount of angular rotation of the roller ring 32. The phase difference between an electrical signal representing the angular position of the roller ring relative to a reference crankshaft position, produced by suitable transducer means as described above, will then represent the fuel injection timing, i.e. such transducer means in combination with the roller ring 32 constitute the fuel injection phase sensor 6D shown in FIG. 2.
Referring now to FIG. 6, an embodiment is shown of the actual injection quantity sensor 6A indicated in FIG. 2. Reference numeral 21 denotes an injection pump spill ring, and numeral 22 a plunger. The plunger is rotated, and also laterally displaced to the right or left (as seen in FIG. 6), by a face cam (not shown in the drawings), to thereby distribute fuel under pressure to the cylinders of diesel engine 1, with the amount of lateral displacement of the plunger 22 determining the amount of fuel delivered in each injection operation. The actual injection quantity sensor 6A includes a movable core 66, which is fixedly attached by a lever to the spill ring 21. A pair of coils 67 are wound around the periphery of a tubular bobbin having a hollow central region within which the movable core 66 moves. The body of the actual injection quantity sensor 6A is fixedly attached to the pump head by means of attachment screw 68. The coils 67 are respectively disposed such that the degree of mutual inductive coupling between them is varied in accordance with an amount of lateral displacement of the movable core 66. When the amount of fuel injected into the cylinders in each fuel injection operation is to be reduced, then the spill ring 21 and movable core 66 are moved to the left (as seen in FIG. 6), while when the amount of fuel injected is to be increased then spill ring 21 and core 66 are moved to the right. A periodically varying input signal of suitable waveform is applied to one of the coils 67 of actual injection quantity sensor 6A from a signal source (not shown in the drawings), whereby an output signal is produced from the other one of coils 67 whose amplitude is determined by the amount of mutual coupling between the coils, and hence by the amount of displacement of the spill ring 21. Thus, if a large quantity of fuel is injected into the cylinders in each injection operation, then the mutual coupling will be low, due to the rightward positioning of movable core 66, and hence the output signal level will be low, for example 1 V. When the engine is operating with low amounts of fuel being injected, during idling for example, then the spill ring 21 and hence core 66 will be positioned at the left, resulting in a high level of output voltage from actual injection quantity sensor 6A, for example 3V.
In the electronic control unit 10, a converter 11 converts the output signal thus generated by the actual injection quantity sensor 6A into a digital signal consisting of pulses whose pulse width is determined in accordance with the amplitude of the analog signal from the actual injection quantity sensor 6A. This pulse width therefore represents the actual fuel injection amount which is input in each injection operation (referred to in the following simply as the actual injection amount). Converter 11 also converts the analog output signals from the cooling water temperature sensor 4 and the accelerator pedal sensor 6C into digital signals having an appropriate number of bits.
The configuration of input circuit 12 of electronic control unit 10 is shown in FIG. 7. This circuit produces an output signal voltage whose level increases in accordance with the intensity of input light applied to phototransistor 61 of the firing time sensor 5, described hereinabove. This output voltage is amplified by amplifier circuit 54, and then applied to a waveform shaping circuit 55, to produce an output signal V c having the waveform shown in FIG. 9(c).
FIG. 8 shows an example of a suitable configuration for each of the reference position sensor 4 and the injection phase sensor 6D, and for input circuits 13 and 13'. Reference numeral 41 denotes a toothed wheel forming part of the reference position sensor 4, which rotates in synchronism with the crankshaft of diesel engine 1. An electromagnetic pick-up 42 is positioned opposite to toothed wheel 41, for producing an AC signal having the waveform shown in FIG. 9(a). Each point in time at which a zero crossing of this signal occurs corresponds to the attainment of a reference angular position by the crankshaft of diesel engine 1, with this position being disposed immediately following a top dead center position. This AC signal is applied to input circuit 13, which performs waveshaping to produce an output signal having the waveform shown in FIG. 9(b), with period T N . This signal is input to microcomputer 14, which counts the pulse periods T N to thereby compute the speed of rotation of diesel engine 1.
The sensor signal from firing time sensor 5 is transferred through input circuit 12 to be input to microcomputer 14, which counts the number of occurrences of the time interval T TP between the output pulses from firing time sensor 5 and the output pulses from reference position sensor 4. Based on this count value and the speed of rotation of diesel engine 1, the angle of crankshaft advance, representing the advance of the angle of actual fuel firing as compared with reference angle of fuel firing is computed by microcomputer 14. Therefore the actual time of ignition of the fuel, relative to the reference crankshaft position, is derived.
As indicated in FIG. 8, the phase sensor 6D and input circuit 13' can be of identical configuration to that shown in FIG. 8. However, as shown in the cross-sectional view of FIG. 18 which shows the physical arrangement of phase sensor 6D, the toothed wheel 6D1 of phase sensor 6D is fixedly mounted on the drive shaft 2a of the fuel injection pump 2, while the electromagnetic pick-up 6D2 of phase sensor 6D is attached to the roller ring 32. Thus, when the fuel injection timing is altered, the electromagnetic pick-up 6D2 will be rotated together with roller ring 32, about the axis of rotation of the pump drive shaft. In this way, he phase of the signal generated by pick-up 6D2 is correspondingly shifted. The resultant output signal from pick-up 6D2 is designated as V d and has the waveform shown in FIG. 9(d). The phase difference T P and the sensor signal from the reference position sensor 4 is indicative of the amount of difference between actual injection and the reference injection, and is used to derive the actual injection phase difference.
FIG. 10 to FIG. 16 are flow diagrams illustrating the flow of processing executed by microcomputer 14. FIG. 10 shows the main processing routine, FIGS. 11 to 16 show various interrupt routines. In FIG. 10, P1 denotes an initialization processing step which must be performed immediately after power is switched on. This includes, for example, clearing of a quantity representing the correction factor, designated in the following as the quantity ΔT and computed as described hereinafter. Next, in step P2, the period T N of output pulses from position sensor 4 is inverted and multiplied by a constant, to obtain the engine speed of rotation N E . A reference position interrupt routine is then executed to determine the value of the pulse period T N , at the timing of a rising edge of an output pulse from reference position sensor 4 (shown in FIG. 9(b)). The processing flow of this interrupt routine is shown in FIG. 11. First, in step R1, a timer value t i is read in, on a rising edge of a pulse of the reference position sensing signal V b shown in FIG. 9(b). The difference between this timer value t i and the value t i-1 of the preceding cycle is then computed in step R2, to obtain the new period T N (=t i -t i-l ). The actual phase difference T P (=t i -t k ), i.e. the actual injection phase difference with respect to the reference crankshaft position, is then obtained in step R3.
The timer value t k is obtained as follows. At the timing of a rising edge of a pulse of the phase signal V d produced from phase sensor 6D, shown in FIG. 9(d), the phase signal interrupt routine shown in FIG. 12 is activated. During the first step R4 of this routine, a timer value t k is computed, which is used in the computation step R3 mentioned above.
Referring again to FIG. 10, following step P2, upon return to the main routine, the actual injection quantity Q is computed in a processing step P3. In this step, a program interrupt is executed, at the point in time when A/D conversion operation, performed during a periodic interrupt subroutine 1 shown in FIG. 14 has been completed. In this program interrupt routine, the actual injection quantity A is obtained from the time difference T Q that is derived during the program interrupt routine shown in FIG. 15. The fixed time interrupt routine shown in FIG. 14 is activated and executed at regular fixed intervals, with a timer value T ST being read in as the first step 37 of the routine. A/D conversion by A/D converter 11 is then initiated (step R8). On completion of this A/D conversion, while the program is returning to the main routine, a jump is performed to the program interrupt routine shown in FIG. 15. In the first step R9 of this interrupt routine, the timer value T E corresponding to the point of completion of the A/D conversion is read. The time interval T ST is subtracted from the time interval T E , to obtain the time interval T Q (step R10). T Q expresses the value of the output pulse width from A/D converter 11, and hence varies in accordance with the actual injection quantity Q, i.e. the actual amount of fuel which is currently being input to each cylinder in a fuel injection operation.
Referring again to FIG. 10, in the next processing step P3, the actual injection quantity Q is computed from the value T Q .
In the next processing step P4, a target value of fuel injection phase difference T B is computed from the speed of rotation N E and the actual injection quantity Q.
In step P5, a judgement is made as to whether or not the current operating condition of the engine is such that an updated value for the compensation amount ΔT can be computed. More specifically, a judgement is made as to whether the disel engine is currently running in an operating condition which will enable accurate and stable firing time data to be obtained from the output signal of the firing time sensor 5. In the present embodiment, this judgement determines whether or not the engine operating condition currently corresponds to a position within the region W shown in FIG. 17, i.e. whether the fuel injection quantity Q is within a predetermined range while at the same time the engine speed of rotation N E is within a predetermined range. In the example of FIG. 17 the region W corresponds to engine operation at medium values of engine speed and engine load. If it is judged that the engine operating conditions are suitable for updating the compensation quantity ΔT, then processing proceeds to step P6. In this step, the value of T TS is obtained, in the same way as the value of T B in step P4, by mapping or by computation.
Next, in step P7, the actual firing time T TP (shown in FIG. 9(c)) is computed. When the rising edge of a pulse of the signal from the firing time sensor 5 occurs, an actual timing signal interrupt routine, shown in FIG. 13, is activated. In step R5 of this routine the timing of a rising edge of the output signal from sensor 5 is read , as time t j . The difference T TP between this value t j and the previously read in value t i is then computed in step R6. In the succeeding step P8, the compensation quantity ΔT is either increased or decreased, in accordance with the difference between the target firing time value T TS and the actual firing time value T TP , such as to bring T TS and T TP towards coincidence. Processing then advances to step P9.
If on the other hand it is judged during step P5 that the current engine operating condition is not suitable for acquiring data to compute a new value of the correction factor ΔT, then the value of ΔT is held unchanged from the previous processing cycle, and a jump is performed to step P9.
In step P9, the basic target phase difference T B is added to the correction factor ΔT, to thereby obtain a post-compensation target phase difference T S , i.e. T S =T B +ΔT. Next, in step P10, the actual phase difference T P is computed. However it should be noted that it would be equally possible to utilize the value of T B which is derived as described above in step P4.
Next, in step P11, the periodic interrupt routine 2 shown in FIG. 16 is executed, whereby the value D of duty ratio of the drive pulses to be applied to electromagnetic valve 37 (shown in FIG. 3) is computed. This is computed on the basis of the deviation between the target phase difference Ts and the actual phase difference T p , such as to bring this deviation to zero. That is to say, the duty ratio of the drive pulses is adjusted such that the pressure within chamber (in FIG. 3) causes timing piston 30, and hence roller ring 32, to be set to a position whereby the fuel injection phase difference deviation is reduced to zero.
Processing then returns to step P2, and the sequence of processing steps described above is repeated, to obtain another value of the output duty ratio D. In this way, each time a program loop is completed, the periodic interrupt routine shown in FIG. 16 is executed, consisting of a periodic interrupt processing step R11 followed by computation of a new value of duty ratio D in step R12. This computation of a value for duty ratio D is performed in synchronism with output of a pulse from output circuit 15, and is used to determine the pulse width.
In the description of the flow charts given above, the actual injection quantity Q is employed as a parameter for computing the basic target phase difference T B and the target firing time T TS and in judging whether the engine operation condition is suitable for acquiring data representing engine operating parameters, for use in computing a new value of correction factor ΔT. However it should be noted that it would be equally possible to utilize some other quantity for this purpose. Specifically, it would be possible to directly replace the actual injection quantity Q in the above description by a value representing the position of the accelerator pedal (indicated as α in FIG. 17).
Furthermore in the above, the present invention is described as being applied to a distributor type of fuel injection pump. However the invention is equally applicable to a diesel engine system employing a fuel injection pump of the type whereby a phase difference between the pump driveshaft position and the engine crankshaft position is converted into a fuel injection timing value.
In addition, with the above embodiment the toothed wheel 6D1 of phase sensor 6D is formed with tooth protrusions which result in the generation of two signal pulses for each revolution of the fuel pump driveshaft (i.e. two pulse for every two revolutions of the engine crankshaft). This matches the number of teeth of the crankshaft reference position sensor 4. However if fuel injection quantity control is to be performed in addition to injection timing control, then since only one signal pulse is produced for each revolution of the engine crankshaft with the described embodiment it would be difficult to derive sufficiently detailed engine speed data if these signal pulses are to be employed as engine speed data for fuel injection quantity control. If injection quantity control is also to be implemented, therefore, the toothed wheel embodiment shown in FIG. 19 is preferable for use as the toothed wheel of the phase sensor 6D, which detects the phase difference between the fuel injection timings and a reference engine crankshaft position as described hereinabove. The number of teeth disposed around the periphery of the toothed wheel in the example of FIG. 19 is increased to 64. It is assumed that the engines has 4 cylinders, and there are provided four positions around the periphery of toothed wheel 6D1 at which a tooth gap occurs, designated as 6Da to 6D d respectively, with each tooth gap corresponding to the position for fuel injection into a specific cylinder The sensor signal waveform which will be obtained from the phase sensor 6D in this case will be as shown in FIG. 20. This signal is input to microcomputer 14, which measures the time from the rising edge of each pulse of the signal until the rising edge of the succeeding pulse, and in this way detects the timings corresponding to the tooth gaps 6Da to 6Dd, to thereby define time points as designated by G in FIG. 20. Such a time point G can be utilized to derive the fuel injection phase difference, which is thereafter employed for control of fuel injection timing in the same way as the injection phase difference derived by the previous embodiment, and in addition can be employed for fuel injection quantity control. In this case, even if the rate of input of engine speed data is high, stable and accurate fuel quantity control can be attained.
With the present invention, fuel injection timing control of a diesel engine is performed essentially by feedback employing time data derived from fuel injection timing phase difference data, i.e. phase difference with respect to a reference engine crankshaft position, with this data being corrected by a correction factor which is computed based on actual firing times occurring within a cylinder of the diesel engine. This enables feedback signals to be derived over the entire operating range of the engine, and provides stable control to be attained. Furthermore the effects of deviations of the fuel injection timings from a target value, resulting from mechanical tolerances in the pump structure, engine mechanical tolerances, and errors resulting from wear as the engine operating life increases, are eliminated. In addition, closed-loop injection timing control is maintained over the entire engine operating range, by ensuring that acquisition and application of fuel injection timing phase difference correction data is only performed when it is known that this correction data can be acquired in an accurate and stable manner, i.e. only while the engine is running within a specific range of operating conditions. When it is judged that the engine is operating outside the latter range, closed-loop control is continued, employing the most recently computed value of correction factor. In this way, precise and stable control of the fuel injection timing is ensured.
Although the present invention has been described in the above with reference to specific embodiments, it should be noted that various changes and modifications to the embodiments may be envisaged, which fall within the scope claimed for the invention as set out in the appended claims. The above specification should therefore be interpreted in a descriptive and not in a limiting sense. | An apparatus for controlling the timing of fuel injection into a diesel engine, including means for computing a target time at which injection should occur and means for sensing when injection actually occurs, with respect to a reference crankshaft position, feedback control means for adjusting the actual injection time to bring this into coincidence with the target injection time, means for sensing when firing of fuel within an engine cylinder actually occurs and for computing a target firing time based on the current operating status of the engine. A compensation factor is computed based on the difference between the actual and target firing times, and is utilized to modify the actual fuel injection time such as to bring the actual and target firing times into coincidence. Means are included for judging whether the engine operating status will permit reliable firing time data to be acquired, and for selectively enabling and inhibiting computation of successive new values of compensation factor based on this judgement. | 5 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to leashes that mechanically couple a human being to a mobile sports device, such as a surfboard, snowboard, skateboard, wakeboard or bodyboard.
BACKGROUND OF THE INVENTION
[0002] Numerous sports devices include a board element upon which a user stands and balances during use. It is often desirable to provide a leash coupling the user to the board element to increase the ease of management and retrieval of the board element. In the prior art a first end of the leash is typically attached to the trailing section of the board element. Board leashes may include a second end having a wrist or ankle strap for attachment to the user's body. The leash is preferably long enough to reduce the likelihood of injury to the user, e.g., a surfer, when the user becomes separated from the board element, while enabling the surfer to readily recover the board element for remounting.
[0003] A rail saver comprising a strip of fabric wider than the cord may optionally be provided to protect the board element from damaging contact with the cord. The rail saver may increase undesirable drag that degrades the mobility of the board element.
[0004] The prior art provides leashes that enable removal of the leash from the user as desired by the user, while securing the leash to the board by means of a cord knotted about a pin located within a plug assembly. The plug assembly (hereafter “plug”) may be fitted into a recessed area of the board, whereby the plug and its pin are located below a substantially planar top surface of the board. The cord may be untied from the pin to facilitate storage of the sports device. Undesirably, the cord may also be detached from the other leash elements and misplaced between uses of the leash.
[0005] The prior art includes attempts to improve leash attachments means. U.S. Pat. No. 5,098,324 discloses a combination rail saver and key holder. U.S. Pat. No. 5,127,861 presents a combination leash attachment and lock for surfboard. U.S. Pat. No. 5,775,965 provides a leash release mechanism for surfboards and the like. U.S. Pat. No. 6,390,872 discloses a surfboard having improved leash plug anchoring. And U.S. Pat. No. 7,013,684 teaches of a cable lock coupling and lock system for surfboards
[0006] The entire disclosures of each and every patent mentioned in this present disclosure, to include U.S. Pat. Nos. 5,098,324; 5,127,861; 5,775,965; 6,390,872; and 7,013,684 as noted above, are incorporated herein by reference and for all purposes.
[0007] There is therefore a long felt need to provide a detachable leash attachment means that more conveniently and manageably affects attachments and detachments of a leash to and from a board element of a sports device. It is the primary object of the present invention to provide a leash connection means that supports comfortable use of the sports device. This and other objects of the invention will become clear from an inspection of the detailed description of the invention and from the appended claims
OBJECTS OF THE INVENTION
[0008] It is an object of the present invention to provide a detachable leash attachment means for attaching and detaching a leash to an element of a sports equipment.
[0009] It is an additional object of certain alternate preferred embodiments of the present invention to provide a detachable leash attachment means for attaching and detaching a leash to a surfboard.
SUMMARY OF THE INVENTION
[0010] Towards these and other objects that will be made obvious in light of the present disclosure, a first alternate preferred embodiment of the method of the present invention is a board connection module provides a fixture or flexible base attached to a rail saver of a leash of a board of a sports device. A strap attached to the base fits around a pin attachment of a surfboard leash plug. The strap is then detachably secured to the base by means of closure material strips, such as hook and loop fasteners.
[0011] A second alternate preferred embodiment of the present invention includes a hook driven by a manually adjustable cam, wherein the hook is driven by the cam to attach to, and release from, the attachment pin of the surfboard leash plug by manual manipulation of the cam. The leash may alternatively be attached to a surfboard, a bodyboard, a skim board, a skate board, or other suitable sports device board.
[0012] A third alternate preferred embodiment of the present invention includes a tapped hook driven by a manually adjustable tapped handle, wherein the tapped hook is driven by the cam to attach to, and release from, the attachment pin of the surfboard leash plug by manual rotation of the tapped handle.
[0013] A fourth alternate preferred embodiment of the present invention includes a spring biased lever arm and a curved post that are used to detachably capture the attachment pin of the surfboard plug.
[0014] A fifth alternate preferred embodiment of the present invention includes a looped cord that may be removabley located around the attachment pin of a surfboard plug to couple a surfboard leash to a surfboard.
[0015] The foregoing and other objects, features and advantages will be apparent from the following description of the preferred embodiment of the invention as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] These, and further features of the invention, may be better understood with reference to the accompanying specification and drawings depicting the preferred embodiment, in which:
[0017] FIG. 1 illustrates a first alternate preferred embodiment of the present invention, or first version, wherein a strap is positioned about a surfboard plug attachment pin;
[0018] FIG. 2 illustrates the first version of FIG. 1 in an attachment state;
[0019] FIG. 2A is a side view of the first version of FIG. 1 in the attachment state of FIG. 2 ;
[0020] FIG. 3 is a top view of a second alternate preferred embodiment of the present invention, or second version;
[0021] FIG. 4 is a side view of the second version of FIG. 3 , wherein a cam and hook are used to couple a surfboard leash to a surfboard;
[0022] FIG. 5 is an additional side view of the second version of FIGS. 3 and 4 , and wherein the hook and cam are in a release state and the surfboard leash is detached from the surfboard;
[0023] FIG. 6 is a side view of a third alternate preferred embodiment of the present invention, or third version, wherein a threaded hook is used to couple a surfboard leash to a surfboard;
[0024] FIG. 6A is a top view of the third version of FIG. 6 ;
[0025] FIG. 7 is a side view of a fourth alternate preferred embodiment of the present invention, or fourth version, wherein a spring biased lever arm and a curved post are used to couple a surfboard leash to a surfboard;
[0026] FIG. 7A is a top view of the fourth version of FIG. 7 ;
[0027] FIG. 8 is a perspective view of a fifth alternate preferred embodiment of the present invention, or fifth version, wherein a looped cord is positioned about a surfboard plug attachment pin;
[0028] FIG. 9 is a perspective view of a fifth version of FIG. 8 , wherein the fifth version is in an attaching state and the surfboard leash is detachably coupled with the leash plug attachment pin; and
[0029] FIG. 9A is a top view of the fifth version of FIG. 9 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0030] The following description is provided to enable any person skilled in the art to make and use the invention and sets forth the best modes contemplated by the inventor of carrying out his or her invention. Various modifications, however, will remain readily apparent to those skilled in the art, since the generic principles of the Present Invention have been defined herein.
[0031] Referring generally to the Figures and particularly to FIGS. 1 , 2 and 2 A, FIG. 1 illustrates a first preferred embodiment of the present invention 2 , or first version 2 in an open position A, wherein the first version 2 is coupled with a surfboard leash cord 4 . The surfboard leash cord 4 may be comprised within a suitable surfboard leash known in the art, such as a FCS CLASSIC LEASH(™) as marketed by Fin Control Systems of 5-7 By the Sea Road, Mona Vale, NSW 2103, Australia.
[0032] The first version 2 is configured to be removabley attached to a leash plug 6 of a surfboard 8 . The leash plug 6 may be a suitable leash plug known in the art having a surfboard leash plug pin 6 A, such as a SHAPERS LEASH PLUG(™) marketed by Shapers Australia of 9/7 Traders Way, Currumbin, Gold Coast, Queensland, Australia, 4223. The plug pin 6 A that is typically a solid cylindrical pin made from a strong, rigid material (e.g., metal, composite, plastic, etc.). However, it is to be understood that pin 6 A could also be hollow and have a non-cylindrical external geometry without departing from the scope of the present invention.
[0033] The first version 2 includes a fixture 10 , a flap 12 and a strap 14 . The fixture 10 is adhered to a rail saver 16 of the leash 4 by stitching, heat treatment, and/or a water resistant adhesive, or other suitable means known in the art, at an attachment surface 10 A of the fixture 10 , as per FIG. 2 . The first version 2 may be sized, shaped and made of suitable materials known in the art and as applicable to and compatible with uses and configurations of surfboard leashes.
[0034] It is understood that the surfboard 8 may be replaced with a bodyboard, a skim board, a skate board, or other suitable sports device board.
[0035] The strap 14 extends from the fixture 10 and is configured to be wrapped around the attachment pin 6 A by a user while the attachment pin 6 A remains fixed within a positioning cup 6 B of the leash plug 6 of the surfboard 8 . A pair of first closure strips 18 A & 18 B are each separately and permanently attached on opposite sides of the strap 14 . The first closure strips 18 A & 18 B are each positioned to separately couple with one of a pair of second closure strips 20 A & 20 B of the flap 12 and the fixture 10 . The first closure strips 18 A & 18 B and the second closure strips 20 A & 20 B are selected to provide a detachable closure of the first version 2 in a coupling position A, as shown in FIG. 2 . The first closure strips 18 A & 18 B and the second closure strips 20 A & 20 B may be matched and paired and may alternately comprise hook and loop fastener strip material, such as VELCRO(™) closure material. For example, the first closure strips 18 A & 18 B may present small nylon hooks and the second closure strips 20 A & 20 B may present small nylon loops, wherein the hooks and loops of the first closure strips 18 A & 18 B and second closure strips 20 A & 20 B are configured to detachably couple the attachment strip 14 with the flap 12 .
[0036] Referring now generally to the Figures and particularly to FIGS. 2 and 2A , FIG. 2 is illustration of the first version 2 of FIG. 1 in an attachment position B, and FIG. 2A is a side view of the first version 2 in the attachment position B. In the attachment position B, the first closure strips 18 A & 18 B and each separately and detachably coupled with one of the second closure strips 20 A & 20 B, and the strap 14 is wrapped around the leash plug pin 6 A.
[0037] Referring now generally to the Figures and particularly to FIGS. 3 , 4 and 5 , FIG. 3 is a top view of a second preferred alternate preferred embodiment of the present invention, or second version 24 . The second version 24 includes a housing 26 and a movable cam 28 . The housing 26 is attached to a rail saver 30 of the surf leash cord 4 by rail saver pins 32 and is detachably coupled with the surfboard 8 .
[0038] Referring now to FIG. 4 , the movable cam 28 is shown in a side view and in a cam closed position C, wherein the cam presses against a curved recessed surface 31 and a hook 32 of the second version 24 is pulled up in compression and against the surfboard leash plug attachment pin 6 A. The hook 32 of the second version 24 is rotatably attached to the movable cam 28 and extends from a cam pin 34 through a hook aperture 36 of the housing 26 . The cam pin 34 is fixed to the housing 26 and the movable cam 28 is rotatably attached to the cam pin 34 . The cam pin 34 is typically a solid cylindrical pin made from a strong, rigid material (e.g., metal, composite, plastic, etc.). However, it is to be understood that cam pin 34 could also be hollow and have a non-cylindrical external geometry without departing from the scope of the present invention. The rotatable coupling of the hook 32 and the movable cam 28 to the housing 26 enables the cam 32 and hook 32 to be moved from the cam closed position C to a cam detach position D, as per FIG. 5 . A user may alternatively transition the second version 26 from the cam closed position C to the cam detach position D by manually rotating a handle 36 of the movable cam 28 about the cam pin 34 . A bottom surface 38 of the housing 26 is configured to press against a top surface 40 of the surfboard 8 when the hook 32 is pulled against the surfboard attachment pin 6 A.
[0039] Referring now generally to the Figures and particularly to FIGS. 6 and 6A , FIG. 6 shows a third alternate preferred embodiment of the present invention 42 , or third version 42 , wherein a tapped hook 44 is alternately positioned towards and away from a tapped handle 46 , whereby rotation of the tapped handle 46 in a first rotational direction pulls a hook section 48 of the tapped hook 44 towards a third version housing 50 of the third version 42 , and rotation of the tapped handle 46 in an opposite rotational direction drives the tapped screw hook section 48 away from the third version housing 50 . A user may secure the third version 42 to the surfboard 8 by (1.) dropping the hook section 48 into the leash cup 6 to place the hook section 44 below the surfboard attachment pin 6 A; (2.) positioning a bottom surface 52 of the third version housing 50 in contact with the surfboard top surface 40 ; and (3.) turning the tapped handle 42 in the first rotational direction to pull the hook section 44 towards the third version housing 46 and up against the surfboard attachment pin 6 A. The user may then detach the third version 42 from the surfboard 8 by turning the tapped handle 46 in the opposite rotational direction until the tapped hook 44 may be removed from the surfboard leash cup 6 B. A tapped section 54 of the tapped hook 44 and a tapped channel 56 of the tapped handle 46 are configured to engage together to drive the tapped hook 44 along an third version axis E, and the rotational movement of the tapped handle 46 occurs within a plane F that is normal to the third version axis E.
[0040] FIG. 6A is a top view of the third version 42 showing the tapped handle 46 and the third housing 50 . The tapped handle 46 is substantively circular and has a one-inch diameter that is normal to the third version axis E.
[0041] Referring now generally to the Figures and particularly to FIGS. 7 and 7A , FIG. 7 illustrates a fourth preferred alternate embodiment of the present invention 58 , or fourth version 58 , wherein a curved post 60 extends away from a fourth bottom surface 62 of a fourth version housing 64 . Both a release arm 66 and a lever arm 68 are coupled to a spring-loaded pin 70 . The spring-loaded pin 70 is coupled with the first version housing 64 and provides a spring bias force to drive a lever end 72 of the lever arm 68 against a hook end 74 of the curved post 60 . The spring bias force may be in the range of from less than one pound to over 100 pounds, and more preferably between 2 pounds and 10 pounds.
[0042] The fourth version 58 is configured to enable the fourth bottom surface 62 of the fourth version housing 52 to be compressed against the top surface 40 of the surfboard 8 when the attachment pin 6 A of the leash cup 6 B is captured by the curved post 60 and the lever arm 68 as shown in the attached position G as illustrated in FIG. 7 . The user may detach the fourth version 58 from the surfboard 8 by pressing the release arm 66 towards the fourth bottom surface 62 of the fourth version housing 64 and in opposition to the spring biased force provided by the spring loaded pin 70 . As the user rotates the release arm 66 against the force of the spring loaded pin 70 , the lever arm 68 is pulled away from the curved post 60 and the user may remove the fourth version 58 from contact with the surfboard leash cup 6 B.
[0043] FIG. 7A is a top view of the fourth version 58 .
[0044] Referring now generally to the Figures and particularly to FIGS. 8 , 9 and 9 A, FIG. 8 illustrates a fifth version of the present invention 76 , or fifth version 76 , in a detached position H. The fifth version 76 includes a base strip 78 , an attachment strip 80 , a guide strip 82 and a looped cord 84 . The base strip 78 . is attached to the surf leash cord 4 and the rail saver 16 by stitching, heat treatment, and/or water resistant adhesive, or other suitable means known in the art. The an attachment strip 80 , the guide strip 82 and the looped cord 84 are attached to the base strip 78 by stitching, heat treatment, and/or water resistant adhesive, or other suitable attachment means known in the art.
[0045] The looped cord 84 is configured and sized, and as pictured in FIGS. 9 and 9A , to (1.) extend from the base strip 78 ; (2.) wrap around the surfboard attachment pin 6 A within the confines of the leash cup 6 B; (3.) extend between the guide strip 82 and the base strip 78 ; and (4.) accept an extension of a first section 80 A of the attachment strip 80 within the looped cord 84 .
[0046] FIG. 9 is a perspective view and FIG. 9A is a side view of the fifth version in a capturing position I. In practice, the user may draw the looped cord 84 first through the leash cup 6 B and around the leash cup attachment pin 6 A, then in between the guide strip 82 and the base strip 78 , and finally detachably capture the looped cord 84 by means of the attachment strip 80 in the capturing position I. The attachment strip includes the first section 80 A, an attached section 80 B and a second section 80 C. The attached section 80 B is attached to the base strip 78 by stitching, heat treatment, and/or a water resistant adhesive, or other suitable means known in the art. The first section 80 A includes a pair first closure strips 18 A and 18 B. The attached section 80 B includes a second closure strip 20 A and the second section 80 C includes another second closure strip 20 B. The first closure strips 18 A 18 B and the second closure strips 20 A & 20 B are positioned to enable a detachable capture of the looped cord 84 . As discussed above, the first closure strips 18 A & 18 B and the second closure strips 20 A & 20 B may be matched and paired, and may alternately comprise hook and loop fastener strip material, such as VELCRO(™) closure material. For example, the first closure strips 18 A & 18 B may present small nylon hooks and the second closure strips 20 A & 20 B may present small nylon loops, wherein the hooks and loops of the first closure strips 18 A & 18 B and second closure strips 20 A & 20 B are configured and positioned to detachably couple the first section 80 A with the second section 80 B while capturing the looped cord 66 in capturing position I. The user may, from capturing position I, release the fifth version 76 from the surfboard 8 by manually separating first closure strips 18 A & 18 B from the second closure strips 20 A & 20 B and withdrawing the looped cord 84 from the leash cup 6 B.
[0047] The above description is intended to be illustrative, and not restrictive. The examples given should only be interpreted as illustrations of some of the preferred embodiments of the invention, and the full scope of the invention should be determined by the appended claims and their legal equivalents. Those skilled in the art will appreciate that various adaptations and modifications of the just described preferred embodiments can be configured without departing from the scope and spirit of the invention. The scope of the invention as disclosed and claimed should, therefore, be determined with reference to the knowledge of one skilled in the art and in light of the disclosures presented above. | A board connection module for detachably coupling a surfboard with a surfboard leash is provided. The leash may include a rail saver, a leash length, and an ankle strap. The leash length and rail saver couple the ankle strap with the board connection module. The board connection module detachably anchors the rail saver with an attachment pin of a leash cup of the surf board. The board connection module may engage the attachment pin of the leash cup with (a.) a cam lock; (b.) a cam lock configured with a push release element; (c.) a hooked shaft having a circular threaded end; (d.) a hook and loop attachment fabric. | 1 |
PRIORITY CLAIM
[0001] The present nonprovisional U.S. patent application claims priority to and benefit from pending Korean patent application no. 10-2013-0124649 filed Oct. 18, 2013.
FIELD AND BACKGROUND OF THE INVENTION
[0002] The present invention relates, in general, to a nail polish bottle intended to contain nail polish liquid therein, and, more particularly, to a nail polish bottle having a pressure opening and closing valve.
DESCRIPTION OF THE RELATED ART
[0003] Korean Patent Laid-Open Publication No. 10-2002-0021579 (published on Mar. 21, 2002) disclosed an “Automatic Nail Polish Bottle”. The automatic nail polish bottle includes a cap, a body, a tube, a covering member, a brush support plate, a brush, a button, and a spring. Internal threads are formed in the cap. External threads are formed on the body to allow the body to be fastened to the cap. The tube is provided in the body to contain nail polish liquid therein. The covering member is movably provided on an upper portion of the body to cover the tube. The brush support plate is screwed to an inlet of the tube and has a hole to permit the passage of the nail polish liquid. The brush is provided on the brush support plate. The button is provided on an outer surface of the body to press the tube. The spring is provided at a predetermined position on an inner surface of the body to restore the button to its original state.
[0004] However, the automatic nail polish bottle is problematic in that, when one desires to use the bottle, the covering member should be pushed in an opening direction, and, after the bottle has been used, a user should push the covering member in a closing direction, so that it is inconvenient to use, and, unless the covering member is closed after the use, the nail polish liquid may unexpectedly leak from the body.
[0005] The foregoing is intended merely to aid in the understanding of the background of the present invention, and is not intended to mean that the present invention falls within the purview of the related art that is already known to those skilled in the art.
[0006] There is a compelling need for a nail polish bottle that prevents leakage of the nail polish and is convenient to use and overcomes the drawbacks of the prior art.
SUMMARY OF THE INVENTION
[0007] One aspect of the present invention is a nail polish bottle, comprising a bottle body; a cap including a disc portion having a center hole and a plurality of air holes formed in the disc portion, the cap having a discharge passage disposed above the center hole and external-air introduction grooves in flow contact with the air holes of the disc portion; and a pressure opening and closing valve mounted to the disc portion such that a skirt portion of the valve sits below the disc portion and such that a top of the valve is above the disc portion, when internal pressure in the bottle body is increased by squeezing the bottle, the skirt portion presses against the disc portion to close the air holes and the top of the valve opens allowing nail polish to flow through the discharge passage if the bottle is upside-down, and when the internal pressure is restored by releasing a squeezing force, the skirt portion moves away from the disc to open the air holes and the top of the valve closes to block polish from escaping through the discharge passage.
[0008] The bottle may further include a structure wherein the top of the valve comprises a pair of pieces that either contact each other to close or else move away from each other to open, depending upon the internal pressure of the bottle body. The pieces may be rectangular pieces. The pair of pieces may contact each other to keep an upper end of a hollow portion of the valve closed until pressure is exerted through the hollow portion. The upper end of the hollow portion of the valve may be above the center hole of the disc portion. The hollow portion of the valve may be inward of a cylindrical portion of the valve. The external air-introduction grooves may have a small enough clearance such that a viscous nail polish in the bottle does not leak out of the bottle through the air holes and grooves even when the bottle is upside down before the bottle is squeezed. It may be the case that when internal pressure in the bottle body. is increased by squeezing the bottle, the skirt portion may. press against the disc portion as a result of radially distal ends of the skirt portion flex toward the disc portion.
[0009] A further aspect of the present invention may comprise a nail polish bottle, comprising a bottle body; a cylindrical cap fastened to the bottle body, and including a disc portion in the cap, with a center hole and a plurality of air holes. formed in the disc portion; a pressure opening and closing valve mounted to the disc portion, a top of the valve above the center hole opening or closing depending on internal pressure of the bottle body, the valve also opening or closing the air holes of the disc portion depending on internal pressure of the bottle body; an inner cap member mounted to the cap, with a discharge passage disposed above the center hole; and an outer cap member mounted to the cap, with at least one external-air introduction groove that is formed on the outer cap member and that is in flow contact with at least one air hole of the disc portion.
[0010] This aspect of the present invention may also be structured so that upon squeezing the bottle body when the bottle is upside-down, a skirt portion of the valve presses again a lower surface of the disc portion so as to block the air holes of the disc portion, while internal pressure forces a gap between pieces of a top of the valve, thereby allowing nail polish to flow through the gap out of the bottle. In some versions, the pieces of the top of the valve comprise a pair of rectangular pieces that may be integrally joined to a top of a cylindrical portion of the valve. In some versions, the rectangular pieces may come into contact with each other to keep an upper end of a hollow portion defined by the cylindrical portion of the valve closed, and, if pressure is exerted through the hollow portion, the rectangular pieces may move away from each other. In certain versions, restoring internal pressure in the bottle as before the bottle was squeezed may close the gap so as to block further flow of nail polish out of the bottle through said gap and may restore the skirt portion to a position away from the disc portion thereby allowing external-air to enter the bottle body through the at least one external-air introduction groove. In some versions, an enlarged groove is formed in the inner cap member and wherein the inner cap member is covered by the outer cap member, the outer cap member coming into contact with an inner circumference of an upper end of the cap.
[0011] There may be versions structured such that the cylindrical cap is fastened to a bottleneck portion of the bottle body, and wherein a helical fastening portion is formed on the bottleneck portion.
[0012] The cap may comprise an upper cylindrical portion and a lower cylindrical portion, the upper cylindrical portion integrally formed on an upper end of the lower cylindrical portion in a stepped configuration.
[0013] In some versions, a helical fastening portion is formed on an inner circumference of the lower cylindrical portion, a stopper protrusion is formed above the helical fastening portion, and the disc portion is formed above the stopper protrusion. In some versions, a locking protrusion is formed on an upper end of an inner circumference of the upper cylindrical portion.
[0014] A skirt portion of the valve may be provided on a lower end of a cylindrical portion. The skirt portion may flex toward the air holes and may block the air holes of the disc portion when internal pressure is increased in the bottle body.
[0015] In some versions, a pair of rectangular pieces is integrally provided on a top of the cylindrical portion, the rectangular pieces coming into contact with each other to keep an upper end of the hollow portion closed unless increased internal pressure from the bottle body is exerted through the hollow portion.
[0016] In some versions of the present invention, the inner cap member comprises a body having a truncated cone shape, and a cylindrical portion is integrally formed on an upper end of the body in such a way as to extend upwards therefrom, and an enlarged groove is defined in the body, and a discharge passage extends from an upper end of the enlarged groove in such a way as to pass through the cylindrical portion, and a pocket is formed in an upper portion of the body so as to accommodate a brush therein, and the cylindrical portion is disposed in the brush, with the discharge passage defined in the cylindrical portion.
[0017] In some versions, the outer cap member comprises a cylindrical portion, with an elliptical hollow portion formed in the cylindrical portion, and an extended inclined portion is integrally formed on a lower end of the cylindrical portion, and an enlarged cylindrical portion is provided on a lower end of the extended inclined portion, and an enlarged inclined hole is formed in a lower end of the hollow portion corresponding to the extended inclined portion in such a way as to extend downwards therefrom, and an inner inclined surface is formed around the enlarged inclined hole, and a plurality of external-air introduction grooves is formed on the extended inclined portion and an outer circumference of the enlarged cylindrical portion.
[0018] The present invention is intended to propose a nail polish bottle, in which a pressure opening and closing valve is mounted to an outlet of a bottle body, so that, if a bottle body made of flexible material, such as a synthetic resin material, is pushed, the internal pressure of the bottle body is increased and thus the pressure opening and closing valve is opened, thereby discharging nail polish liquid from an interior of the bottle body to a brush and, if force is eliminated from the bottle body, the internal pressure of the bottle body is restored to its original state and thus the pressure opening and closing valve is closed, thereby automatically preventing the nail polish liquid from leaking.
[0019] In a further aspect of the present invention, there is provided a nail polish bottle, including a bottle body; a cylindrical cap fastened to a bottleneck portion of the bottle body, and including a disc portion in the cap, with a center hole and a plurality of air holes formed in the disc portion; a pressure opening and closing valve mounted to the disc portion, the pressure opening and closing valve opening or closing the center hole and the air hole of the disc portion; an inner cap member mounted to the cap, with a discharge passage and an enlarged groove formed in the inner cap member; and an outer cap member mounted to the cap, with a plurality of external-air introduction grooves formed on the outer cap member, whereby the inner cap member is covered by the outer cap member that comes into contact with an inner circumference of an upper end of the cap, and the enlarged groove of the inner cap member coupled to the discharge passage is disposed above the center hole of the disc portion.
[0020] The bottle body may be made of a flexible nylon material by injection molding, and a side portion of the bottle body may be compressed by external force and then may be restored to its original state, with a helical fastening portion formed on the bottleneck portion.
[0021] The cap may include an upper cylindrical portion and a lower cylindrical portion, with the upper cylindrical portion being integrally formed on an upper end of the lower cylindrical portion in a stepped configuration, and a helical fastening portion may be formed on an inner circumference of the lower cylindrical portion, and a stopper protrusion may be formed above the helical fastening portion, and the disc portion may be formed above the stopper protrusion, and the center hole and the plurality of air holes may be formed in the disc portion, with a locking protrusion formed on an upper end of an inner circumference of the upper cylindrical portion.
[0022] The pressure opening and closing valve may be made of a silicone material by injection molding, and a skirt portion may be provided on a lower end of a cylindrical portion that has a hollow portion therein, and a protruding step may be provided on an upper end of an outer circumference of the cylindrical portion, and a pair of rectangular pieces may be integrally provided on a top of the cylindrical portion, the rectangular pieces coming into contact with each other to keep an upper end of the hollow portion closed, and, if pressure is exerted through the hollow portion, the rectangular pieces may move away from each other.
[0023] The inner cap member may include a body having a truncated cone shape, and a cylindrical portion may be integrally formed on an upper end of the body in such a way as to extend upwards therefrom, and an enlarged groove may be defined in the body, and a discharge passage may extend from an upper end of the enlarged groove in such a way as to pass through the cylindrical portion, and a pocket may be formed in an upper portion of the body in such a way as to accommodate a brush therein and to be around a lower end of the cylindrical portion, and the cylindrical portion may be disposed in the brush, with the discharge passage defined in the cylindrical portion.
[0024] The outer cap member may include a cylindrical portion, with an elliptical hollow portion formed in the cylindrical portion, and an extended inclined portion may be integrally formed on a lower end of the cylindrical portion, and an enlarged cylindrical portion may be provided on a lower end of the extended inclined portion, and an enlarged inclined hole may be formed in a lower end of the hollow portion corresponding to the extended inclined portion in such a way as to extend downwards therefrom, and an inner inclined surface may be formed around the enlarged inclined hole, and a plurality of external-air introduction grooves may be formed on the extended inclined portion and an outer circumference of the enlarged cylindrical portion.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] Various embodiments are herein described, by way of example only, with reference to the accompanying drawings, wherein:
[0026] FIG. 1 is a perspective view showing a nail polish bottle according to one embodiment of the present invention in an assembled state;
[0027] FIG. 2 is an exploded perspective view showing the nail polish bottle according to one embodiment of the present invention;
[0028] FIG. 3 is a sectional taken along line A-A of FIG. 1 showing the nail polish bottle according to one embodiment of the present invention;
[0029] FIG. 4 is an enlarged view showing portion B of FIG. 3 in detail in accordance with one embodiment of the present invention;
[0030] FIG. 5 is a partial sectional perspective view showing a cap in accordance with one embodiment of the present invention;
[0031] FIG. 6 is a partial sectional perspective view showing a pressure opening and closing valve in accordance with one embodiment of the present invention;
[0032] FIG. 7 is a partial sectional perspective view showing an inner cap member in accordance with one embodiment of the present invention;
[0033] FIG. 8 is a partial sectional perspective view showing an outer cap member in accordance with one embodiment of the present invention; and
[0034] FIGS. 9 and 10 illustrate the use of the nail polish bottle according to one embodiment of the present invention, in which FIG. 9 shows a state in which a bottle body is pushed TO with the nail polish bottle turned upside down to get a manicure, and FIG. 10 shows a state in which the pushed bottle body is released.
DETAILED DESCRIPTION OF THE INVENTION
[0035] The following detailed description is of the best currently contemplated modes of carrying out the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.
[0036] Referring to FIGS. 1 to 4 , a nail polish bottle according to the present invention includes a bottle body 10 . A cylindrical cap 20 is fastened to a bottleneck portion 11 of the bottle body 10 , and includes a disc portion 23 in the cap 20 , with a center hole 21 and a plurality of air holes 22 formed in the disc portion 23 . A pressure opening and closing valve 30 is mounted to the disc portion 23 , and serves to open or close the center hole 21 and the air hole 22 of the disc portion 23 . An inner cap member 40 is mounted to the cap 20 , with a discharge passage 41 and an enlarged groove 42 formed in the inner cap member 40 . An outer cap member 50 is mounted to the cap 20 , with a plurality of external-air introduction grooves 56 formed on the outer cap member 50 . Thereby, the inner cap member 40 is covered by the outer cap member 50 that comes into contact with an inner circumference of an upper end of the cap 20 , and the enlarged groove 42 of the inner cap member 40 coupled to the discharge passage 41 is disposed above the center hole 21 of the disc portion 23 .
[0037] The bottle body 10 is made of a flexible nylon material by injection molding, and a side portion of the bottle body 10 is compressed by external force and then is restored to its original state, with a helical fastening portion 12 formed on the bottleneck portion 11 .
[0038] Referring to FIG. 5 , the cap 20 includes an upper cylindrical portion 24 and a lower cylindrical portion 25 , with the upper cylindrical portion 24 being integrally formed on an upper end of the lower cylindrical portion 25 in a stepped configuration. A helical fastening portion 26 is formed on an inner circumference of the lower cylindrical portion 25 . A stopper protrusion 27 is formed above the helical fastening portion 26 . The disc portion 23 is formed above the stopper protrusion 27 , and the center hole 21 and the plurality of air holes 22 are formed in the disc portion 23 , with a locking protrusion 29 formed on an upper end of an inner circumference of the upper cylindrical portion 24 .
[0039] Thus, as shown in FIGS. 3 and 4 , when the helical fastening portion 26 of the cap 20 is fastened to the helical fastening portion 12 formed on the bottleneck portion 11 of the bottle body 10 , the upper end of the bottleneck portion 11 is stopped by the stopper protrusion 27 , thus preventing the cap 20 from being excessively fastened to the bottleneck portion 11 of the bottle body 10 . The nail polish liquid contained in the bottle body 10 is discharged through the center hole 21 that is formed in the disc portion 23 of the cap 20 , and external air is introduced into the bottle body 10 through the air holes 22 of the cylindrical portion 23 .
[0040] Referring to FIG. 6 , the pressure opening and closing valve 30 is made of a silicone material by injection molding. A skirt portion 33 is provided on a lower end of a cylindrical portion 32 in which a hollow portion 31 is formed. A protruding step 34 is provided on an upper end of an outer circumference of the cylindrical portion 32 , and a pair of rectangular pieces 35 and 36 is integrally provided on a top of the cylindrical portion 32 . The rectangular pieces 35 and 36 come into contact with each other to keep an upper end of the hollow portion 31 closed. If pressure is exerted through the hollow portion 31 , the rectangular pieces 35 and 36 move away from each other.
[0041] Hence, as shown in FIG. 4 , the cylindrical portion 32 of the pressure opening and closing valve 30 is placed around the center hole 21 of the disc portion 23 formed in the cap 20 , so that the skirt portion 33 covers a lower surface of the disc portion 23 . The protruding step 34 is stopped by an upper surface of the disc portion 23 , so that the cylindrical portion 32 of the pressure opening and closing valve 30 is mounted around the center hole 21 of the disc portion 23 , and the skirt portion 33 blocks the air holes 22 formed in the disc portion 23 , from the lower surface of the disc portion 23 , thus preventing the nail polish liquid in the bottle body 10 from being introduced into the air holes 22 . In contrast, if the internal pressure of the bottle body 10 is reduced, the skirt portion 33 moves away from the lower surface of the disc portion 23 , so that the air hole 22 is opened.
[0042] Referring to FIG. 7 , the inner cap member 40 includes a body 43 having a truncated cone shape. A cylindrical portion 44 is integrally formed on an upper end of the body 43 in such a way as to extend upwards therefrom. AR enlarged groove 42 is defined in the body 43 . A discharge passage 41 extends from an upper end of the enlarged groove 42 in such a way as to pass through the cylindrical portion 44 . A pocket 46 is formed in an upper portion of the body 43 in such a way as to accommodate a brush 47 therein and to be around a lower end of the cylindrical portion 44 . The cylindrical portion 44 is disposed in the brush 47 , with the discharge passage 41 defined in the cylindrical portion 44 .
[0043] Referring to FIG. 8 , the outer cap member 50 includes a cylindrical portion 51 , with an elliptical hollow portion 52 formed in the cylindrical portion 51 . An extended inclined portion 53 is integrally formed on a lower end of the cylindrical portion 51 . An enlarged cylindrical portion 54 is provided on a lower end of the extended inclined portion 53 . An enlarged inclined hole 55 is formed in a lower end of the hollow portion 52 corresponding to the extended inclined portion 53 in such a way as to extend downwards therefrom. An inner inclined surface 57 is formed around the enlarged inclined hole 55 . A plurality of external-air introduction grooves 56 is formed on the extended inclined portion 53 and an outer circumference of the enlarged cylindrical portion 54 .
[0044] Thereby, as shown in FIG. 4 , the circumference of the upper end of the extended inclined portion 53 of the outer cap member 50 is locked by the locking protrusion 29 of the cap 20 so as to prevent unexpected removal. The body 43 of the inner cap member 40 is fitted into the enlarged inclined hole 55 of the outer cap member 50 , so that the body 43 of the inner cap member 40 comes into close contact with the inner inclined surface 57 of the outer cap member 50 , and thereby the brush of the inner cap member 40 is exposed to the outside through the hollow portion 52 of the outer cap member 50 .
[0045] An operation of the nail polish bottle according to the present invention configured as described above will be described in detail with reference to FIGS. 9 and 10 .
[0046] First, as shown in FIG. 9 , if the bottle body 10 is pushed in a direction of arrow 65 in a state in which the nail polish bottle is turned upside down for the purpose of a manicure, the rectangular pieces 35 and 36 of the pressure opening and closing valve 30 are moved away from each other by pressure. Simultaneously, the nail polish liquid 70 contained in the bottle body 10 is discharged through a gap between the rectangular pieces 35 and 36 of the pressure opening and closing valve 30 , the enlarged groove 42 and the discharge passage 41 of the inner cap member 40 . The nail polish liquid discharged from the discharge passage 41 of the inner cap member 40 permeates the brush 47 , thus allowing a user to apply the nail polish liquid.
[0047] In this regard, the skirt portion 33 of the pressure opening and closing valve 30 blocks the air holes 22 formed in the disc portion 23 , from the lower surface of the disc portion 23 , so that the nail polish liquid of the bottle body 10 is not introduced into the air holes 22 , thus preventing the nail polish liquid from leaking to the outside through the external-air introduction grooves 56 of the outer cap member 50 .
[0048] Further, as shown in FIG. 10 , if a pushing force is removed from the bottle body 10 after a user finishes using the nail polish, the bottle body 10 is restored to its original state in the direction of arrow 66 , and the rectangular pieces 35 and 36 of the pressure opening and closing valve 30 are closed by their own elastic force (restoring force), thus preventing the nail polish liquid in the bottle body 10 from leaking to the brush 47 .
[0049] As such, according to the present invention, even if the bottle body 10 is laid down or turned, upside down, the rectangular pieces 35 and 36 of the pressure opening and closing valve 30 are closed, thus preventing the nail polish liquid 70 from unexpectedly leaking from the bottle body 10 .
[0050] Further, if the pushing force is eliminated from the bottle body 10 , the bottle body 10 is restored to its original state by its own elasticity. Here, the skirt portion 33 of the pressure opening and closing valve 30 moves away from the lower surface of the disc portion 23 , so that the air holes 22 of the disc portion 23 are opened, and thereby air introduced through the external-air introduction grooves 56 of the outer cap member 50 is fed through the air holes 22 of the disc portion 23 into the bottle body 10 .
[0051] As described above, the present invention provides a nail polish bottle, which is configured so that, if a bottle body is pushed, the internal pressure of the bottle body is increased and thus the pressure opening and closing valve is opened, thereby discharging nail polish liquid contained in the bottle body through a discharge passage to a brush and allowing a user to apply to polish to his or her nails, and, if force is eliminated from the bottle body, the internal pressure of the bottle body is restored to its original state and thus the pressure opening and closing valve is closed, thereby automatically preventing the nail polish liquid from leaking.
[0052] While the invention has been described with respect to a limited number of embodiments, it will be appreciated that many variations, modifications and other applications of the invention may be made. Therefore, the claimed invention as recited in the claims that follow is not limited to the embodiments described herein. | A nail polish bottle comprises a bottle body, a cap including a disc portion having a center hole and one or more air holes and including a discharge passage and one or more external-air introduction grooves in flow contact with the air holes. A pressure opening and closing valve is mounted to the disc portion such that a skirt portion of the valve may sit below the disc portion and a top of the valve may be above the disc portion. The skirt portion may press against the disc portion to close the air holes. When internal pressure in the bottle body opens the top of the valve, nail polish may flow through the discharge passage if the bottle is upside-down. When the internal pressure is released, the top of the valve may close and the skirt portion may move away from the disc to open the air holes. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present application claims benefit of U.S. Provisional 60/389,685, filed Jun. 17, 2002 which is explicitly incorporated herein by reference in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable.
BACKGROUND
Intracellular bacterial toxins enter cells, modify targets, and in many cases ultimately destroy the targeted cells thereby contributing to the disease process. Currently, there are no techniques for blocking intracellular virulence factors once they have entered the cytosol of cells. Further, no techniques exist which utilize inactive mutants derived from a toxin in order to inhibit the wild-type toxin at the intracellular cite.
Clostridium difficile is the leading cause of hospital acquired diarrhea and pseudomembranous colitis, a multifactorial disease involving steps in colonization, adherence, inflammation and cellular intoxication. TcdA and TcdB are two large clostridial toxins (LCTs) produced by C. difficile and are involved in development of pseudomembranous colitis. TcdB, (SEQ ID NO: 1), the focus of this study, glucosylates isoforms of small GTPases Rho, Rac and Cdc42 within the effector binding region at residues Threonine-37 (Rho) or Threonine-35 (Rac and Cdc42). The physiological impact of TcdB's activity includes disruption of tight junctions, increased epithelial permeability, as well as actin condensation and cell death.
TcdB can be divided into enzymatic, translocation and receptor binding domains, although detailed analysis of these regions has not been carried out to date. The first 546 amino acids of TcdB contain the enzymatic region, which is followed by a putative translocation and receptor-binding domain. Enzymatic activity appears to require the amino-terminal 546 residues since amino or carboxy terminal deletions of this fragment decrease activity. Within the enzymatic region, tryptophan 102 has been shown to be essential for UDP-glucose binding. A conserved DXD motif within LCTs is essential for LCT glucosyltransferase activity. Other studies, involving analysis of chimeras of the TcdB and TcsL enzymatic domain suggest residues 364 to 516 confer substrate specificity.
Steps in cell entry by TcdB have been broadly defined, yet events subsequent to entry are not well understood. For example, while we have a profile of the time-course for TcdB cell entry, very little is known about post-entry events that lead to glucosylation. Steps between membrane translocation and substrate interaction are not understood in TcdB intoxication. In fact almost no information exists in this regard for any intracellular toxin. In the cytosol, TcdB is capable of glucosylating multiple substrates, but whether inactivation of Rho, Rac and Cdc42 in combination is necessary for complete intoxication, or if other substrates are targeted, is not known. It has been found that overexpression of Rho isoforms protects cells from TcdB, suggesting inactivation of all substrates may not be necessary for cellular intoxication. Interestingly, Rho has also been shown to regulate the suppression of apoptosis, so it is not entirely clear whether overexpression of Rho is protective at the substrate inactivation level or prevents events downstream of glucosylation. Additionally, while some TcdB-intoxicating events, such as depolymerization of actin, can be attributed to inactivation of Rho, other processes like apoptosis may be linked to activities other than substrate inactivation. Given TcdB's large size (˜270 kD), and broad impact on cell physiology, it is possible the toxin may possess yet undefined activities in addition to glucosylation.
It would be desirable to have a vaccine or therapeutic composition for inhibiting or preventing action of the C. difficile TcdB toxin.
SUMMARY OF THE INVENTION
The invention herein contemplates, in one embodiment, a mutant of native C. difficile TcdB toxin polypeptide wherein the mutant is substituted at position 395, such that the cysteine at position 395 in the native TcdB toxin has been replaced with another amino acid, for example, a tryptophan residue and wherein the mutant is not cytotoxic (non-toxic). The invention further comprises fragments of the TcdB toxin, which are effective in inhibiting TcdB toxin or are effective as a vaccine, and are non-toxic. The invention further contemplates a vaccine generally applicable to the prevention or treatment of C. difficile disease. Additionally, the present invention contemplates a method of inhibiting, modulating, or treating a C. difficile or a C. sordellii infection in a subject. Further, the present invention contemplates a monoclonal antibody raised against the C. difficile TcdB toxin mutant. In addition, the present invention contemplates a method of making an antibody against C. difficile TcdB toxin comprising immunizing an animal with an immunogenic amount of the C. difficile TcdB toxin mutant. These and other embodiments of the invention will be described further below.
DESCRIPTION OF THE DRAWINGS
FIG. 1 . shows chromatography gels of LFnTcdB deletion and site-directed mutants. Panel A: Overview of deletion and site directed mutants. Deletion mutants were generated by PCR, cloned in-frame with lfn in pET 15b, expressed in E. coli BL-21, and subsequently purified by Ni 2+ affinity chromatography. Site-directed mutants were generated by the Quick-change method, using complementary mutation encoding oligonucleotides, and pLMS200 as template. Panel B: DS-PAGE analysis of his-tagged fusions. Lane 1, Molecular Weight Marker; Lane 2, TcdB W102A ; Lane 3, TcdB C395W ; Lane 4, TcdB C395S ; Lane 5, TcdB 35-556 ; Lane 6, TcdB 1-170 ; Lane 7, TcdB 1-420 ; Lane 8, TcdB 1-500 ; Lane 9, TcdB 1-556 ; Lane 10, Molecular Weight Marker.
FIG. 2 . is a gel depicting glucosylation activity of deletion and site-directed mutants on RhoA, Rac1 and Cdc42. Each mutant and TcdB was tested for glucosylation activity on recombinant substrates GST-RhoA, GST-Rac1 and GST-Cdc42, using [ 14 C]UDP-Glucose as cosubstrate. Following a 2 h incubation, the reaction mix was resolved by SDS-PAGE and exposed to film for 48 h. Lane 1, TcdB; Lane 2, TcdB W102 A; Lane 3, TcdB C395W ; Lane 4, TcdB C395S ; Lane 5, TcdB 1-556 ; Lane 6, TcdB 1-500 ; Lane 7, TcdB 1-420 ; Lane 8, TcdB 1-170 ; Lane 9, TcdB 35-556 .
FIG. 3 . shows inhibition of TcdB cytopathic effects by TcdB mutants. HeLa cells were cotreated with TcdB and each TcdB fusion plus PA. The cells were followed for 7 h and cytopathic effects were determined by visualization. Panel I is a micrograph depicting CHO cells treated with competitive inhibitors; A, PBS alone; B., TcdB alone; C, PA,LFn plus TcdB; D, PA,TcdB 1-170 plus TcdB; E, PA,TcdB 1-420 plus TcdB; F, PA,TcdB 1-500 plus TcdB; G, PA,TcdB 33-556 plus TcdB; H, PA, TcdB C395W , plus TcdB; I, PA, TcdB W102A plus TcdB; Panel II is a summary of inhibitors capable of blocking TcdB cytopathic effects; ▪=TcdB 1-420 ; □=TcdB W102A ; =TcdB C395W ; =TcdB 33-556 ; =TcdB 1-500 .
FIG. 4 . is a graphical representation depicting sustained inhibition by supplemental treatments with inhibitor. HeLa cells were cotreated with TcdB and TcdB 1-500 plus PA. During the course of the assay TcdB 1-500 and PA were added to the cells at 1 h intervals for 12 h. The cells were then followed for 30 h and visualized for cytopathic effects. Open circles TcdB; open diamonds=PA,TcdB 1-500 ; closed circles=TcdB 1-500 plus TcdB.
FIG. 5 . is a graphical representation depicting the protection of CHO cells expressing TcdB 1-556 . GeneSwitch-CHOpGene/TcdB 1-556 cells were induced with mifepristone in the presence or absence of TcdB 1-500 plus PA. Cells were then observed for rounding and cytopathic effects at the indicated time-points. Open Circles=Uninduced Control; Closed Circles=Mifepristone-induced, PA,TcdB 1-500 ; Open Squares=Mifepristone-induced control.
FIG. 6 . is a chart demonstrating the inhibitory effects following inhibitor treatments prior to or following treatment with TcdB. In a 96-well plate, HeLa cells were treated with TcdB 1-500 plus PA at time points prior to or following treatment with TcdB. Cells were amended with inhibitor every 30′ and observed for cytopathic effects at 8 h following toxin treatment.
FIG. 7 . is a graphical representation depicting TcdB 1-500 inhibition of TcsL cytopathic effects. HeLa cells were treated with TcdB 1-500 plus PA for 30 min prior to treatment with TcsL. To enhance TcsL cytopathic activity, cells were treated with the toxin using an acid pulse where cells were subjected to TcsL in acid medium (pH 4.0) for 10 min. followed by replacement with neutral medium (pH 7.4) and TcdB 1-500 plus PA. The cells were amended with inhibitor every 30′ for 12 h, then followed for 18 h to determine cytopathic effects. Open circles=TcsL; closed circles=PA,TcdB 1-500 plus TcsL.
FIG. 8 . Differential glucosylation of extracts from cells treated with TcdB plus inhibitor. HeLa cells were plated in T-25 flasks and grown until semiconfluent, then treated with PA, TcdB 1-500 and TcdB was added to the cells. Three hours after TcdB treatment, cell extracts were collected and subjected to a TcdB glucosylation using [ 14 C]UDP-Glucose as cosubstrate. The reactions were subsequently resolved by SDS-PAGE and exposed to film for 48 h. Lane 1=untreated HeLa cells; Lane 2=TcdB-treated cells; Lane 3=TcdB plus inhibitor treated cells.
DETAILED DESCRIPTION OF THE INVENTION
The invention contemplated herein comprises, in a preferred embodiment, non-cytotoxic C. difficile TcdB toxin derivatives and deletions (mutants) which are deficient in at least one specific function required for toxicity and which are effective intracellular inhibitors of native TcdB toxin or are effective in producing immunity against TcdB toxin. The present invention demonstrates that enzymatically inactive fragments of the TcdB enzymatic domain are effective intracellular inhibitors of native TcdB. The present invention comprises purified derivatives (mutants) of C. difficile TcdB toxin which are deficient in glucosyltransferase and glucosylhydrolase activity. The mutants are considered to be useful as a vaccine for both humans and animals.
Examples of animals which may be treated are cattle, chickens, turkeys, ostriches, emu, ducks, horses, donkeys, mules, pigs, sheep, goats antelope, buffalo, llamas, cats, lions, tigers, dogs, bears, guinea pigs, hamsters, chinchillas, mink, ferrets, rodents, parrots, parakeets, peacocks, seals, sea lions, orcas, monkeys, chimpanzees, baboons, orangutans, gorillas, reptiles, and other zoo and livestock animals.
The term “mutant”, where used herein, refers to a fragment, point deletion, point substitution, or a deletion of multiple residues of the TcdB protein sequence, and may be encoded by a nucleotide sequence intentionally made variant from a native sequence. The present invention also contemplates nucleotide sequences which encode the mutants.
The mutants of the present invention preferably have at least one substituted amino acid in the enzymatic domain of the TcdB toxin which includes amino acid position 395 of the sequence of the native TcdB toxin as shown in SEQ ID NO: 1.
As noted above, the novel mutants contemplated herein comprise at least one amino acid substitution or deletion of the native C. difficile TcdB toxin. For example, the amino acid at position 395 (also referred to herein as the “critical position”) of the amino acid sequence of the native C. difficile TcdB toxin (SEQ ID NO: 1) may be substituted with a different amino acid in the same position.
In particular, the invention comprises mutants wherein the native cysteine at position 395 has been substituted with a tryptophan residue at position 395. However, any amino acid residue which would provide a mutant effective in inhibiting TcdB toxin, and which is not cytotoxic, may be substituted for the cysteine residue at position 395. Examples of other amino acids which may be used to substitute the cysteine residue include alanine, valine, leucine, isoleucine, proline, methionine, phenylalanine, glycine, threonine, tyrosine, asparagine, aspartic acid, glutamine, glutamic acid, lysine, arginine, and histidine. Mutants which are cytotoxic, e.g., a serine-substitute, also comprise the invention, particularly when they are used in a diagnostic assay as described below. Mutants comprising deletions of portions of the enzymatic domain include, for example, a modified C. difficile TcdB toxin having a deletion of amino acid positions 501–556 (SEQ ID NO: 3), 421–556 (SEQ ID NO: 5), 171–556 (SEQ ID NO: 7), or 1–34 (SEQ ID NO: 9) are also contemplated. An especially preferred embodiment comprises a mutant having at least one substitution in the enzymatic domain. The mutants of the present invention preferably have deficient glucosyltransferase and glucosylhydrolase activity compared to the native C. difficile TcdB toxin, and are non-toxic, and in an especially preferred embodiment are antigenic, whereby vaccines produced from them induce anti-TcdB toxin antibodies in vivo as explained in more detail below.
As noted above, it is an object of the present invention to provide novel vaccines comprising the TcdB toxin mutants described herein, or antigenic fragments thereof, which when administered to animals or humans, are capable of inducing production of protective antibodies directed against C. difficile TcdB toxin, thereby providing prophylaxis against infection by C. difficile disease states resulting from such infection, and/or from the TcdB toxin itself. It is a particular aim of the present invention to provide such a vaccine that is relatively safe and simple to produce. Antibodies and antisera raised against the mutants are also capable of use in therapy for at least some, if not all, disease states, in which TcdB toxin is involved.
In further aspects of the present invention there is provided recombinant DNA which encode any proteins, fragments, or amino acid sequences thereof described or claimed herein. Such recombinant DNA is conveniently provided by PCR amplification of the DNA encoding for the desired sequence, using primers targeted at respective ends of the double stranded sequence of which it forms one half, using methods well known to those of ordinary skill in the art.
In a further aspect of the present invention there are provided antisera raised to the mutants, or antigenic fragments thereof, of the invention and antibodies derived therefrom. Furthermore, the present invention provides monoclonal antibodies against the mutants, or antigenic fragments thereof, of the invention and hybridoma cells for production thereof as described in more detail below.
The present invention further contemplates TcdB toxin mutants which have additional substitutions which are merely conservative substitutions of amino acids. By “conservative substitution” is meant the substitution of an amino acid by another one of the same class; the classes according to Table I.
TABLE I
Classes of amino acids suitable for conservative substitution.
CLASS
AMINO ACID
Nonpolar:
Ala, Val, Leu, Ile, Pro, Met, Phe, Trp
Uncharged polar:
Gly, Ser, Thr, Cys, Tyr, Asn, Gln
Acidic:
Asp, Glu
Basic:
Lys, Arg, His
As is well known to those skilled in the art, altering any given non-critical amino acid of a protein by conservative substitution may not significantly alter the activity of that protein because the side-chain of the amino acid which is inserted into the sequence may be able to form similar bonds and contacts as the side chain of the amino acid which has been substituted for.
Non-conservative substitutions (outside the classes of Table I) are possible provided that these do not excessively affect the immunogenicity of the polypeptide and/or reduce its effectiveness in inhibiting TcdB toxin.
The polypeptides of the invention may be prepared synthetically, or more suitable, they are obtained using recombinant DNA technology. Thus, the invention further provides a nucleic acid which encodes any of the mutants of TcdB toxin which have at least one substitution and/or deletion as described herein.
Such nucleic acids may be incorporated into an expression vector, such as a plasmid, under the control of a promoter as understood in the art. The vector may include other structures as conventional in the art, such as signal sequences, leader sequences and enhancers, and can be used to transform a host cell, for example a prokaryotic cell such as E. coli or a eukaryotic cell. Transformed cells can then be cultured and polypeptide of the invention recovered therefrom, either from the cells or from the culture medium, depending upon whether the desired product is secreted from the cell or not.
As used herein, the terms “complementary” or “complementarity” are used in reference to polynucleotides (i.e., a sequence of nucleotides) related by the base-pairing rules. For example, for the sequence “A-G-T,” is complementary to the sequence “T-C-A.” Complementary may be “partial,” in which only some of the nucleic acids' bases are matched according to the base pairing rules. Or, there may be “complete” or “total” complementary between the nucleic acids. The degree of complementary between nucleic acid strands has significant effects on the efficiency and strength of hybridization between nucleic acid strands. This is of particular importance in amplification reactions, as well as detection methods which depend upon binding between nucleic acids.
Nucleic acids of the present invention also include DNA sequences which hybridize to the DNA sequences which encode the mutant polypeptides described herein, or their complementary sequences, under conditions of high or low stringency and which encode proteins having activity against TcdB toxin and/or which preferably can stimulate antibodies against native TcdB toxin.
Hybridization and washing conditions are well known and exemplified in Sambrook, J., Fritsch, E. F. and Maniatis, T. Molecular Cloning: A Laboratory Manual, Second Edition, Cold Spring Harbor Laboratory Press, Cold Spring Harbor (1989), particularly Chapter 11 and Table 11.1 therein (expressly entirely incorporated herein by reference). The conditions of temperature and ionic strength determine the “stringency” of the hybridization.
In one embodiment, high stringency conditions are prehybridization and hybridization at 68° C., washing twice with 0.1×SSC, 0.1% SDS for 20 minutes at 22° C. and twice with 0.1×SSC, 0.1% SDS for 20 minutes at 50° C. Hybridization is preferably overnight.
In one example, low stringency conditions comprise conditions equivalent to binding or hybridization at 42° C. in a solution consisting of 5×SSPE (43.8 g/l NaCl, 6.9 g/l NaH 2 PO 4 .H 2 O and 1.85 g/l EDTA, pH adjusted to 7.4 with NaOH), 0.1% SDS, 5×Denhardt's reagent [50×Denhardt's contains per 500 ml: 5 g Ficoll (Type 400, Pharmacia), 5 g BSA (Fraction V; sigma) and 100 μg/ml denatured salmon sperm DNA] followed by washing in a solution comprising 5×SSPE, 0.1% SDS at 42° C. when a probe of about 500 nucleotides in length is employed.
In another embodiment, low stringency conditions are prehybridization and hybridization at 68° C., washing twice with 2×SSC, 0.1% SDS for 5 minutes at 22° C., and twice with 0.2×SCC, 0.1% SDS for 5 minutes at 22° C. Hybridization is preferably overnight.
In an alternative embodiment, very low to very high stringency conditions are defined as prehybridization and hybridization at 42° C. in 5×SSPE, 0.3% SDS, 200 ug/ml sheared and denatured salmon sperm DNA, and either 25% formamide for very low and low stringencies, 35% formamide for medium and medium-high stringencies, or 50% formamide for high and very high stringencies, following standard Souther blotting procedures.
The carrier material is then washed three times each for 15 minutes using 2×SSC, 0.2% SDS preferably at least 45° C. (very low stringency), more preferably at least at 50° C. (low stringency), more preferably at least at 55° C. (medium stringency), more preferably at least at 60° C. (medium-high stringency), even more preferably at least at 65° C. (high stringency), and most preferably at least at 70° C. (very high stringency).
It is well known in the art that numerous equivalent conditions may be employed to comprise low stringency conditions; factors such as the length and nature (e.g., DNA, RNA, base composition) of the probe and nature of the target (e.g., DNA, RNA, base composition, present in solution or immobilized, etc.) And the concentration of the salts and other components (e.g., the presence or absence of formamide, dextran sulfate, polyethylene glycol) are considered and the hybridization solution may be varied to generate conditions of low stringency hybridization different form, but equivalent to, the above listed conditions. In addition, conditions which promote hybridization under conditions of high stringency (e.g., increasing the temperature of the hybridization and/or wash steps, the use of formamide in the hybridization solution, etc.) are also know in the art.
When used in reference to a double-stranded nucleic acid sequence such as a cDNA or genomic clone, the term “substantially homologous” refers to any probe which can hybridize to either or both strands of the double-stranded nucleic acid sequence under conditions of low stringency as described above.
When used in reference to a single-stranded nucleic acid sequence, the term “substantially homologous” refers to any probe which can hybridize (i.e., it is the complement of) the single-stranded nucleic acid sequence under conditions of low stringency as described above.
As used herein, the term “hybridization” is used in reference to the pairing of complementary nucleic acids. Hybridization and the strength of hybridization (e.e., the strength of the association between the nucleic acids) is impacted by such factors as the degree of complementary between the nucleic acids, stringency of the conditions involved, the T m (melting temperature) of the formed hybrid, and the G:C ration within the nucleic acids. As used herein the term “stringency” is used in reference to the conditions of temperature, ionic strength, and the presence of other compounds such as organic solvents, under which nucleic acid hybridizations are conducted.
As used herein, the terms “cell,” “cell line,” and “cell culture” are used interchangeably and all such designations include progeny. The words “transformants” or “transformed cells” include the primary transformed cell and cultures derived from that cell without regard to the number of transfers. All progeny may not be precisely identical in DNA content, due to deliberate or inadvertent mutations. Mutant progeny that have the same functionality as screened for in the originally transformed cell are included in the definition of transformants.
As used herein, the term “vector” is used in reference to nucleic acid molecules that transfer DNA segment(s) from one cell to another. The term “vehicle” is sometimes used interchangeably with “vector”.
The terms “recombinant DNA vector” as used herein refers to DNA sequences containing a desired coding sequence and appropriate DNA sequences necessary for the expression of the operably linked coding sequence in a particular host organism. DNA sequences necessary for expression in prokaryotes include a promoter, optionally and operator sequence, a ribosome binding site and possibly other sequences. Eukaryotic cells are known to utilize promoters, polyadenylation signals and enhancers. It is not intended that the term be limited to any particular type of vector. Rather, it is intended that the term encompass vectors that remain autonomous within host cells (e.g., plasmids), as well as vectors that result in the integration of foreign (e.g., recombinant nucleic acid sequences) into the genome of the host cell.
The term “expression vector” and “recombinant expression vector” as used herein refers to a recombinant DNA molecule containing a desired coding sequence and appropriate nucleic acid sequences necessary for the expression of the operably linked coding sequence in a particular host organism. Nucleic acid sequences necessary for expression in prokaryotes usually include a promoter, an operator (optional), and a ribosome binding site, often along with other sequences. Eukaryotic cells are known to utilize promoters, enhancers, and termination and polyadenylation signals. It is contemplated that the present invention encompasses expression vectors that are integrated into host cell genomes, as well as vectors that remain unintegrated into the host genome.
The terms “in operable combination,” “in operable order,” and “operably linked,” as used herein refer to the linkage of nucleic acid sequences in such a manner that a nucleic acid molecule capable of directing the transcription of a given gene and/or the synthesis of a desired protein molecule is produced. The term also refers to the linkage of amino acid sequences in such a manner so that a functional protein is produced.
The mutants described herein may be expressed in either prokaryotic or eukaryotic host cells. Nucleic acids encoding the mutants may be introduced into bacterial host cells by a number of means including transformation or transfection of bacterial cells made competent for transformation by treatment with calcium chloride or by electroporation. If the mutants are to be expressed in eukaryotic host cells, nucleic acid encoding the protein or toxin of interest may be introduced into eukaryotic host cells by a number of means including calcium phosphate co-precipitation, spheroplast fusion, electroporation, microinjection, lipofection, protoplast fusion, and retroviral infection, for example. When the eukaryotic host cell is a yeast cell, transformation may be affected by treatment of the host cells with lithium acetate or by electroporation, for example.
In a preferred version of the invention, the mutant is characterized as having 50% or less of the glucosyltransferase and glucoslyhydrolase activity of wild type TcdB toxin, as measured by assays described herein. In a more preferred version of the invention, the mutant is characterized as having 30% or less of the glucosyltransferase and glucosylhydrolase activity of wild type TcdB toxin, as measured by assays described herein. In a more preferred version of the invention, the mutant has less than 20% of the glucosyltransferase and glucosylhydrolase activity of wild type TcdB toxin as measured by assays described herein. In a more preferred version of the invention, the mutant has less than 10% of the glucoslytransferase and glucosylhydrolase activity of wild-type TcdB toxin, as measured by assays described herein. More preferably, the mutant has less than 5% of the glucosyltransferase and glucosylhydrolase activity of the wild-type TcdB toxin, as measured by assays described herein. Even more preferably, the mutant has less than 0% of the glucosyltransferase and glucosylhydrolase activity of wild-type TcdB toxin, as measured by assays described herein. More particularly, the invention as contemplated herein is a mutant (mutein) of C. difficile TcdB toxin polypeptide which comprises: (a) a polypeptide having a substitution at position 395 of the amino acid sequence of native C. difficile TcdB toxin, wherein the cysteine at position 395 has been replaced with tryptophan (SEQ ID NO: 11) or with another amino acid; or (b) a modified C. difficile TcdB toxin having a deletion of amino acid positions 501–556 (SEQ ID NO: 3), 421–556 (SEQ ID NO: 5), 171–556 (SEQ ID NO: 7), or 1–34 (SEQ ID NO: 9), and wherein the mutant of (a) or (b) is effective in inhibiting or modulating the cytotoxic effect of C. difficile TcdB toxin or is effective as a vaccine against C. difficile and wherein the mutant is not cytotoxic.
While the invention will now be described in connection with certain preferred embodiments in the following examples so that aspects thereof may be more fully understood and appreciated, it is not intended to limit the invention to these particular embodiments. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included within the scope of the invention as defined by the appended claims. Thus, the following examples, which include preferred embodiments will serve to illustrate the practice of this invention, it being understood that the particulars shown are by way of example and for purposes of illustrative discussion of preferred embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of formulation procedures as well as of the principles and conceptual aspects of the invention.
EXAMPLES
During analysis of the TcdB enzymatic domain a set of mutants were identifiable which were unable to modify substrate, yet were capable of blocking TcdB cytopathic effects. Herein are described generation and analyses of these mutants and the demonstration that these proteins are potent intracellular inhibitors of TcdB and block glucosylation of a previously undescribed target. These mutants show, for the first time, that a toxin derivative can be used to effectively block the activity of the native toxin within the cell. This inhibitory activity also suggests a new paradigm for a therapeutic approach to treat toxin-based diseases.
Enzymatic and Cytopathic Activity of Mutants
As summarized in FIG. 1 , 4 deletion and 3 site-directed mutants in the TcdB enzymatic domain were constructed, cloned and isolated from E. coli . The nomenclature for each of these mutants is summarized in panel A of FIG. 1 . One site-directed mutant, TcdB W102A wherein the tryptophan at position 102 is substituted with alanine has been previously characterized and served as a control in cytotoxicity and enzymatic assays [Busch, 2000]. Experiments conducted in the present work suggested TcdB 1-556 (SEQ ID NO: 1) could be inactivated by n-ethylmaleimide (data not shown), indicating a role for the sole cysteine (position 395 ) in enzymatic activity, thus site-directed mutants TcdB C395S , TcdB C395W were produced. Amino-terminal and carboxy-terminal deletions were also generated in an attempt to further identify inactive mutants. Since these mutants lacked receptor binding and translocation domains, the fragments were fused to the cell entry proteins of anthrax lethal toxin. This anthrax toxin derivative consists of anthrax protective antigen (PA), and a truncated form of anthrax lethal toxin (LFn), to which heterologous fusions are made. PA-LFn has been used by several groups for the cytosolic delivery of a variety of proteins, and we previously used this system to deliver TcdB 1-556 to cultured mammalian cells [Spyres, 2001]. Using this delivery system, the fusions were tested for cytopathic activity and only TcdB 1-556 and TcdB C395S were cytotoxic (data not shown).
To determine if lack of cytotoxicity was due to attenuation of enzymatic activity, mutants were tested for glucosylation of RhoA, Rac1 or Cdc42. As shown in FIG. 2 , only TcdB 1-556 , and TcdB C395S glucosylated substrate. In line with earlier reports carboxy-terminal deletions and TcdB W102A were unable to glucosylate substrate. The remainder of the site-directed and deletion mutants were also deficient in glucosylation. Furthermore, this loss of activity was maintained across all of the shared substrates since these same mutants were attenuated in glucosylation of RhoA, Rac1 and Cdc42.
Each mutant was also analyzed for glucosylhydrolase activity using radiolabeled UDP-glucose in the absence of substrate. Fusions were incubated with [ 14 C]UDP-glucose and the liberated sugar was separated by anion-exchange chromatography. As shown in Table 1, even with extended (16 h) incubation glucosylhydrolase activity was significantly reduced for all enzymatically inactive mutants. Without wishing to be constrained by theory, the absence of substrate modification by these mutants could be accounted for, at least in part, by defective hydrolase activity.
TcdB Mutants as Inhibitors of Native Toxin
Since the inactive mutants could be effectively delivered to the cytosol of cells via the PA, LFn system, we were presented with the unique opportunity to examine the effects these mutants might have when administered in combination with wild-type TcdB. Thus, HeLa cells were treated with TcdB in the presence or absence of PA plus each attenuated mutant. As shown in FIG. 3(I) , PA-delivered TcdB 1-500 , TcdB 1-420 , TcdB W102A , TcdB C395W , or TcdB 35-556 , attenuated TcdB cytopathic effects suggesting the mutants had an antagonistic impact on TcdB intoxication. The inhibitor effects were dependent on the presence of inactive enzymatic domain mutants since PA-LFn alone did not inhibit TcdB.
It was clear from the results in FIG. 3 (II), that approximately 7 h after delivery of inhibitory fragments to the TcdB treated cells that the protective effect began to decrease. This observation suggested that the inhibitory effect of the enzymatically inactive mutants has a limited lifetime. To address this possibility, the initial competition was set-up as before and the inhibitor (TcdB 1-500 ) was added to the cells at 1 h time intervals during the course of the assay. As shown in FIG. 4 , using this approach greater than 50% of the cells demonstrated no cytopathic effects and appeared to be protected from the wild-type toxin during the course of the assay (>30 h). Hence, continued administration maintained the protective effect against TcdB. Continued addition of the inhibitor after 12 h, did not improve or change the inhibition of TcdB, suggesting TcdB had lost activity or that the accumulated inhibitor was in sufficient excess so that its protective effect was extended.
Inactive Mutants Protect CHO Cells Expressing TcdB 1-556
The fact that the TcdB inhibitors lack native translocation and receptor binding domains suggested that inhibition occurred within the cytosol. However, inhibition at the cell surface could not be formally excluded since cell surfacing-interacting regions of TcdB have not been fully elucidated. To determine if inhibition of TcdB was occurring within the cytosol, a CHO cell line capable of inducible expression of TcdB 1-556 was generated. A tightly regulated expression system, pSwitch, was selected which allows expression only in the presence of the hormone mifepristone. GeneSwitch-CHOpGene/TcdB 1-556 cells showed early toxic effects, such as rounding, at around 4 h following addition of mifepristone and were no longer viable by 24 h. To test the inhibitor on these cells, mifepristone was added to the cells and inhibitor was added 2 h later and subsequently added every 30 min for an additional 3 h. As shown in FIG. 5 , mifepristone treated GeneSwitch-CHOpGene/TcdB 1-556 cells were protected from the effects of TcdB 1-556 when the inhibitor was added at 2 h following induction. The inhibitor clearly slows the cytopathic activity of these cells following induction. Cells eventually show cytopathic effects similar to that control since the cell continues to express TcdB 1-556 . These results demonstrate that the inhibitor is capable of blocking TcdB intoxication at a site within the cell.
TcdB-Inhibitors as Tools to Dissect the Time-Course of Posttranslocation Events
In earlier studies we reported on the time-course of entry by TcdB, based on results from lysosomotropic inhibitor assays [Qa'Dan, 2000]. The inhibitors now provided a reagent to determine the time-course of events occurring after translocation into the cytosol. At a given time-point, if intoxication events have been initiated, then addition of the inhibitor should no longer have an effect. In this experiment cells were pretreated with the inhibitor or treated with the inhibitor at time-points following TcdB treatment. As shown in FIG. 6 , protection occurs in cells when the inhibitor is added as early as 40 min before treatment with TcdB. Protection also occurs when the inhibitor is added up 40 min after treatment with TcdB. Only when the inhibitor is added over 40 min prior to treatment with TcdB or over 40 min after treatment with TcdB is there a noticeable cytopathic effect. Given that cell entry takes approximately 20 min, these results suggested intoxication events require at least a 40 min time period after translocation to initiate cytotoxic effects.
Inhibition of Intoxication by C. sordellii Lethal Toxin (TcsL)
A variety of events, including substrate related and substrate unrelated, could occur during the 40 min posttranslocation time-period. If the inhibitor blocked processes unrelated to substrate interaction, we suspected the mutant might block another highly related LCT, which does not share similar substrate targets with TcdB. An ideal candidate for this experiment was TcsL, which is closely related to TcdB, yet modifies a different set of Ras proteins including Ras, and Ral. TcsL does share Rac as a common substrate with TcdB. We tested the TcdB inhibitor's ability to block TcsL intoxicaion. In recent work we reported that acid pH enhances TcsL entry [Qa'Dan, 2001], so the initial treatment with TcsL was carried out by providing an extracellular acid pulse to TcsL. In this assay cells were pretreated with the inhibitor, then acid-pulse treated with TcsL, and subsequently treated with additional inhibitor during the time-course of the assay. As can be seen in FIG. 7 , TcdB 1-500 was also able to block the activity of TcsL. Similar to results with TcdB, the inhibitor was capable of reducing TcsL's cytopathic effects by almost 50%. These results suggested the TcdB inhibitor was blocking LCT intoxication events that might not be related to substrate targeting or that blocking a single target was sufficient to prevent toxic effects.
Effects of Inhibitor on Substrate Glucosylation in Cultured Cells
The results from the TcsL inhibition assay suggested the inhibitor prevented toxin-specific activities that might not be related to targeting Rho, Rac and Cdc42. For this reason it was important to determine if the inhibitor prevented glucosylation of these substrates during TcdB intoxication. Thus, a set of differential glucosylation reactions were carried out that involved examining extracts from cells treated with TcdB, or treated with TcdB plus the inhibitor, for a decrease in substrate that could be glucosylated. As shown in FIG. 8 using a minimal intoxicating dose of TcdB, cells showed a relatively equal amount of Rho substrate that could be glucosylated from both TcdB-treated and TcdB-plus-inhibitor treated cells. While there did not appear to be a difference in targeting of Rho, Rac or Cdc42 there was a change in the ability to glucosylate a second protein that migrated at a size larger than the Rho proteins. The larger protein was below the level of detection in extracts from TcdB treated cells yet this protein was glucosylated in extracts from cells treated with TcdB plus the inhibitor. These results further suggest the inhibitor prevents an LCT activity other than glucosylation of Rho, Rac and Cdc42.
Attenuated mutants of TcdB inhibit wild-type toxin at an intracellular site. To our knowledge this is the first example of an approach that blocks the activity of an intracellular bacterial toxin within the cytosol of intoxicated cells. This inhibitory effect also suggests some yet undefined aspects of TcdB. Clearly, while unable to modify substrate, the mutants carry out functions within the cytosol, which allow inhibition. The exact mode of inhibition is not clear; however, the preliminary evidence indicates the inhibitor prevents glucosylation of a substrate other than Rho, Rac or Cdc42. This is a feasible possibility since some of the inhibitors do not encompass the region of TcdB reported to interact with Rho, Rac and Cdc42. Work by Hofmann et al. [Hofmann, 1998] using chimeric derivatives between the enzymatic domains of TcsL and TcdB, suggested residues 365–516 conferred substrate specificity. Our deletion analysis shows residues 1–420 are able to inhibit TcdB intoxication, while the 1–170 deletion has no inhibitory effect. Finally, the mutants also inhibit TcsL, which shares only one substrate, Rac, with TcdB. If inhibition were due to Rho, Rac and Cdc42 interaction then the inhibitor should be less effective on TcsL, but it is not. The amino terminal domains of these two proteins are homologous (78% homology) and could share activities, and yet undefined common substrates.
Experimental Procedures
Tissue Culture, Bacterial Strains and Chemical Reagents
Human cervical adenocarcinoma cells American Type Culture Collection (ATCC) Manassas, Va. CCL-2 (HeLa) were grown in supplemented RPMI 1640 (RP-10) [Starnbach, 1994] with 10% fetal bovine serum at 37° C. in a humid atmosphere with 7% CO 2 . Clostridium difficile strain VPI 10463, and Clostridium sordellii strain 9714 were obtained from ATCC and used as a source of culture supernatant, genomic DNA, TcdB and TcsL. All reagents were of molecular biology grade and were purchased from Sigma Chemical Co., St. Louis, Mo. unless otherwise noted.
Construction of Recombinant LFn-TcdB Fusions
The region encoding for the enzymatic domain of TcdB i.e., TcdB nucleotides 1–1668 (SEQ ID NO:2)) was genetically fused to lfn, cloned expressed and purified in E. coli as previously described [Spyres, 2001]. Using a similar approach, four other fusions of LFnTcdB were also constructed. Briefly, fragments encoding regions TcdB 1-500 (SEQ ID NO: 3 encoded by nucleotides 1–1500 (SEQ ID NO: 4)), TcdB 1-420 (SEQ ID NO: 5 encoded by nucleotides 1–1260 (SEQ ID NO: 6)), TcdB 1-170 (SEQ ID NO: 7 encoded by nucleotides 1–510 (SEQ ID NO: 8)), and TcdB 35-556 (SEQ ID NO: 9 encoded by nucleotides 103–1668 (SEQ ID NO: 10)), were PCR amplified and cloned into the BamHI site of pABII [Spyres, 2001] to make the plasmids pLMS201, pLMS202, pLMS204, and pLMS301 respectively. Plasmids were transformed into E. coli XL 1-blue (Stratagene) and candidate clones were sequenced, then transformed into E. coli BL-21 Star (INVITROGEN) for expression.
Site-directed mutants were generated using Pfu Turbo DNA polymerase and the QuickChange mutagenesis approach (Stratagene). Oligonucleotides for generation of TcdB1-556 C395S (SEQ ID NO: 11, where Xaa at position 395 is serine) were GTTTACTATTAAATTGCTAGAATATGAGTCTTTCACAG (sense) (SEQ ID NO: 13), CTGTGAAGACTCATATTCTAGCAATTTAATAGTAAAAC (antisense) (SEQ ID NO: 14); TcdB1-556 C395W (SEQ ID NO: 11, where Xaa at position 395 is tryptophan) GTTTTACTATTAAATTGCTACCTATGAGTCTTTCACAG (sense) (SEQ ID NO: 15), CTGTGAAAGACTCATATTGGAGCAATTTAATAGTAAAAC (antisense) (SEQ ID NO: 16); TcdB1-556 W102A (SEQ ID NO: 12) AAAAATTTACATTTTGTTGCTATTGGAGGTCAA (sense) (SEQ ID NO: 17), TTGACCTCCAATAGCAACAAAATGTAAATTTTT (antisense) (SEQ ID NO: 18). Mutants were selected in E. coli XLI-blue and confirmed by sequencing, followed by transformation into E. coli BL-21 Star for expression.
Purification of Recombinant Proteins and TcdB
Expression of LFnTcdB fusions was induced with 0.2 mM iso-propyl-β-D-thiogalactopyranoside in log phase (OD 600 0.8) cultures at 16° C. Cells were harvested by centrifugation at 8700×g, resuspended in binding buffer (5 mM imidazole, 500 mM NaCl, 20 mM Tris-HCl, pH7.9) supplemented with a protease inhibitor cocktail containing 4-(2-aminoethyl)benzenesulfonyl fluoride, phosphoramidon, pepstatin A, bestatin, and E-64 and lysed by sonication. LFnTcdB fusion proteins were isolated using nickel 900 cartridges following the manufacturer's instructions (NOVAGEN). As a second purification step, proteins were fractionated on a high-resolution anion exchange (MONO-Q) column (Amersham Pharmacia). Recombinant PA was isolated from E. coli BL-21, harboring the plasmid, pSRB/ET-15b-PA (a generous gift from Steven Blanke), as previously described [Whilhite, 1998]. TcdB and TcsL were purified as previously described [Qa'Dan, 2000]. Recombinant clones of RhoA, Rac1, and Cdc42 (a generous gift of Alan Hall) were expressed and purified as previously described [Spyres, 2001].
Glucosylhydrolase/Glucosylation Assays
Glucosylation reactions were carried out as previously described [Spyres, 2001]. Glucosylhydrolase assays were carried out in a reaction mix containing 50 mM n-2hydroxyethylpiperazine-n′-2-ethane sulfonic acid, 100 mM KCl, 1 mM MnCl 2 , 1 mM MgCl 2 , 100 μg/ml BSA, 0.2 mM GDP, 40 μM [ 14 C]UDP-glucose (303 Ci/mol; ICN Pharmaceuticals), 100 μM UDP-glucose and 3 pmol of TcdB or 10 pmol of each fusion protein. The assay was allowed to incubated overnight at 37° C. and similar to a previously described protocol [Ciesla, 1998], the cleaved glucose was separated using AG1-X2 anion exchange resin and counted in a liquid scintillation counter.
Assay for Cytopathic Effects and Inhibitor Assays
To determine the cytopathic activity of each fusion and site-directed mutant, HeLa cells were plated in 96 well microtiter plates (3×10 4 cells/well) and allowed to incubate overnight. The following day the cells were treated with 30 pmol of each fusion plus 8.5 pmol of PA and observed for 48 h for signs of cytopathic effects. For inhibition assays, HeLa cells were plated as before and treated with 4 pmol of the appropriate LFnTcdB fusion plus 8.5 pmol of PA in a final volume of 100 μl. At the same point the cells were cotreated with 80 fmol of TcdB and observed for cytopathic effects. In a second competition assay, 30 pmol of TcdB 1-500 plus 8.5 pmol of PA were added to cells in a final volume of 100 μl and allowed to incubate 30 min, at which point 20 fmol of TcdB was added to the cells. Following the initial treatment, 30 pmol of TcdB 1-500 and 8.5 pmol of PA were added every 30 min for the first 90 min and every hour thereafter up to 12 h. The cells were observed for cytopathic effects for an additional 18 h. Similar competition assays were carried out using 2 pmol of TcsL. For inhibition assays with TcsL, cells were subjected to a brief acid-pulse, which enhances cytotoxic activity for this toxin. For TcsL competition, cells were pretreated with TcdB 1-500 and PA for 30 min at which point cells were treated with TcsL via an acid pulse as previously described [Qa'Dan, 2001]. The cells were then amended with 30 pmol of TcdB 1-500 , 8.5 pmol of PA every 30 min up to 12 h and followed for 16 h. For differential glucosylation assays, HeLa cells semi-confluent (1×10 6 ) were first treated with 325 pmol of PA and 300 pmol of TcdB 1-500 followed by treatment with 50 fmol of TcdB in a final volume of 10 ml. Following 3 h of treatment cells were washed 3 times in ice-cold PBS, scraped and extracts were prepared as previously described [Spyres, 2001]. Using each extract as target substrate, glucosylation reactions were identical to those previously described with changes only to reaction volume (30 μl) and amount of substrate (80 μg).
Generation of TcdB-expressing CHO Cells
A DNA sequence coding for the enzymatic domain of TcdB (amino acids 1 to 556) placed downstream and in-frame with a Kozak sequence (GNNATGG) was cloned between the HindIII and EcoRI sites of plasmid pGene/V5-His version B (INITROGEN) multiple cloning site. The recombinant plasmid was linearized with SapI and introduced into GeneSwitch-CHO cells (INITROGEN) by lipofection according to the protocol supplied with the LIPOFECTAMINE PLUS Reagent Kit (Gibco Life Technologies). Stably transfected cells were selected for on selective growth medium consisting of complete F-12 (HAM) medium plus zeocin (300 mg/ml) and hygromycin (100 mg/ml) by feeding the cells with selective medium every 3 to 4 days until foci could be seen. Antibiotic resistant cells were treated with trypsin (0.25%) solution for 3 min, diluted with 5 volumes of complete F-12 (HAM) medium and harvested by centrifugation at 250×g for 5 min. Cells were then resuspended in complete F-12 (HAM) medium, and diluted to a final cell density of five cells per ml. One hundred microliters of cell suspension was used to seed the wells of two 96-well plates. Only wells containing single foci were subcultured on selective medium in 12 and 24-well plates. Expression of TcdB was induced in the different cell lineages of transfected CHO cells by the addition of mifepristone (10 −8 M), to the selective medium. GeneSwitch-CHOpGene/TcdB1-556 a lineage of transfected cells showing nearly. 100% rounding in 24 h in the presence of mifepristone was identified and chosen for the experiments reported herein.
Statistical Analysis
Results were analyzed using the statistical software component of Excel 2001. Sample variations are reported as standard deviation from the mean, and significance was confirmed by student's T-test (p<0.05).
Utility
Since the preferred embodiments of the mutants contemplated herein are inactive, and therefore are not lethal, but are effective in binding to native TcdB toxin, they will make excellent therapeutics or vaccines against C. difficile toxins or infections in their pure and partially pure forms. The mutant toxin may be therapeutically administered to inhibit active TcdB in subjects having existing C. difficile infections or circulating TcdB toxin, for example, for treating or inhibiting diarrhea or pseudomembranous colitis.
The administration of a human vaccine comprising one or more of the mutants described herein is applicable to the prevention or treatment of a C. difficile infection in a human or animal. The vaccine may be administered by epicutaneous injection, subcutaneous injection, intramuscular injection, interdermal injection (injection by infusion), sustained-release repository, aerosolization, parenteral delivery, inoculation into an egg, and the like, by known techniques in the art. Although this approach is generally satisfactory, other routes of administration, such as i.v. (into the blood stream) may also be used in a manner known to those of ordinary skill in the art. In addition, the vaccine can be given together with adjuvants and/or immuno-modulators to boost the activity of the vaccine and the subject's response, the subject being a human or animal as described elsewhere herein.
The amount of protein in each therapeutic or vaccine dose can be selected as an amount which induces an antitoxin or immunoprotective response without significant, adverse side effects. Such amount in a vaccine will vary depending upon which specific immunogen is employed, how it is presented, and the size of the subject treated. Generally, it is expected that each therapeutic or immunogenic dose of the protein will comprise 0.1–1000 μg/kg of weight of the subject, preferably 0.2–100 μg/kg, and most preferably 1–10 μg/kg. An optimal amount for a particular vaccine can be ascertained by standard studies involving observation of appropriate immune responses in subjects. Following an initial vaccination, subjects may receive one or several booster immunization adequately spaced. Therapeutic doses for inhibiting TcdB toxin may also be from 10 μg–1 mg/kg, for example.
Accordingly in one aspect, the invention provides a method of treatment comprising administering an effective amount of a vaccine of the present invention to a subject. The vaccine formulations of the present invention may be used for both prophylactic and therapeutic purposes. The vaccine compositions of the present invention can be formulated according to known methods of preparing pharmaceutically useful compositions, whereby these materials are combined in a mixture with a pharmaceutically acceptable carrier vehicle. Suitable vehicles and their formulation are described, for example, in Remingtons' Pharmaceutical Sciences , (Mack Publishing Co., 1980).
The TcdB toxin mutants can be administered in combination with a pharmaceutical carrier compatible with the protein and the subject. Suitable pharmacological carriers include, for example, physiological saline (0.85%), phosphate-buffered saline (PBS), Tris hydroxymethyl aminomethane (TRIS), Tris-buffered saline, and the like. The protein may also be incorporated into a carrier which is biocompatible and can incorporate the protein and provide for its controlled release or delivery, for example, a sustained release polymer such as a hydrogel, acrylate, polylactide, polycaprolactone, polyglycolide, or copolymer thereof. An example of a solid matrix for implantation into the subject and sustained release of the protein antigen into the body is a metabolizable matrix, as known in the art.
Adjuvants may be included in the vaccine to enhance the immune response in the subject. Such adjuvants include, for example, aluminum hydroxide, aluminum phosphate, Freund's Incomplete Adjuvant (FCA), liposomes, ISCOM, and the like. The vaccine may also include additives such as buffers and preservatives to maintain isotonicity, physiological pH and stability. Parenteral and intravenous formulations of the vaccine may include an emulsifying and/or suspending agent, together with pharmaceutically-acceptable diluents to control the delivery and the dose amount of the vaccine.
Factors bearing on the therapeutic or vaccine dosage include, for example, the age and weight of the subject. The range of a given dose is about 25–5000 μg of the purified mutant receptor protein per ml, preferably about 100–1000 μg/ml preferably given in about 0.1–5 ml doses. The vaccine or therapeutic should be administered to the subject in an amount effective to ensure that the subject will develop an immunity to protect against a C. difficle infection or a therapeutic response against a current C. difficile infection. For example, a vaccine for immunizing an about 5-lb. piglet against C. difficile would contain about 100–5000 μg protein per ml, preferably given in 1–5 ml doses. The immunizing dose would then be followed by a booster given at about 21–28 days after the first injection. Preferably, the vaccine is formulated with an amount of the TcdB toxin mutant effective for immunizing a susceptible subject against an infection by more than one strain C. difficile.
The present invention further contemplates a monoclonal antibody raised against the C. difficile TcdB toxin mutant. The monoclonal antibody may be prepared by a method comprising immunizing a suitable animal or animal cell with an immunogenic C. difficile TcdB toxin mutant to obtain cells for producing an antibody to said mutant, fusing cells producing the antibody with cells of a suitable cell line, and selecting and cloning the resulting cells producing said antibody, or immortalizing an unfused cell line producing said antibody, e.g. by viral transformation, followed by growing the cells in a suitable medium to produce said antibody and harvesting the antibody from the growth medium in a manner well known to those of ordinary skill in the art. The recovery of the polyclonal or monoclonal antibodies may be preformed by conventional procedures well known in the art, for example as described in Kohler and Milstein, Nature 256, 1975, p. 495.
In a further aspect, the invention relates to a diagnostic agent which comprises a monoclonal antibody as defined above. Although in some cases when the diagnostic agent is to be employed in an agglutination assay in which solid particles to which the antibody is coupled agglutinate in the presence of a C. difficile toxin in the sample subjected to testing, no labeling of the monoclonal antibody is necessary, it is preferred for most purposes to provide the antibody with a label in order to detect bound antibody. In a double antibody (“sandwich”) assay, at least one of the antibodies may be provided with a label. Substances useful as labels in the present context may be selected from enzymes, fluorescers, radioactive isotopes and complexing agents such as biotin. In a preferred embodiment, the diagnostic agent comprises at least one antibody covalently or non-covalently bonded coupled to a solid support. This may be used in a double antibody assay in which case the antibody coupled to the solid support is not labeled. The solid support may be selected from a plastic, e.g. latex, polystyrene, polyvinylchloride, nylon, polyvinylidene difluoride, cellulose, e.g. nitrocellulose and magnetic carrier particles such as iron particle coated with polystyrene.
The monoclonal antibody of the invention may be used in a method of determining the presence of C. difficile TcdB toxin in a sample, such as blood, plasma, or serum, the method comprising incubating the sample with a monoclonal antibody as described above and detecting the presence of bound toxin resulting from said incubation. The antibody may be provided with a label as explained above and/or may be bound to a solid support as exemplified above.
In a preferred embodiment of the method, a sample desired to be tested for the presence of C. difficile is incubated with a first monoclonal antibody coupled to a solid support and subsequently with a second monoclonal or polyclonal antibody provided with a label. In an alternative embodiment (a so-called competitive binding assay), the sample may be incubated with a monoclonal antibody coupled to a solid support and simultaneously or subsequently with a labeled C. difficile TcdB toxin competing for binding sites on the antibody with any toxin present in the sample. The sample subjected to the present method may be any sample suspected of containing a C. difficile TcdB toxin. Thus, the sample may be selected from bacterial suspensions, bacterial extracts, culture supernatants, animal body fluids (e.g. serum, colostrum or nasal mucous) and intermediate or final vaccine products.
Apart from the diagnostic use of the monoclonal antibody of the invention, it is contemplated to utilize a well-known ability of certain monoclonal antibodies to inhibit or block the activity of biologically active antigens by incorporating the monoclonal antibody in a composition for the passive immunization of a subject against diseases caused by C. difficile producing a TcdB toxin, which comprises a monoclonal antibody as described above and a suitable carrier or vehicle. The composition may be prepared by combining a therapeutically effective amount of the antibody or fragment thereof with a suitable carrier or vehicle. Examples of suitable carriers and vehicles may be the ones discussed above in connection with the vaccine of the invention. It is contemplated that a C. difficile -specific antibody may be used for prophylactic or therapeutic treatment of a subject having a C. difficile infection or a subject which may potentially incur a C. difficile infection.
A further use of the monoclonal antibody of the invention is in a method of isolating a C. difficile TcdB toxin, the method comprising adsorbing a biological material containing said toxin to a matrix comprising an immobilized monoclonal antibody as described above, eluting said toxin from said matrix and recovering said toxin from the eluate. The matrix may be composed of any suitable material usually employed for affinity chromatographic purposes such as agarose, dextran, controlled pore glass, DEAE cellulose, optionally activated by means of CNBr, divinylsulphone, etc. in a manner known per se.
In a still further aspect, the present invention relates to a method of determining the presence of antibodies against C. difficile TcdB toxin in a sample, the method comprising incubating the sample with C. difficile TcdB toxin and detecting the presence of bound antibody resulting from incubation. A diagnostic agent comprising the TcdB toxin used in this method may otherwise exhibit any of the features described above for diagnostic agents comprising the monoclonal antibody and be used in similar detection methods although these will detect bound antibody rather than bound TcdB toxin as such. The diagnostic agent may be useful, for instance as a reference standard or to detect anti-toxin antibodies in body fluids, e.g. serum, colostrum or nasal mucous, from subjects exposed to the toxin or C. difficile.
The monoclonal antibody of the invention may be used in a method of determining the presence of a C. difficile toxin, in a sample, the method comprising incubating the sample with a monoclonal antibody and detecting the presence of bound toxin resulting from said incubation.
The present invention further contemplates a nucleic acid sequence encoding a C. difficile TcdB toxin mutant wherein the nucleic acid sequence is a cDNA similar to a cDNA which encodes native C. difficile TcdB toxin, but differs therefrom only in having instead a substituted codon which encodes the substituted amino acid or amino acids in the mutant TcdB toxin, as defined herein, and wherein the substituted codon is any codon known to encode the substitute amino acid residue. The mutant TcdB toxin described herein may be produced by well-known recombinant methods using cDNA encoding the mutant TcdB toxin, the cDNA having been transfected into a host cell in a plasmid or other vector.
In particular, the present invention contemplates any antigenic Clostridium difficile TcdB toxin mutant wherein the TcdB toxin mutant lacks the toxicity of a native C. difficile TcdB toxin.
As noted above, the invention contemplates a vaccine for use in immunizing a human or an animal against an infection by Clostridium difficile , the vaccine comprising a purified non-toxic C. difficile TcdB toxin mutant.
Alternatively, the present invention contemplates a method for immunizing a subject against an infection by Clostridium difficile by administering an effective quantity of a vaccine comprising at least one purified non-toxic C. difficile TcdB toxin mutant as defined elsewhere herein. In this method, the vaccine may be administered by epicutaneous injection, subcutaneous injection, intramuscular injection, interdermal injection, intravenous injection, sustained-release repository, aerosolization, parenteral delivery, or inoculation into an egg. In one embodiment of the method, the vaccine induces an effective antibody titer to prevent or eliminate the infection without administration of a booster of the vaccine.
The present invention further contemplates a serum for treating a subject with an existing a Clostridium difficile infection comprising antibodies against a C. difficile TcdB toxin wherein the antibodies are raised against a C. difficile TcdB toxin mutant as defined elsewhere herein.
The present invention further contemplates an antibody against a Clostridium difficile TcdB toxin wherein said antibody is raised against a C. difficile TcdB toxin mutant as defined elsewhere herein.
The present invention further contemplates a method of treating a human or animal having, or disposed to having, a Clostridium difficile infection, comprising administering to the subject a therapeutically effective amount of an antibody against to an TcdB toxin of C. difficile , the antibody raised against a C. difficile TcdB toxin mutant as defined elsewhere herein. The method for a Clostridium difficile infection may comprise administering a serum comprising the antibodies effective against C. difficile TcdB toxin.
The present invention further contemplates a method of making a hybridoma which secretes an antibody against C. difficile TcdB toxin, the method comprising fusing a lymphocyte from an animal immunized with a C. difficile TcdB toxin mutant with cells capable of replicating indefinitely in cell culture to produce the hybridoma and further isolating the hybridoma. The hybridoma may further secrete an antibody against C. difficile TcdB toxin.
Additionally, the present invention further contemplates an immunoassay for C. difficile TcdB toxin in which a sample is contacting a sample which may contain a C. difficile TcdB toxin or a portion thereof with an antibody raised against a C. difficile TcdB toxin mutant to form an antibody-TcdB toxin complex and further detecting the antibody-TcdB toxin complex to determine the presence of the C. difficile TcdB toxin.
The present invention further contemplates a polynucleotide which encodes a mutant of C. difficile TcdB toxin polypeptide as defined herein. In addition, the present invention further contemplates a vector containing a polynucleotide which encodes a mutant of C. difficile TcdB toxin polypeptide as defined herein. The present invention further contemplates a host cell containing a vector containing a polynucleotide which encodes a mutant of C. difficile TcdB toxin polypeptide as defined herein. The present invention further contemplates a process for producing a mutant of C. difficile TcdB toxin polypeptide by culturing the host cell described herein thereby expressing the mutant and purifying the mutant from the cultured host cell. The present invention further contemplates a non-toxic mutant of C. difficile TcdB toxin comprising a substitution in the cysteine residue of the native form of the toxin.
The present invention is not to be limited in scope by the specific embodiments described herein, since such embodiments are intended as but single illustrations of one aspect of the invention and any functionally equivalent embodiments are within the scope of this invention. Indeed, various modifications of the invention in addition to those shown and described herein will become apparent to those skilled in the art from the foregoing description and accompanying drawings. | An active or passive vaccine utilizing purified non-toxic mutant TcdB toxins from Clostridium difficile for humans and animals against infections caused by C. difficile and/or C. sordellii. Persons most potentially affected by C. difficile infections include hospitalized patients, infants, and elderly persons. The TcdB toxin mutant of the vaccine preferably lacks the toxicity of a native C. difficile TcdB toxin. A serum comprising antibodies raised to the TcdB toxin mutant is also available for treating humans or animals against C. difficile infections. The serum may be used in a method for conferring passive immunity against C. difficile. Antibodies to the TcdB toxin mutant may be used in diagnostic tests or in treatments to clear TcdB toxin from bodily fluids. The mutant TcdB toxin may be produced by recombinant methods using cDNA encoding the toxin, the cDNA contained for example in a plasmid or host cell. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to a vehicle lighting system and more specifically to a lighting system especially adapted for use with trucks or trailers which will assist a driver in observing conditions at the rear of the vehicle at night when backing, turning corners and the like by illuminating the rear wheels and areas adjacent the rear wheels of the vehicle. The lighting system includes a light unit capable of different modes of operation which is mounted under a vehicle body forwardly and/or rearwardly of the rear wheels with the light unit being constructed in such a manner to direct a light beam downwardly and outwardly in relation to the vehicle body and wheels to illuminate ground surface areas and obstacles that may exist up to a certain height to enable a driver to more safely operate a vehicle at night and avoid the possibility of the light shining into the eyes of other vehicle operators.
2. Description of the Prior Art
Vehicles have been provided with various types of lights to enable safer operation at night including lights which project forwardly of the vehicle and backup lights which illuminate areas to the rear of a vehicle. Running lights are provided on load carrying bodies of truck or trailer type vehicles to enable approaching drivers to more easily see a vehicle. Efforts have been made to provide auxiliary lights which are actuated in response to steering control of a vehicle. My prior U.S. Pat. No. 4,024,497 discloses a lighting system in which additional lights are energized when the existing running lights and brake lights are energized. The following U.S. patents are also relevant to this field of endeavor.
U.S. Pat. No. 3,032,646
U.S. Pat. No. 4,006,453
U.S. Pat. No. 4,297,675
U.S. Pat. No. 4,309,742
U.S. Pat. No. 4,325,052
U.S. Pat. No. 4,725,928
The above patents do not disclose the specific structure of the above invention including the association of the light unit with respect to the vehicle body and rear wheels to project a light beam downwardly and outwardly in relation to the rear wheels to illuminate the rear wheels and an area adjacent the rear wheels of the vehicle to enable a vehicle operator to operate the vehicle more safely at night.
SUMMARY OF THE INVENTION
An object of the present invention is to provide automatic rear lighting capability on truck or trailer type vehicles to increase driving safety at night when the vehicle is cornering, backing up, braking, moving or stopping by improving nighttime driving and maneuvering rear vision for the vehicle operator.
Another object of the invention is to provide a vehicle lighting system which will illuminate the vehicle rear wheels and adjacent surface areas and adjacent obstacles, if present, up to a predetermined height which includes a light unit constructed and mounted in a manner to provide a downwardly and outwardly directed light beam with the light unit being positioned above but forwardly and/or rearwardly of the wheels and inwardly of the outer surfaces of the vehicle to assure proper illumination of the desired surface areas without blinding other vehicle operators, pedestrians and the like.
A further object of the invention is to provide a light unit for a truck or trailer type vehicle which is associated with the rearmost wheels on the vehicle to illuminate the wheels and surrounding areas to facilitate nighttime operation of the vehicle in a safe manner by illuminating hazards, obstacles or other conditions adjacent the rear wheels of the vehicle during normal operation at night.
These together with other objects and advantages which will become subsequently apparent reside in the details of construction and operation as more fully hereinafter described and claimed, reference being had to the accompanying drawings forming a part hereof, wherein like numerals refer to like parts throughout.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a trailer illustrating the rear wheels and adjacent surface areas and obstacles illuminated by the light unit of the present invention.
FIG. 2 is a perspective view looking upwardly at the undersurface of a trailer load body illustrating one mounting position of the light unit between the wheels of a tandem wheel assembly.
FIG. 3 is a sectional view taken substantially upon a plane passing along section line 3--3 on FIG. 2 and on an enlarged scale illustrating structural details of the light unit.
FIG. 4 is a top perspective view of the bottom wall and sealed beam light assembly of the light unit.
FIG. 5 is a bottom perspective view of the assembly of FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The light unit of the present invention is generally designated by reference numeral 10 and is illustrated in association with a vehicle load carrying body generally designated by reference numeral 12 which, as illustrated in FIG. 1, is the load carrying body of a trailer having tandemly arranged rear wheel assemblies 14 supported therefrom in a conventional manner with the light unit 10 being constructed and mounted in such a manner to illuminate an area of the ground surface generally designated by reference numeral 16 and obstructions such as a telephone line or electric line supporting pole 18, street curb, or other similar obstructions which frequently are encountered when maneuvering a trailer 12 at night. As illustrated in FIGS. 2 and 3, the light unit 10 is mounted from a vertically disposed sidewall or frame member 20 below a floor or bottom frame member 22 of the trailer 12 with the light unit 10 being positioned generally above and between the tandem wheel assemblies 14. However, the light unit 10 can be mounted in front of or rearwardly of the tandem wheel assemblies 14 or a single wheel assembly if desired. If only a single wheel is provided, the light may be in front of or in back of the wheel and likewise, the position of the light unit in relation to tandem wheel assemblies can be varied to lower the area of illumination as desired as shown in FIG. 1.
The light unit 10 includes a mounting box or casing 24 which includes an upper wall 26, and a removable lower wall 28 paralleling each other with the lower wall being spaced from and connected to the upper wall 26 by front and rear walls 30 which are perpendicular to the walls 26 and 28 and an outer wall 32 and an inner wall 34 which are perpendicular to the front and rear walls 30 but slightly inclined in relation to the upper and lower walls 26 and 28 as illustrated in FIG. 3 with the outer wall 32 and the inner wall 34 being parallel to each other. The outer wall includes a pair of internally threaded adapters 36 receiving a pair of fastener bolts 38 which mounts the inclined inner wall 32 against the vertical inner surface of the side wall or flange 20 on the trailer 12 thus orienting the upper and lower walls 26 and 28 inclined with the inner wall 34 being positioned slightly lower than the outer wall 32.
The lower wall 28 includes an enlarged central offset area 40 which receives a lamp assembly 42 which may be a sealed beam unit or the like provided with a downwardly exposed lens 44. The removable bottom wall 28 is constructed of transparent plastic material such as "Lexan" and is generally circular in configuration and spaced from the lens 44 of the sealed beamed unit 42. The offset area 40 is joined to the bottom wall 28 by a peripheral upwardly extending flange 46 which merges with an outwardly and upwardly curved transition flange 48 which joins with the planar portion of bottom wall 28 and extends vertically from wall 28 as a circular flange 50 which has four vertical bosses 52 on the exterior thereof.
The upwardly facing juncture between flange 46 and transition flange 48 defines an upwardly facing horizontal shoulder 54 which supportingly engages a mounting and supporting ring 56 for the sealed beam unit 42. The ring 56 includes a lower generally horizontal, downwardly facing flange 58 integral with an inner generally cylindrical wall 60 and a outer cylindrical wall 62 of less height. The flange 58 engages shoulder 54 and the outer wall 62 closely fits the transition flange 48 and vertical flange 50 with the upper edge of the outer wall 62 terminating in an inturned flange 63 below the upper edge of the flange 50.
The inner wall 60 includes an upwardly extending lower portion which tapers inwardly at a small degree of taper at 64 and an upper cylindrical portion 66 which terminates in an inwardly extending peripheral horizontal flange 68 at its upper edge. The outer surface of the lower portion of inner wall 60 includes vertical stiffening ribs 67. The ring 56 is constructed of resilient material such as rubber or the like and tightly fits a peripheral flange 70 on the sealed beam unit 42 with the tapered portion 64 enabling the ring 56 and the sealed beam unit 42 to be assembled by forcing the seal beam unit up into the ring 56 until the flange 68 engages the upper surface of the flange 70 on the sealed beam unit 42. The sealed beam unit 42 is of conventional construction and includes the lens 44 and the flange 70 as an integral part thereof.
The exterior surface of the inner wall 60 is spaced from the outer wall 62 to form an upwardly facing groove or recess 72 which receives a depending cylindrical flange 74 on a retaining or clamping ring 76 of rigid construction which is horizontally disposed and rests against the upper edge of flange 50. The ring 76 includes outwardly extending tabs 78 overlying the bosses 52 to receive retaining screws 80 therethrough to clamp the ring 76 securely in place with the lower edge of the flange 74 clamping the horizontal flange 58 downwardly onto the shoulder 54 in sealed relation. The periphery of the flange 68 due to the snug engagement of the upper wall portion 66 which has been somewhat extended when the sealed beam unit is forced into the ring 56 forms an effective seal between the sealed beam unit and the ring 56 all of which effectively seals the interior of the offset portion of the bottom wall with the sealed beam unit to prevent ingress of any material which would occlude transparency of the interior of the offset portion 40 of the bottom wall 28.
Th exterior surface of the inner wall 60 tapers inwardly and includes an outwardly extending peripheral flange 82 which has an outwardly curved upper surface 84 and a horizontal bottom surface 86 which engages the interior surface of the flange 74 on the clamping ring 76 to further form a seal and cushioning support for the sealed beam unit 42.
The sealed beam unit 42 includes connector units 90 provided with electrical conductors 92 secured thereto by screws 94. One conductor 92 extends through an opening at the juncture between the front or rear wall 30 and the lower wall 28 with both the front and rear walls 30 having an identical opening therein to enable the electrical conductor 92 to extend outwardly of the housing 2 in either direction. A sealing grommet is provided for the opening and conductor 92 and a plug is provided for the unused opening. A conventional connector is provided on the conductor 92 to enable the light unit 10 to be connected to a source of electrical energy in a manner to enable optional operational characteristics as set forth hereinafter. The other conductor 92 is connected to ground at adapter 36.
The light unit 10 includes a structure in which the bottom wall 28 is removable by the use of screw threaded fasteners 104 and a gasket 106 mounted on a thickened edge portion 108 of wall 28. This enables the sealed beam unit 42 to be easily changed in the event it becomes inoperative. Also, the casing 24 is completely waterproof and may be constructed of rigid plastic material that is resistant to breakage and provides a durable and longlasting structure.
The slanted housing enables the light unit to be mounted against the inner surface of the vertical side wall or side flange above and forwardly and/or rearwardly of the vehicle wheels to illuminate downwardly and outwardly at an angle of approximately 5° . The light unit includes the use of a circuit board arrangement utilizing solid state components rather than relay switches and other mechanical components disclosed in my prior U.S. Pat. No. 4,024,497. The light unit can be arranged for different operational modes in response to turn signal and/or emergency flasher operation. Attached hereto is a System Summary and Installation Instructions (23 pages) and schematic wiring diagrams for a one way and four way unit (page 24) and a two way unit (page 25) setting forth actual installation instructions as well as detailed information relating to the benefits including reproductions of photograph illustrating pictorially the functional advantages of the unit when operating a trailer at night. The attached booklet (Exhibit A) is incorporated herein as a portion of the disclosure in this application. The control unit for operating the light unit 10 is mounted interiorly or just outside of the turn signal control box normally provided in load carrying vehicles thereby eliminating the addition of control units in the vehicle cab. Also, the light unit, when energized, will be continuously illuminated rather than flashing when the vehicle running lights are energized. During one-way operation, there is a separate control to energize either the right or left light unit along with the turn signal. During four way operation, the light units operate separately when right or left turn signals are activated and all light units operate when the emergency flashes operate. During two way operation, the light units operate separately from the right or left turn signal but do not operate when the emergency flashes are used.
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. | A vehicle lighting system for use with trucks or trailers which will assist a driver in observing conditions at the rear of the vehicle at night when backing, turning corners and the like by illuminating the rear wheels and areas adjacent the rear wheels of the vehicle. The lighting system includes a light unit mounted under a vehicle body above but forwardly and/or rearwardly of the rear wheels with the light unit being constructed in such a manner to direct a light beam downwardly and outwardly in relation to the vehicle body and wheels to illuminate ground surface areas and obstacles that may exist up to a certain height to enable a driver to more safely operate a vehicle at night and avoid the possibility of the light shining into the eyes of other vehicle operators. | 1 |
BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to an ironing device having a housing and a pumping device for transporting fluid from a receptacle onto an ironing article.
German Patent 198 29 675 A1 discloses an ironing device with a housing in which is disposed a pumping device with a diaphragm pump. The diaphragm pump has a pump chamber whose volume can be varied by a pump element. A feeder having a return valve is led from a receptacle integrated into the housing to the pump chamber and a pressure pipe having a return valve is led from the pump chamber to a spray nozzle. The pump element can be operated by an operating part, with the operating part being fashioned as a ductile diaphragm. The diaphragm pump can transport fluid from the receptacle through the spray nozzle onto an ironing article.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide an ironing device that overcomes the hereinafore-mentioned disadvantages of the heretofore-known devices of this general type and that creates a constructively simple ironing device having few locations between a receptacle and an outlet of a fluid that are simple to seal.
With the foregoing and other objects in view, there is provided, in accordance with the invention, an ironing device, including a housing, a receptacle holding fluid, and a pumping device for transporting the fluid from the receptacle onto an ironing article. The receptacle is fluidically connected to the housing. The pumping device is disposed in the housing, is fluidically connected to the receptacle, and has at least one hose pump for pumping the fluid.
Particularly few locations, which are simple to seal, between the receptacle and an outlet of the fluid can be reached with a hose pump when a single-piece hose is led from the receptacle through a pump part of the hose pump to a connection of a spray nozzle and/or a single-piece hose is led from a receptacle through a pump part of the hose pump to a connection of a steam chamber. The configuration provides a corresponding reduction in sealing outlay, additional components, assembly space, weight, assembling outlay, and costs.
The invention prevents pump parts, apart from the hose, from coming in contact with the fluid by providing moving displacers and bearings thereof to act upon the hose and thereby effect a pumping action. Such hose pumps are safe to run dry or, respectively, can be operated without fluid without causing damage. Such pumps are also particularly reliable.
Given hose pumps, scaling can be mostly prevented in the area of the pump. The hose coming in contact with the fluid is always set free from lime as a result of its motion or, respectively, deformation, and the hose protects the other pump parts from the fluid. Furthermore, hose pumps can obtain a desired conveying capacity in a constructively simple way through a hose cross-section. The hose pump forms a regenerative or self-priming system, so that a constant conveying capacity can be obtained independently of a level in the receptacle.
The hoses can be simply and flexibly laid in the housing, so that a particularly simple installation is possible. The hose can be produced from different materials appearing expedient to someone skilled in the art, with the hose being particularly made of flexible, conventional plastics. Silicone hoses are preferably utilized because water is typically used for moistening the ironing article.
In accordance with another feature of the invention, the receptacle can be disposed in the housing and/or outside the housing. A separate external receptacle can be fashioned with a large volume particularly for large amounts of ironing articles. A hose provided for a separate receptacle can be led to a connecting point that is integrated into the housing of the ironing device, whereby a hose of a separate receptacle can be connected to the connecting point. However, it is also possible that a sufficiently long hose to a separate receptacle already is disposed in the housing. The hose can be disposed in a retaining space in the housing, so that it can be wound up and unwound on a rotatable axle.
In accordance with a further feature of the invention, the at least one hose pump has a pump part, the housing has a spray nozzle with a nozzle connection, and at least one single-piece hose fluidically connects the receptacle to the nozzle connection through the pump part.
Instead of guiding a number of single-piece hoses from the receptacle through a pump part of the hose pump, it is also generally possible to provide a number of hoses and/or channels at a branch point with fluid by a hose led through the pump part, for example, a hose led from the receptacle through the pump part can provide for a channel branch point, which is integrated into the housing and can be controlled by an operator, whereby, proceeding from the channel branch point, individual outlets can be provided with fluid via a channel system integrated into the housing.
In accordance with an added feature of the invention, the housing has a steam chamber with a chamber connection, the at least one single-piece hose is at least two single-piece hoses, and at least one of the two single-piece hoses fluidically connects the receptacle to the chamber connection through the pump part.
In accordance with an additional feature of the invention, the at least one hose pump has a pump part, the housing has a steam chamber with a chamber connection, and at least one single-piece hose fluidically connects the receptacle to the chamber connection through the pump part.
In accordance with yet another feature of the invention, the receptacle is separate from the housing, the at least one hose pump has a pump part, and at least one hose is fluidically connected to the separate receptacle through the pump part.
In accordance with yet a further feature of the invention, at least one single-piece hose has a hose part and fluidically connects the receptacle to the pumping device through the pump part at a hose part, and the at least one hose pump has at least one displacer rolling off onto the hose part.
Given hose pumps, a pumping action is generally achieved in that driven displacers act upon a hose. The displacers can perform different movements that appear expedient to someone skilled in the art, for example, a displacer of a hose diaphragm pump having a return valve in flow direction in front of the displacer and a return valve in flow direction behind the displacer can execute a translational rocking motion perpendicular to the axis of the hose.
In accordance with yet an added feature of the invention, at least one displacer is at least two displacers, and one of the two displacers prevents a backflow of the fluid into the receptacle.
Hose pumps having at least one displacer rolling off onto a hose part are particularly advantageously utilized. As a result of the rolling motion of the displacer carried out on the hose part, a flow direction can be determined, so that at least one return valve can be foregone vis-à-vis the previously described hose diaphragm pump. If the hose pump has at least two displacers, advantageously, three or more displacers, one displacer always can be used for preventing a backflow into the receptacle, return valves can be completely foregone, and a particularly simple and cost-efficient hose pump can be obtained.
In accordance with yet an additional feature of the invention, at least one part of the hose pump is extrusion-coated given the production of the housing, namely a bearing component of at least one displacer, which is normally fashioned in a fixed manner relative to the housing. Additional mounting parts can be foregone and the assembling outlay, the weight, and the expenses can be reduced. Furthermore, additional components can be omitted by fashioning at least one part of the hose pump as one piece with the housing. A bearing component of at least one displacer is particularly advantageous for such a purpose.
In accordance with again another feature of the invention, at least a part of the at least one hose pump is formed in one piece or integral with the housing.
In accordance with again a further feature of the invention, the at least one displacer has a bearing component formed in one piece with the housing.
In accordance with again an added feature of the invention, the at least one hose pump has at least one part produced from plastic.
If at least one part of the hose pump or preferably the entire hose pump is composed of plastic, it can be particularly simply and cost-efficiently realized. Moreover, it is advantageous to fashion individual components as one piece with the housing that normally is produced from plastic.
In accordance with a concomitant feature of the invention, there is provided a motor connected to the at least one hose pump for operating the at least one hose pump.
An operation can manually operate the hose pump or, more advantageously, a motor can operate the hose pump, particularly, an electromotor, so that high operating comfort can be achieved.
Other features that are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in an ironing device, it is, nevertheless, not intended to be limited to the details shown because various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of an ironing device according to the invention; and
FIG. 2 is an enlarged, exploded, perspective view of a pumping device of FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In all the figures of the drawing, sub-features and integral parts that correspond to one another bear the same reference symbol in each case.
Referring now to the figures of the drawings in detail and first, particularly to FIG. 1 thereof, there is shown a schematically represented ironing device having a plastic housing 10 that is attached to a heatable metal ironing sole 34 . A handle 33 is molded onto a side of the housing 10 opposite the ironing sole 34 . A receptacle 13 is integrated into the housing 10 above the ironing sole 34 in the direction of the handle 33 . A pumping device 11 also is disposed in the housing 10 through which liquid 12 , particularly water, can be transported from the container 13 and/or a separate container 14 onto an ironing article.
The pumping device 11 inventively has a hose pump 15 (FIG. 2 ). A first single-piece silicone hose 16 is led from the receptacle 13 through a pump part 18 of the hose pump 15 to a connection 19 of a spray nozzle 21 and a second single-piece silicone hose 22 is led through the pump part 18 of the hose pump 15 to a connection 24 of a steam chamber 26 . The steam chamber 26 is disposed directly above or, respectively, on the side of the ironing sole 34 facing the handle 33 . A press switch 45 integrated at the handle 33 can operate the spray nozzle 21 .
A third single-piece silicone hose 17 is led from the receptacle 14 through the pump part 18 of the hose pump 15 to a connection 20 of the spray nozzle 21 and a fourth single-piece silicone hose 23 is led through the pump part 18 of the hose pump 15 to a connection 25 of the steam chamber 26 .
The pump part 18 is firmly connected to the housing 10 through a cover 30 and through a flange 31 that is screwed down with the housing 10 . It is also possible to realize the pump part as one piece with a housing of the ironing device. Three cylindrical displacers 27 , 28 , 29 are disposed in the pump part 18 , are driven by an electromotor 32 , and can be rolled off onto the four silicone hoses 16 , 17 , 22 , 23 for generating a pumping action. The electromotor 32 is provided with current through non-illustrated current cables that are led through a cable channel 44 into the housing 10 to the electromotor 32 .
The electromotor 32 has a motor shaft 35 , which, in a mounted state, is led through a first bearing 36 in the cover 30 , through a middle area past the three cylindrical displacers 27 , 28 , 29 , and through a second bearing 37 in the pump part 18 . The motor shaft 35 drives the displacers 27 , 28 , 29 in a frictionally engaged fashion, namely, comparable to a sun wheel driving a planet. The pump part 18 , the displacers 27 , 28 , 29 , the cover 30 , and the flange 31 are fashioned preferably as plastic molded parts.
The silicone hoses 16 , 17 , 22 , 23 are led through four non-illustrated openings at a bottom side 38 of the pump part 18 into the pump part 18 , are disposed adjacent one another at an inside wall of the pump part 18 to an upper side 39 and through four openings 40 , 41 , 42 , 43 out of the pump part 18 . The displacers 27 , 28 , 29 roll off onto the inside wall through the silicone hoses 16 , 17 , 22 , 23 and generate a squeezing motion of the silicone hoses 16 , 17 , 22 , 23 continuing in flow direction or, respectively, press the silicone hoses 16 , 17 , 22 , 23 flat against the inside wall. Prior to a displacer 27 , 28 , or 29 being lifted off by the silicone hoses 16 , 17 , 22 , 23 , a following displacer 27 , 28 , or 29 presses the silicone hoses 16 , 17 , 22 , 23 flat against the inside wall of the pump part 18 , so that the fluid cannot flow back into the receptacle 13 or, respectively, 14 . | An ironing device includes a housing, a receptacle holding fluid, and a pumping device for transporting the fluid from the receptacle onto an ironing article. The receptacle is fluidically connected to the housing and the pumping device is disposed in the housing, is fluidically connected to the receptacle, and has at least one hose pump for pumping the fluid. | 3 |
This invention relates to cationic cross-linked starches and to the use of those starches in papermaking. More particularly, the present invention is directed to cationization and cross-linking of starch, and the use of that cationized cross-linked starch in the wet end system of a paper machine.
The cationized cross-linked starch of the invention is particularly adapted for use in the wet-end system of a paper machine and more particularly in the furnish. The wet-end of the paper machine is where paper fiber in a dilute water slurry of pulp fiber is combined with a variety of materials, including starches, to provide various paper properties or characteristics as the aqueous slurry is distributed onto a paper machine wire, as in a Fourdrinier machine. Three types of paper processes are known, and are referred to as "Acid", "Neutral" or "Alkaline", which correspond generally to the pH of the furnish. Acid furnishes generally have a pH of less than 6.0 while Neutral furnishes have a pH between about 6.5 and 7.5. Alkaline furnishes have a pH above 7.5. Acid, Neutral and Alkaline processes also differ in their make-up, which can affect the performance of additives such as cationic starches. Acid processes have been primarily used in paper manufacture, but Neutral and Alkaline processes are on the increase in the manufacture of paper.
Starches modified in various ways have been used in papermaking to improve paper characteristics. Starches modified to be cationic are known to aid in the retention of fines, adsorb onto the anionic cellulosic fibers to improve pigment binding efficiency, and improve the dry strength of the resulting paper. However, as is more fully described below, over cationization of the pulp or paper furnish results in poor sheet formation and poor drainage of the furnish on the paper machine.
Starch Loading is a term used hereafter to describe the amount of cationic starch added to a paper furnish to improve the parameters of drainage, retention and strength properties, and is usually expressed in units of pounds of starch per ton of paper fiber on a weight to weight basis. Paper furnish or pulp is anionic (negatively charged), and it can adsorb only as many cationic (positive) charges from the starch as there are available anionic charges. Near the isoelectric point, i.e., where the charges are balanced, optimum drainage, retention, and sheet formation of paper should occur. Over cationization of the furnish results in loss of drainage and poor sheet formation. Cationic starch is important to paper manufacturing plants that use high amounts of fillers such as clays and calcium carbonate (CaCO 3 ) in the paper stock. High filler amounts have been shown to be detrimental to wet and dry paper strength. Cationic starch addition to the furnish is used to counteract the loss of wet and dry strength of high filler paper.
Drainage (or de-watering ability) is a critical parameter in paper manufacture because it is directly related to how fast the paper machine can run; the greater the speed, the higher the production rate. Yet, it is a parameter that has largely been ignored with respect to starch. The value of heavy starch loading has not been appreciated nor practiced in the paper industry. Further, the utilization of such heavy starch loading while enjoying rapid drainage has not been attainable.
It is a particular object of this invention to provide a new cationic starch particularly useful in paper manufacture.
It is another object of this invention to provide a new method of papermaking utilizing heavy starch loading in paper manufacture.
It is also an object of this invention to provide improved drainage in order to increase the speed of paper manufacture with heavy loading of starch.
It is another object of this invention to improve the drainage of furnish in a paper machine as well as increase starch loading, yet also enhance the retention of fines and fillers of the paper furnish.
It is also an object of this invention to improve the drainage and retention properties of the furnish in a paper machine as well as increased starch loading, yet also enhance the wet and dry properties of the resulting paper.
Still further objects and advantages of the invention will be found by reference to the following description.
SUMMARY OF THE INVENTION
According to the invention, a cationic starch which has been cross-linked after cationization is added to anionic paper pulp or furnish during paper manufacture. The starch of the invention is added to achieve a near zero Zeta potential and to balance the charges in the furnish. Thus, when the anionic charges of the fibers are high, higher levels of starch may be added but, in any event, over cationization is to be avoided, as before pointed out. Adding the cationized cross-linked starch permits starch loading up to about 50 pounds of starch per ton of fiber, permits drainage increases in a range of from about 10 to about 20-fold, as measured by a Dynamic Drainage Jar and enhances the wet and dry strength and other properties of the paper which includes the cationic cross-linked starch. According to the invention, the viscosity of cationized cross-linked starch which is in the range of from about 500 cps to about 3000 cps, as measured on a Brookfield viscometer, at 1.4 percent starch solids at 95° C., at 20 rpm, using a number 21 spindle, results in the enhancement of drainage of the furnish.
The cationization and subsequent cross-linking of the starch which is added in paper manufacture is important to the invention. The starch is cationized to a degree of substitution (DS) of greater than 0.005, but not greater than 0.050, preferably to a DS of from about 0.030 to about 0.040. Thereafter, the cationized starch is cross-linked with a cross-linker which may be a polyfunctional organic or inorganic compound wherein functional groups, such as epoxides or anhydrides, on the cross-linker are reactive with hydroxyl groups on the starch. The degree of substitution (DS) is defined as the average number of hydroxyl groups on each anhydroglucose unit which are derivatized with substituent groups and is described generally in STARCH: Chemistry and Technology, second edition, R. L. Whister, J. N. Bemiller, and E. F. Paschall, editors, Academic Press, Inc., 1984. The DS serves as a measure of the charge on the cationized and cross-linked starch and is related to the average number of monovalent cations on the hydroxyl groups on each anhydroglucose unit.
While not intending to be bound by any theory of the invention, it is believed cationization with subsequent cross-linking of the starch encloses some of the cationically charged portions or branches of the starch as well as increases the molecular weight, and therefore the hydrodynamic volume, of the starch. The enclosure of some of the portions of the cationically charged starch enhances the starch loading of the starch into the paper; the cross-linking, however, also builds the molecular weight (hydrodynamic volume) of the starch polymer which will enhance the de-watering ability of the starch to permit increase in the speed of the papermaking process. The increase in size of the starch polymer aids in bridging the fines and fillers of the paper furnish, resulting in enhancement of retention and drainage. Furthermore, the cationized and cross-linked starch enhances other paper properties as demonstrated hereinafter.
The term "paper" refers generally to fibrous cellulosic materials, as well as fibers from synthetics such as polyamides, polyesters, and polyacrylic resins, mineral fibers such as asbestos and glass, and combinations of fibers.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the effect on drainage of an alkaline furnish using 3 different crosslinking agents for the cationic starch.
FIG. 2 shows the effect on drainage of an alkaline furnish using varying cationization of the crosslinked starch.
FIG. 3 shows the effect on drainage of an alkaline furnish using cationic crosslinked potato starch.
FIG. 4 shows the effect on drainage of an alkaline furnish using cationic crosslinked waxy maize starch.
FIG. 5 is a comparison of cationic cross-linked corn, waxy maize and potato starches and the effect on drainage of an alkaline furnish.
FIGS. 6-9 show the effect of cationic crosslinked starch on drainage of mill furnishes.
FIG. 10 shows the comparison of crosslinked, then cationized starch versus cationized starch which is then crosslinked.
DESCRIPTION OF THE PREFERRED EMBODIMENT
According to the preferred practice of the invention, starch is cationized to a degree of substitution (DS) of from about 0.030 to about 0.040. The starch may be cationized by any known method such as by reacting starch in an alkaline medium with tertiary or quaternary amines followed by neutralization, and washing and drying as desired. Known methods for cationizing starch are described in U.S. Pat. Nos. 4,146,515 to Buikema et al. and 4,840,705 to Ikeda et al. In one important aspect of the invention, cornstarch is cationized by reaction of the starch with (3-chloro-2-hydroxypropyl) trimethyl ammonium chloride in an alkaline medium provided by sodium hydroxide to form the cationic (2-hydroxypropyl) trimethyl ammonium chloride starch ether with a molar degree of substitution (DS) of the ether on the starch in the range of from about 0.030 to about 0.040.
The starch used of the invention may be from a variety of sources such as corn, waxy maize, potato, rice, wheat, sorghum, and the like. The starch must have hydroxyl or another functional group to permit it to be cross-linked. This invention can utilize cationic starch regardless of its method of preparation. Some cationic starches, however, have a positive charge in acidic environments, due to protonation of a substituent, such as protonation of an amino nitrogen, but lose their positive charge under neutral or basic conditions. Other cationic starches carry a positive charge over the entire pH range, such as those having quaternary ammonium, quaternary phosphonium, tertiary sulfonium, or other substituents. It is preferred to use a cationic starch which retains a positive charge that has been derivatized to contain a quaternary ammonium ion because of enhanced flexibility in pH. Frequently, such quaternary ammonium-containing starch has been derivatized by etherification of hydroxyl groups with an appropriate etherifying agent having a cationic character such as (3-chloro-2 hydroxypropyl) trimethyl ammonium chloride, the methyl chloride quaternary salt of N-(2,3-epoxypropyl) dimethylamine or N-(2,3-epoxypropyl) dibutylamine or N-(2,3-epoxypropyl)methylaniline.
After cationization, the starch is cross-linked with a cross-linker which is reactive with the hydroxyl functionality of the starch. The starch may be cross-linked with polyepoxide compounds such as a polyaminepolyepoxide resin (which is a reaction product of 1,2-dichloroethane and epichlorohydrin), phosphrousoxychloride, 1,4 butanediol diglycidyl ether, dianhydrides, acetals and polyfunctional silanes. These and other suitable cross-linkers are described in U.S. Pat. Nos. 3,790,829; 3,391,018; and 3,361,590. The molecular weight of cross-linked starch is not only difficult to measure, but molecular weight determinations in starches are subject to general ambiguity due to the lack of adequate standards for Gel Permeation Chromotography (GPC), and the difficulty in Laser Light Scattering techniques. It is known, however, that the molecular weight of starch, including cross-linked starch, has a high correlation to the viscosity of the starch; the more viscous the starch the higher the molecular weight. The cationic cross-linked starch is cross-linked to a viscosity in the range of from about 500 cps to about 3000 cps, preferably from about 500 cps to about 1500 cps as measured on a Brookfield viscometer using as 1.0 Be Slurry (at 21° C.) to obtain a 1.4 percent solids, measuring hot paste viscosity (95° C.) after a period of 10 minutes, at 20 rpm (No. 21 spindle). The amount of cross-linker used is a function of the time and kind of cross-linker, as well as reaction conditions, all of which are chosen to provide the viscosity in the specified range.
The cationic cross-linked starch of the invention may be mixed into a paper furnish having a pH of from 6.0 to about 9.0 as a wet-end additive. The general manufacturing process for paper, including the term "wet-end", is well-known to those skilled in the art and described generally in Pulp & Paper Manufacture, Vol. III, Papermaking and Paperboard Making, R. G. McDonald, editor: J. N. Franklin, Tech. Editor, McGraw Hill Book Co., 1970. The furnish may include hardwood, softwood or a hardwood/softwood blend. Addition of the cationic cross-linked starch may occur at any point in the papermaking process; i.e. prior to conversion of the wet pulp into a dry web or sheet. Thus, for example, it may be added to the fiber while the latter is in the headbox, beater, hydropulper, or stock chest. The furnish may include additives, dyes, and/or fillers such as clays, CaCO 3 , alum and the like. Indeed, the invention advantageously permits the use of higher levels of starch and fillers in lieu of more expensive cellulosic fiber, the result being paper with enhanced strength made with less expensive raw materials in shorter process times with higher retention of fines and fillers.
Typically cationic corn, potato, and waxy maize starches substituted to a DS in the range of 0.030 to 0.040, exhibit peak or maximum drainage rates at about 5 to about 15 pounds of starch per ton of paper fiber. In accord with the invention, starch loading of cationic cross-linked cornstarch of similar DS having a viscosity of about 1000 cps (1.0 Be slurry, 95° C. hot paste) provides peak drainage increases of 30 percent to 50 percent over cationic corn or potato starches, at about 20 to about 40 pounds of starch per ton of paper fiber, giving starch loading improvements of about 100% to 400%. While the cationic cross-linked starch of the invention improves certain paper properties at lower starch loading levels, the benefits of the invention are most enjoyed at starch loadings of 20 to 40 pounds per ton of fiber, provided that over cationization is avoided.
The following Examples set forth exemplary methods for making the cationic cross-linked starch of the invention and practicing the method of the invention in a papermaking process.
EXAMPLE I
4000g of cornstarch in an aqueous slurry is reacted with 430 g of 65% (3-chloro-2-hydroxypropyl) trimethyl ammonium chloride and 1 liter of 8% aqueous sodium hydroxide in a saturated salt solution at 45° C. for 18 hours at 15 ml alkalinity titer (10 ml sample, 0.1N H 2 SO 4 ). The cationized starch has a DS of 0.032. 2.0 g of a 20% aqueous solution of Etadurin-31 from Akzo Chemie America, a polyaminopolyepoxide polymer, (0.01% by weight addition, based upon the weight of the starch) is added to cross-link the cationized starch. After 1 hour at 45° C., a 100 ml aliquot is removed and neutralized with hydrochloric acid to a pH of 4.0, and the slurry is filtered, and the resultant cake washed with water. A portion of the washed cake is then re-suspended in water to a Be of 1.0 at 21° C., heated at 95° C. for 10 minutes, and the viscosity measured on a Brookfield viscometer at 20 rpm. When the hot paste (95° C.) viscosity of the samples prepared in this manner approach 1000 cps, the reaction mixture is neutralized to a pH of 4.0 with hydrochloric acid and the suspension filtered, washed with water, and dried to about 10% moisture.
PERFORMANCE OF THE CATIONIZED CROSS-LINKED STARCH OF EXAMPLE I
(a) Drainage
A paper stock is prepared by adding 114 g of a 50:50 blend of hardwood/softwood bleached paper fiber, re-suspended in water using a Waring blender, 2.85 g clay (50#/ton fiber) and 2.85 g precipitated calcium carbonate (CaCO 3 ) as fillers to 37.85 1 (10.0 gallons) of water pH adjusted to pH 7.5. Drainage evaluations are performed by measuring the volume of filtrate through a standard qualitative filter paper for a period of 1 minute, the results of which are shown in Table I. One liter of the furnish is subjected to a constant shear rate from a 1000 rpm agitator during starch addition. Typical drainage enhancements using the cationized cross-linked starch of the invention versus cationic corn or cationic potato starches are in the range of 30 percent to 50 percent.
TABLE I______________________________________(Commercial Drainage Results)Standard Error of Prediction (SE) = 1.0%Pound starch/ Commercial Commercial CationicTon Fiber Cationic Potato Cationic Corn Cross-linked______________________________________ 0 20 ml 20 ml 20 ml 5 77 ml 34 ml 25 ml10 178 ml 126 ml 35 ml15 154 ml 180 ml 67 ml20 140 ml 142 ml25 240 ml30 256 ml40 232 ml50 112 ml______________________________________
(b) Retention
Retention percentages of the paper furnish are measured in a manner similar to drainage. Retention is defined as the amount of fiber and filler retained in the paper sheet divided by the total fiber and filler in the paper furnish. A 70 mesh wire screen is substituted for the filter paper used in the drainage measurement, and the first 100 ml of filtrate is collected while the furnish is subjected to a constant 500 rpm agitator shear rate. An oven dry method is used to measure percent solids in the filtrate. The results of the tests, as shown in Table II below, show that retention improvements of the cationized cross-linked starch of Example I over cationic corn and cationic potato are typically in the range of 5% to 10% absolute retention.
TABLE II______________________________________(Retention Percentage)Standard Error of Prediction = 0.21Pound Starch/ Commercial Commercial CationicTon Fiber Cationic Potato Cationic Corn Cross-linked______________________________________ 0 75.2% 75.2% 75.2% 5 77.3% 77.4% 76.7%10 78.2% 78.2% 76.9%15 80.8% 78.0% 78.4%20 80.6% 78.5% 80.4%25 80.9% 81.4% 82.3%30 79.6% 79.4% 84.9%40 81.3% 79.2% 85.3%50 79.4% 77.5% 87.3%______________________________________
EXAMPLE II
(Comparison of Cross-Linkers)
a) Phophorous oxychloride is used to cross-link cationized cornstarch (2-hydroxypropyl) trimethyl ammonium chloride starch ether, DS 0.028, by reacting 0.18 ml of the cross-linker with 1700 g of the cationized cornstarch at pH 10.0 at 45° C. for 15 minutes to a Brookfield hot paste (95° C.) viscosity of 950 cps.
b) 1,4-Butanediol diglycidyl ether is used to cross-link cationized cornstarch (2-hydroxypropyl) trimethyl ammonium chloride starch ether, DS 0.033, by reacting 1.5 ml of the cross-linker with 1700 g of the cationized cornstarch at 16.5 ml alkalinity titer (10 ml sample, 0.1N H 2 SO 4 ) for 20 hours at 45° C. to a Brookfield hot paste (95° C.) viscosity of 980 cps.
c) A polyaminepolyepoxide resin (Etadurin-31) is used to cross-link cationized cornstarch (2-hydroxypropyl) trimethyl ammonium chloride starch ether, DS 0.032, as in Example I to a Brookfield hot paste (95° C.) viscosity of 980 cps.
DRAINAGE PERFORMANCE
The drainage performance of the cationic cross-linked starches described in (a), (b) and (c) above are tested by the method described in Example I using a furnish having 0.3% fiber, 50#/ton clay, and 50#/ton CaCO 3 , at a pH of 7.5. The drainage performance of each cationic cross-linked starch is illustrated in FIG. 1. These results show approximately the same peak drainage for each of the cross-linkers, with the starch cross-linked with the polyaminepolyepoxide resin (Etadurin-31) showing a slightly better starch loading ability.
EXAMPLE III
(Effects of Varying Cationization)
The following cornstarches are cationized (2-hydroxypropyl) trimethyl ammonium chloride with the DS of the quaternary ammonium group being varied as follows:
______________________________________Cationized Cornstarch DS______________________________________X42 0.032X82 (Series) 0.020______________________________________
The above starches are cross-linked as shown below with polyaminepolyepoxide resin (Etadurin-31) to the indicated hot paste (95° C.) viscosities which correlate with the degree of cross-linking.
______________________________________Cationic Cross-linkedCornstarch Brookfield Viscosity______________________________________X82 (not cross-linked) 395 cpsX82A 540 cpsX82B 690 cpsX82C 980 cpsX82D 1100 cpsX42B3 980 cps______________________________________
The drainage performance of each of the above cationized cross-linked starches was tested as described in Example I using the standard laboratory furnish having 0.3% fiber, 50#/ton clay, 50#/ton CaCO 3 , the furnish having a pH of 7.5. The effect upon drainage of each cross-linked starch is illustrated in FIG. 2. These data indicate that a lower molecular substitution of cationic material onto the starch adversely affects drainage on this furnish.
EXAMPLE IV
(Comparison of Starches)
Corn, potato and waxy maize starches are cationized with a quaternary ammonium group ((2-hydroxypropyl) trimethyl ammonium chloride) to a DS of 0.035, and cross-linked with the polyaminepolyepoxide resin to Brookfield viscosities, for time of cross-linking reaction indicated below.
TABLE III______________________________________Starch Designation______________________________________ Hours of Cross-linkingPotato X80 (not cross-linked) 0.0Potato X80A 0.5Potato X80B 1.0Potato X80C 2.0Potato X80D 3.0Potato X80E 5.0 Brookfield ViscosityWaxy X77 (not cross-linked) 1640 cpsWaxy X77A 2640 cpsWaxy X77B 2950 cpsWaxy X77C 2970 cpsCorn X42B.sub.3 980 cpsCorn X42B.sub.4 1170 cps______________________________________
The drainage for the above waxy maize and potato starches in the furnish described in Example I was performed and the results are illustrated in FIGS. 3 and 4.
Due to the inherently higher molecular weight of the waxy maize and potato starches, the cross-linking reaction was significantly different than in the cornstarch counterpart. The resulting products did however demonstrate the same drainage trends as can be seen in FIGS. 3 and 4, with increasing peak drainages and starch loading correlating very well with the extent of the cross-linking reaction. FIG. 5 is a comparison study of the best of each of the three starches, evaluating peak drainage and starch loading.
EXAMPLE V
(Comparison of Mill Furnishes Using Cationic Cross-linked Starch)
Thick stock (about 3% fiber) was obtained from 4 different paper mills that prepare alkaline paper. This thick stock was then prepared for evaluation of drainage (dilution to 0.3% fiber, including any chemical additives present in the Mill furnish), using a series of cross-linked cationic cornstarches (X42, see Example III) for the comparison with the standard cationic potato starch. In all cases (FIGS. 6 to 9), the Mill furnishes confirmed what had been seen in the laboratory prepared furnishes, that synthetically cross-linking a cationic starch dramatically affects the net available charge of the cationic starch, starch loading, and the water releasing ability of the paper furnish (drainage). It is interesting to note that in the laboratory furnishes, cationic cornstarch cross-linked to a viscosity of 1170 cps (hereinafter known as X42B4), demonstrated the highest water releasing ability, whereas in all of the Mill furnishes the optimum cross-linked starch in the X42 series is X42B3 (980 cps) which is slightly less cross-linked (X42B2 has a viscosity of 870 cps). Zeta Potential measurements and Colloidal Titrations of the Mill furnishes showed that Mill preparation of the fiber versus a re-pulping laboratory method differs in the amount of anionic sites generated. Additionally, the Mill furnishes tend to have higher levels of fines and fillers than the laboratory furnish, adding to the anionic (charge) nature of the furnish. The difference in reactivity of the X42 series of starches suggest that optimization of the cross-linking level on the cationic starch is necessary for each Mill furnish to obtain maximum enhancements in drainage, retention, and starch loading.
EXAMPLE VI
(Comparison of Cross-linked, Then Cationized Starch Versus Cationized Starch Which Then Is Cross-linked)
The following cornstarches were cross-linked with the polyaminepolyepoxide resin to a Brookfield hot paste (95° C.) viscosity as indicated below.
______________________________________Cornstarch Brookfield Viscosity DS______________________________________X11A 650 cps 0.033X11B 770 cps 0.032X11C 1000 cps 0.034______________________________________
The above cross-linked starches were cationized after cross-linking by the addition of (3-chloro-2-hydroxypropyl) trimethyl ammonium chloride. The drainage of the latter cross-linked then cationized cornstarches was compared to one of the X42 series of cationic then cross-linked cornstarches (X42B4, 1170 cps), and also the standard cationic potato starch with the results shown in FIG. 10. These results demonstrate that in the X11 series, the correlation between increase in viscosity and increased peak drainage remains as in the X42 series (cationic, then cross-linked), absent however is the shift to higher starch loadings as the viscosity increases as in the X42 series. This phenomenon evidences that cations are enclosed in the cationic then cross-linked process, whereas in the cross-linked then cationized starches this enclosure is to a much lesser degree.
EXAMPLE VII
(Miami University Pilot Paper Machine Trial For Strength Evaluation)
A pilot paper machine trial was performed at Miami University, Oxford, Ohio. A furnish consisting of a 50:50 blend of bleached Kraft hardwood/softwood, with a Canadian Standard Freeness (CSF) of 410, 10% (200 pounds/ton of fiber) CaCO 3 , 0.1% (2 pounds/ton of fiber) of AKD size, 0.05% (1 pound/ton of fiber) of a cationic retention aid, all at a headbox consistency of 0.4% solids was prepared as needed and reagents added on a continuous feed basis. The pilot paper machine produced a continuous 12 inch wide roll of paper at a rate of 10 ft./min. Starch additions were made at 0.5%, 1.0%, 1.5% and 3.0% levels (10, 20, 30 and 60 pounds/ton of fiber respectively), and the machine was run for approximately 1 hour at each level for the various starches tested. Additionally, a blank determination was made with no starch additions (0.0%). A 70 g/m 2 basis weight sheet was produced. The starches included in this trial consisted of a cationic potato starch (DS 0.040), a cationic cornstarch: X22B (DS 0.032), a cationic cross-linked cornstarch: X23B (DS 0.032) cross-linked to a 1100 cps level, and a cross-linked then cationized corn starch: X11C (DS 0.032) cross-linked to a 1000 cps level. The strength parameters that were tested include Internal Bond (Scott Bond), Tensile, Fold, and Burst, along with the parameters Porosity and Hercules Size Test (HST). Analysis of Variation (ANOVA) was performed on the above parameters, in addition to Moisture, Ash, Grammage, and Caliper, with respect to the changing starches and levels. It was determined that the Moisture, Grammage and Caliper parameters had a low correlation to the effects of the changing starches and correlation to the effects of the changing starches and their levels, with Ash at a slightly higher correlation coefficient. It was, therefore, assumed that the changes seen in the strength parameters were attributable to the various starches and their levels of addition, calculated at 95% confidence.
Table IV summarizes the results of the paper trial with an average response of the starch across all levels of addition with respect to the blank.
TABLE IV______________________________________Level Potato X22B X23B X11C______________________________________INTERNAL BOND (SCOTT BOND)(Scott Bond Units), Root MeanSquare Error (RMSE) = 3.20.0% 50 50 50 500.5% 49 53 64 581.0% 56 64 76 691.5% 66 68 90 803.0% 84 73 106 103Average Unit 14 14 34 28IncreaseOver Blank:BURST(Pounds per Square Inch)RMSE = 0.680.0% 9.9 9.9 9.9 9.90.5% 10.8 10.6 12.4 11.81.0% 12.3 14.2 14.0 12.61.5% 13.3 14.4 14.6 14.03.0% 16.6 15.3 15.4 14.1Average Unit 3.4 3.7 4.2 3.2IncreaseOver Blank:TENSILE(Kg/m.sup.2)RMSE = 0.2840.0% 5.15 5.15 5.15 5.150.5% 5.93 5.03 5.05 4.691.0% 6.32 6.32 5.44 5.101.5% 6.26 6.20 5.92 5.573.0% 6.71 7.10 5.86 5.68Average Unit 1.16 1.01 0.42 0.11IncreaseOver Blank:MACHINE DIRECTION FOLD(Number of Folds)RMSE = 1.50.0% 3 3 3 30.5% 4 4 7 51.0% 6 8 9 81.5% 7 9 13 83.0% 13 9 14 14Average Unit 4 4 8 6IncreaseOver Blank:POROSITY(Cubic Feet per Minute)RMSE = 35.10.0% 404 404 404 4040.5% 386 383 345 3381.0% 386 308 351 3281.5% 351 309 346 3203.0% 281 269 267 243Average Unit -53 -87 -77 -97IncreaseOver Blank:HST(Seconds)RMSE = 19.90.0% 116 116 116 1160.5% 134 137 171 1701.0% 230 243 210 1591.5% 205 253 230 1623.0% 255 227 195 186Average Unit 90 99 86 53IncreaseOver Blank:______________________________________
Although the invention has been described with regard to its preferred embodiments, it should be understood that various changes and modifications as would be obvious to one having the ordinary skill in this art may be made without departing from the scope of the invention which is set forth in the claims appended hereto.
The various features of this invention which are believed new are set forth in the following claims. | A new cationized subsequently cross-linked starch is described in connection with improved method of paper making in the wet-end system of a paper machine utilizing a Neutral or Alkaline furnish. | 3 |
FIELD
This invention relates to wearable power generating devices.
BACKGROUND
The popularity of wearable and/or portable electronic devices has created a substantial market for such devices. Portable electronic devices include personal electronic devices, such as smart phone, cell phones, MP3 players, and Bluetooth, etc. One limitation of such devices is the amount of energy that can be conveniently stored in the devices. Accordingly, substantial resources have been devoted to maximizing the energy storage capacity for both a given volume and a given weight. Nonetheless, portable electronic devices are still limited by the amount of energy that can be stored in the devices.
Consequently, portable electronic devices require frequent recharging. Moreover, as the device ages, the capacity of the energy storage system of the device deteriorates, necessitating more frequent charging.
Recharging a portable electronic device is generally a simple matter. A number of convenience enhancing devices have been developed allowing portable electronic devices to be rapidly charged and to be charged using a variety of power sources such as 12 v power systems commonly found in motorized vehicles. Additionally, backup batteries are commonly made available so that a fresh battery can be used to replace a depleted battery.
Even with all of the advances in powering portable electronic devices, however, providing power can be a challenge. For example, many people enjoy using portable electronic devices while hiking. The availability of power sources for recharging portable electronic devices is very limited, however, along hiking trails. Even when charging sources are available, however, recharging the power system of the portable electronic device requires the portable electronic device or the power source to remain in a specific location. Even for quick charging systems, the delay in activities is an undesired consequence.
In response to the foregoing limitations, the possibility of scavenging human power and either using it directly, or storing it for later use, to power portable electronic devices has been explored. Power harvesting generators which use human motion offer an attractive grid-free and portable energy source that can be used to power and recharge wearable and personal electronics. These generators harvest energy from everyday human motion, such as walking, running, standing up, and sitting down and use the harvested energy to charge the battery (or other storage reservoir) of a personal electronic device or even power the electronic devices directly.
In general, power harvesting devices are mechanical-to-electrical energy converters that usually consist of a mass-spring system coupled to a frame which is displaced by outside vibrations, shocks, or other motion. The mass-spring system acts as a damper for the motion of the frame, thereby acquiring kinetic energy. Transduction of mechanical to electrical energy by mass-spring system can be electromagnetic (magnet moving relative to a coil), electrostatic (charged objects moving past each other), or piezoelectric (strain in a bending element produces output voltage).
Transduction of human motion for powering wearable or portable electronics presents particular challenges. By way of example, frequencies of ordinary human motion (e.g. walking) are typically very low (˜1-2 Hz), the amplitudes of the movements are high (˜10 cm), and the weight and size of the device is limited to unobtrusive dimensions. As a consequence, the amount of power available from typical generating systems is limited to a few mW. Moreover, wearable electronics are becoming increasingly sophisticated and consuming more and more power.
Another limitation of known systems is that the known systems harvest power in only one dimension. By way of example, a moving piston within a generator positioned in the heel of a shoe can be used to generate power. Of course, any energy available from motion in other directions, such as pivoting motions, is lost.
Accordingly, there is a need for a lightweight generator that can be used to convert a movement into power. It would be beneficial if such a device were not limited to harvesting power available in a single dimension.
SUMMARY
A wearable generator system in one embodiment includes a plurality of coils, each of the plurality of coils extending within a respective one of a plurality of planes, a magnet for generating a magnetic field, and a support attached to a support anchor point and to the magnet, and suspending the magnet at a position whereat the magnet is not frictionally engaged with a fixed surface, the support having a length selected such that the magnetic field is movable across each of the plurality of coils.
In accordance with another embodiment, a wearable generator system includes at least one first coil, each of the at least one first coils extending within a respective one of at least one first plane, a first magnet for generating a first magnetic field, and a first support having a first portion fixedly positioned with respect to the at least one first coil and a second portion spaced apart from the first portion, the second portion fixedly attached to the first magnet at a location lower than the first portion.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a perspective view of a wearable generator system including a plurality of generator pouches, an energy storage pouch and a charging holster in accordance with principles of the present invention;
FIG. 2 depicts a schematic diagram of the electrical circuit of the wearable generator system of FIG. 1 ;
FIG. 3 depicts a perspective view of a power harvester that is located in one of the generator pouches of FIG. 1 ;
FIG. 4 depicts the power harvester of FIG. 3 after the wearer of the wearable generator system has moved from a first position;
FIG. 5 depicts the power harvester of FIG. 3 after the wearer of the wearable generator system has stopped moving;
FIG. 6 depicts a simplified perspective view of the power harvester of FIG. 3 showing the magnet field of the magnet of the power harvester with the magnet centrally located within a coil volume defined by the power harvester coils;
FIG. 7 depicts a simplified perspective view of the power harvester of FIG. 3 showing the magnet field of the magnet of the power harvester intersecting two different coils; and
FIG. 8 depicts a partial cutaway perspective view of an alternative power harvester with a cube-shaped coil volume.
DESCRIPTION
For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and described in the following written specification. It is understood that no limitation to the scope of the invention is thereby intended. It is further understood that the present invention includes any alterations and modifications to the illustrated embodiments and includes further applications of the principles of the invention as would normally occur to one skilled in the art to which this invention pertains.
Referring to FIG. 1 , there is depicted a representation of a wearable generator system generally designated 100 . The generator system 100 in this embodiment includes a belt 102 that can be fastened about a wearer using male clasp 104 and female clasp 106 . Supported on the belt 102 are plurality of generator pouches 108 , 110 , 112 , and 114 , an energy storage pouch 116 , a charging holster 118 , and an auxiliary pouch 120 .
The generator pouches 108 / 110 / 112 / 114 house a respective one of the power harvesters 124 1-4 shown in FIG. 2 . The power harvesters 124 1-4 generate electrical power which is directed to a conditioning and charging circuit 126 which is housed within the energy storage pouch 116 . The conditioning and charging circuit 126 includes one or more energy storage devices along with conditioning and control electronics.
The conditioning and charging circuit 126 includes a processing circuit and a memory. The processing circuit may suitably be a general purpose computer processing circuit such as a microprocessor and its associated circuitry. The processing circuit is operable to carry out the operations attributed to it herein. Within the memory are program instructions. The program instructions are executable by the processing circuit and/or any other components as appropriate.
The conditioning and charging circuit 126 control the components therein for conditioning energy received from the power harvesters 124 1-4 and using the conditioned energy to charge the energy storage devices. The conditioning and charging circuit 126 further direct energy from the energy storage devices or from the power harvesters 124 1-4 to a charging component 128 located in the charging holster 118 . The charging component 128 may include contacts for directly charging an electrical component placed into the charging holster 118 or coils for inductively charging an electrical component. In alternative embodiments, an electrical component such as a sensor or communications component may be hardwired into the charge control system 122 .
The conditioning and charging circuit 126 may also direct energy from the energy storage devices or from the power harvesters 124 1-4 to a charging component 130 located in the auxiliary pouch 120 . The auxiliary pouch 120 may thus be used to charge replaceable batteries used in portable electronics.
Each of the power harvesters 124 1-4 in this embodiment are identical and are described in more detail with reference to the power harvester 124 1 shown in simplified form in FIG. 3 . The power harvester 124 1 includes a number of coils 132 x . Each of the coils 132 x includes one or more turns of electrically conductive material and is electrically isolated from the other of the coils 132 x . A support line 138 (seen more clearly in FIG. 4 ) is attached at one end to a support anchor point 140 and at another end to a magnet 142 .
The magnet 142 is supported by the support line 138 in a manner which allows for movement of the magnet 142 within the space defined by the coils 132 x . For example, as a wearer accelerates in the direction of the arrow 144 of FIG. 3 , the inertia of the magnet 142 causes the magnet 142 to be displaced from the location of FIG. 3 to the location of FIG. 4 . Such movement may be effected by using a rigid material for the support line 138 but allowing the support line 138 to swivel about the support anchor point 140 . Alternatively, a non-rigid material or even a resiliently stretchable material may be used to construct all or a portion of the support line 138 . In one embodiment, the support line 138 thus further allows for rotation of the magnet 142 such as in the direction of the arrow 146 of FIG. 5 .
The movement of the magnet 142 with respect to the coils 132 x generates electricity as discussed with further reference to FIGS. 6 and 7 . FIG. 6 depicts a simplified view of the power harvester 124 1 showing only coils 132 1-3 . The coils 132 1-3 are each substantially positioned within a respective plane, each of the planes intersecting the planes in which the other of the coils 132 1-3 are positioned. By way of example, the planes in which the coils 132 2 and coils 132 3 lie intersect along the line 150 while the planes in which the coils 132 1 and coils 132 3 lie intersect along the line 152 . The coils 132 1-3 thus define a coil volume generally identified as 154 which is substantially in the form of a sphere. The magnet 142 is suspended within the coil volume 154 and the magnetic field 156 of the magnet 142 emanates from the magnet 142 .
As the magnet 142 moves, such as from the position depicted in FIG. 6 to the position depicted in FIG. 7 , the magnetic field 156 moves across various of the coils 132 1-3 . As depicted in FIG. 7 , the magnetic field 156 has crossed the coil 132 2 and the coil 132 3 . As the magnetic field 156 crosses the coils 132 2-3 , a current is generated in the coils 132 2-3 which is transferred to energy storage devices within the conditioning and charging circuit 126 . The conditioning and charging circuit 126 then boosts the voltage generated by the harvester to the one usable by a sensor, personal electronic device, or a battery or a capacitor as appropriate.
More specifically, electromagnetic power harvesting uses the voltage induced in a conductive coil moving relative to a permanent magnet. Using Faraday's law, the voltage induced in a generator where a coil moves through a permanent magnetic field (V EMF ) can be expressed by:
V EMF = - ⅆ Φ ⅆ t = - ⅆ ⅆ t ( Nlz ( t ) B ( t ) )
where N is the number of turns of the coil, B is the strength of the magnetic field, Φ is the magnetic flux, and/is the length of a side of one loop in the coil. The generated output power is given in general by P=V EMF 2 /R tot .
Thus, each of the coils 132 2-3 generates electrical power. As is evident from FIGS. 6 and 7 , the coils 132 2-3 are orientated differently. Accordingly, even if the movement of the magnet 142 is such that power generation is maximized for the coil 132 2 , the coil 132 3 still generates some amount of power. Given the multiple orientations of the coils 132 x as depicted in FIG. 3 , any movement of the magnet 142 will generate some power in at least one of the coils 132 x . The wearable generator system 100 is thus capable of generating power for a wide variety of movements. Consequently, the wearable generator system 100 may be positioned about an individual's waist, on an arm or a leg, etc. and still provide energy.
Because the wearable generator system 100 is able to generate power without limitation as to the particular movement exhibited by the magnet 142 , power generation is maximized, in general, by maximizing movement of the magnet 142 . To this end, the support line 138 may be a flexible line such that kinetic energy of the magnet 142 is not lost through frictional contact.
The support anchor point 140 is positioned such that when the belt 102 is positioned on a wearer, the support anchor point 140 is at the upper portion of the power harvester 124 1 . In embodiments wherein the orientation of the power harvester 124 1 is not controlled, or wherein the power harvester 124 1 is subject to large accelerations or inversion, an additional line or lines may be used to maintain the magnet 142 suspended within the coil volume 156 . In embodiments wherein additional lines are used to keep the magnet 142 suspended at different orientations of the power harvesters 124 x , some amount of slack in the lines is preferably provided. Accordingly, movement of the magnet is generally limited by a single one of the lines to maximize movement of the magnet 142 .
Movement of a magnet positioned within a coil volume may further be adjusted by connecting lines to the magnet asymmetrically. By way of example, FIG. 8 depicts an embodiment of a power harvester 170 with an asymmetrically suspended magnet 172 . The power harvester 170 includes a rectangular frame 174 with coils 176 positioned on all six sides of the frame 174 . The coils 176 thus define a rectangular coil volume in which the magnet 172 is suspended by a support line 178 attached to a support line anchor 180 on the frame 174 . A tether line 182 is attached to a tether anchor point 184 on the frame 174 and to the magnet 172 . Coil volumes of other shapes may be used for different applications. Additionally, while coils 176 are positioned on all sides of the frame 174 , some embodiments may utile coils on less than all of the sides.
While the magnet 172 is supported at substantially the midpoint of the magnet 142 by the support line 178 , the tether 182 is attached to the magnet 172 closer to one end of the magnet 172 . Accordingly, as the magnet 172 moves to the left, the tether 182 will cause the magnet 172 to spin because the magnet 172 is asymmetrically supported by the support line 178 and the tether line 180 . Axial movement of the magnet 172 is thus converted to a spinning motion which causes a magnetic field of the magnet 172 to cross several of the coils 176 . Thus, contact between the magnet 172 and the frame 174 and coils 176 can be reduced, thereby reducing frictional loss, while increasing the crossing of coils 176 by the magnetic field of the magnet 172 .
While the invention has been illustrated and described in detail in the drawings and foregoing description, the same should be considered as illustrative and not restrictive in character. It is understood that only the preferred embodiments have been presented and that all changes, modifications and further applications that come within the spirit of the invention are desired to be protected. | A wearable generator system in one embodiment includes a plurality of coils, each of the plurality of coils extending within a respective one of a plurality of planes, a magnet for generating a magnetic field, and a support attached to a support anchor point and to the magnet, and suspending the magnet at a position whereat the magnet is not frictionally engaged with a fixed surface, the support having a length selected such that the magnetic field is movable across each of the plurality of coils. | 5 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional No. 60/611,553 filed Sep. 20, 2004, and which is hereby incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] The present invention is generally related to vehicle stability control. More particularly, the invention relates to the control of damping components as part of a vehicle stability control.
BACKGROUND OF THE INVENTION
[0003] Steering stability and performance of a vehicle are largely characterized by the vehicle's understeer and oversteer behavior. The vehicle is in an understeer condition if the vehicle yaw is less than the operator steering input, where turning the steering wheel more does not correct the understeer condition because the wheels are saturated. The vehicle is in an oversteer condition if the vehicle yaw is greater than the operator steering input. Surfaces such as wet or uneven pavement, ice, snow or gravel also present vehicle stability and handling challenges to the driver. Similarly, in a panic or emergency situation, such as during obstacle avoidance, a driver may react by applying too much steering or failing to counter-steer to bring the vehicle back to its intended path. In any of these cases, the actual vehicle steering path deviates from the intended steering path.
[0004] Modern vehicles sometimes incorporate active vehicle control sub-systems that enhance operator comfort and safety, including sub-systems which address such deviations in the vehicle path. One such subsystem is known as a vehicle stability enhancement (VSE) system that assists the vehicle operator in providing vehicle handling. The VSE system helps the vehicle operator maintain control during rapid or emergency steering and braking maneuvers and can correct for understeer and oversteer conditions. The VSE system senses wheel speed, steering angle, vehicle speed and yaw rate. The VSE system uses these inputs to reduce engine torque and apply vehicle braking to maintain the vehicle travel along the intended path.
[0005] Another active vehicle control sub-system is known as an active front steering (AFS) system for providing automatic front-wheel steering. AFS systems employ a steering actuator system that receives an operator intended steering signal from a hand wheel sensor, a vehicle speed signal and a vehicle yaw rate signal, and provides a correction to the operator steering signal to cause the vehicle to more closely follow the vehicle operator's intended steering path to increase vehicle stability and handling. The AFS system is able to provide steering corrections much quicker than the vehicle operator's reaction time, so that the amount of operator steering is reduced. In such applications, the AFS system includes yaw rate measurements and feedback control to generate an additional steering input to the front wheels.
[0006] Semi-active suspension systems are also incorporated into some modern vehicles and are generally characterized by dampers which are controlled to change the suspension characteristics of the vehicle based on road conditions, vehicle speed, yaw and other considerations. Variable fluid-based dampers are known having discrete damping states and continuously variable damping states. Variability in damping may be attained by variable orifice devices or controlled viscosity fluids (e.g. magnetorheological (MR) or electrorheological (ER)) within the damping device. Variable dampers are used predominantly to achieve low speed ride comfort and high speed handling enhancement. However, variable damping techniques are known to enhance vehicle stability in certain understeer and oversteer situations.
[0007] The VSE, AFS and suspension control systems are generally effective at maintaining vehicle stability in light of slowly varying or static road conditions. However, severe and rapidly transient road conditions (e.g. pot holes) effect inputs which may significantly disrupt stability controls when active.
[0008] Therefore, it is desirable to account for transient road conditions in vehicle stability systems and minimize the undesirable effects thereof on such systems and controls so that the systems can provide the intended vehicle path across a variety of slowly and rapidly changing road conditions.
SUMMARY OF THE INVENTION
[0009] The present invention actively controls vehicle suspension damping as part of a vehicle stability control. A vehicle has a semi-active suspension including a plurality of controllable suspension dampers. In accordance with one aspect of the present invention, a method for vehicle stability suspension control includes determining turning direction for the vehicle and damper motion direction for each of the plurality of controllable suspension dampers. Open loop damping commands are determined for the plurality of controllable suspension dampers. Closed loop damping commands are also determined for the plurality of controllable suspension dampers. Control of each of the plurality of controllable suspension dampers is carried out in accordance with respective ones of the open loop and closed loop damping commands as a function of turning direction and respective damper motion direction. The closed loop damping commands are preferably implemented in conjunction with vehicle oversteer and understeer events. The open loop and closed loop damping commands are determined based on respective pluralities of vehicle dynamics metrics including vehicle speed, vehicle lateral acceleration and steering wheel angle.
[0010] In accordance with another aspect of the present invention, a method for vehicle stability suspension control includes providing vehicle stability control critical and non-critical combinations of vehicle corner dampers, damper motion directions, and vehicle turning directions. A feedback damper control signal is provided to the vehicle stability control critical combinations and a feedforward damper control signal is provided to the vehicle stability control non-critical combinations. The feedback and feedforward damper control signals are determined based on respective pluralities of vehicle dynamics metrics including vehicle speed, vehicle lateral acceleration and steering wheel angle.
[0011] In accordance with another aspect of the present invention, a control apparatus for the vehicle suspension system includes a feedback controller effective to provide a suspension damper feedback command, wherein the feedback controller includes a respective plurality of vehicle dynamics metrics. The control apparatus for the vehicle suspension system further includes a feedforward controller effective to provide a suspension damper feedforward command, wherein the feedforward controller includes a respective plurality of vehicle dynamics metrics. And, the control apparatus for the vehicle suspension system also includes a suspension damper command arbitrator effective to determine which of the feedback command and the feedforward command is used to control each of the controllable suspension dampers, wherein the suspension command arbitrator includes a respective plurality of vehicle dynamics metrics. The feedback controller preferably includes vehicle yaw rate error and vehicle lateral velocity error. And, the respective pluralities of vehicle dynamics metrics of the feedback controller and the feedforward controller include vehicle speed, vehicle lateral acceleration and steering wheel angle.
[0012] In accordance with another aspect of the present invention, a method for suspension control includes determining vehicle turning direction and a respective damper motion direction for each vehicle corner damper. During a vehicle stability enhancement suspension control, for example vehicle oversteer or understeer events, vehicle corner dampers corresponding to predetermined control critical combinations of vehicle turning direction and respective corner damper motion direction are closed loop controlled whereas vehicle corner dampers corresponding to predetermined control non-critical combinations of vehicle turning direction and respective corner damper motion direction are open loop controlled.
[0013] These and other advantages and features of the invention will become apparent from the following description, claims and figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a block schematic diagram illustrating a controlled vehicular damping system in accordance with the present invention;
[0015] FIG. 2 is a control schematic diagram illustrating a preferred implementation of the damper feedback control of FIG. 1 in accordance with the present invention;
[0016] FIG. 3 is a table of exemplary vehicle yaw rate proportional gain calibrations for the control of FIG. 2 exemplifying the preferred relationship to vehicle speed and lateral acceleration in accordance with the present invention;
[0017] FIG. 4 is a detailed block schematic diagram illustrating a preferred implementation of the damper command arbitration block of FIG. 1 in accordance with the present invention; and
[0018] FIG. 5 is a table illustrating critical and non-critical corner damper and motion combinations for use by the damper command arbitration block of FIG. 2 in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0019] With reference first to FIG. 1 , a schematic block diagram of a vehicle 11 suspension damper control system in accordance with the present invention is illustrated. The vehicle 11 provides a plurality of vehicle dynamics metrics 12 from sensors or derivations, including vehicle yaw rate ({dot over (ψ)}), vehicle lateral acceleration (α y ), vehicle speed (V x ), steering wheel angle (δ) and individual damper positions (P n ). The system includes a plurality of suspension dampers 13 individually associated with the respective suspension corners of the vehicle 11 . Each damper effects a damping force (F d ) upon vehicle 11 in accordance with damper commands 16 , for example control currents for effecting a desired damping response in a MR based damper. The system further includes damper command arbitration block 15 for determining damping forces for application to the plurality of dampers based on a closed loop suspension feedback command 18 , a suspension feedforward command 14 , and exemplary vehicle dynamics metrics including vehicle understeer/oversteer conditions 20 and vehicle yaw rate ({dot over (ψ)}) as further described herein below.
[0020] Closed loop suspension feedback command 18 is determined in accordance with an exemplary feedback control as follows. Vehicle speed (V x ) and steering wheel angle (δ) are provided to yaw rate command block 17 . A desired yaw rate command ({dot over (ψ)} DES ) is calculated by yaw rate command block 17 , for example as disclosed in U.S. Pat. Nos. 5,720,533, 5,746,486 and 5,941,919, all of which are assigned to the assignee of the present invention and are hereby incorporated herein by reference.
[0021] Vehicle speed (V x ), steering wheel angle (δ) and lateral acceleration (α y ) are provided to lateral velocity command block 19 . A desired lateral velocity command (V yDES ) is calculated by lateral velocity command block 19 , for example as disclosed in U.S. Pat. No. 6,035,251, which is assigned to the assignee of the present invention and is hereby incorporated herein by reference.
[0022] Lateral velocity estimator 21 is provided with vehicle yaw rate ({dot over (ψ)}), vehicle lateral acceleration (α y ) and vehicle speed to estimate therefrom the vehicle lateral velocity (V yEST ). An estimate of lateral velocity can be made through integration of vehicle lateral velocity rate ({dot over (V)} y ) as represented by the following relationship among the inputs to block 21 :
{dot over (V)} y =α y −{dot over (ψ)}· V x (1)
However, due to characteristic sensor bias and degradation of an integrated signal caused thereby, it is preferred to utilize a diminishing, integrator effective to substantially eliminate the effect of the bias on the integrated output. Further details respecting such an integration technique implementation in a stability control application can be found in U.S. Pat. No. 6,056,371, which is assigned to the assignee of the present invention and is hereby incorporated herein by reference.
[0023] Desired yaw rate command ({dot over (ψ)} DES ), calculated by yaw rate command block 17 is compared to vehicle yaw rate ({dot over (ψ)}) at node 23 to determine vehicle yaw rate error ({dot over (ψ)} ERR ). Similarly, desired lateral velocity command (V yDES ) calculated by lateral velocity command block 19 is compared to vehicle lateral velocity (V yEST ) at node 25 to determine vehicle lateral velocity error (V yERR ). Both error signals, ({dot over (ψ)} ERR ) and (V yERR ), are provided to feedback control block 27 for use in calculating the suspension feedback command for input to the command arbitration block 15 .
[0024] FIG. 2 illustrates an exemplary control within feedback control block 27 . Therein, proportional and derivative (PD) components of the suspension feedback command from both error signals, ({dot over (ψ)} ERR ) and (V yERR ), are determined. Vehicle lateral velocity rate error ({dot over (V)} yERR ) may be determined from vehicle lateral velocity error (V yERR ) through traditional derivative processing techniques. Alternatively, the lateral velocity rate error ({dot over (V)} yERR ), is determined with the lateral velocity rate ({dot over (V)} y ), as calculated in lateral velocity estimator 21 and assumption that the lateral velocity rate command is null. With such assumptions, the lateral velocity rate error is substantially equivalent to the lateral velocity rate as shown in the relationship below.
{dot over (V)} yERR ≈{dot over (V)} y (2)
[0025] A lateral velocity derivative gain (K dVy ) is applied to the vehicle lateral velocity error derivative ({dot over (V)} yERR ), and the resultant component provided to summing node 28 . A lateral velocity proportional gain (K pVy ) is similarly applied to the vehicle lateral velocity error (V yERR ), and the resultant component provided to summing node 28 . Vehicle yaw rate error derivative ({umlaut over (ψ)} ERR ) is determined from yaw rate error ({dot over (ψ)} ERR ). A yaw rate derivative gain (K d{dot over (ψ)} ) is applied to the vehicle yaw rate error derivative ({umlaut over (ψ)} ERR ), and the resultant component provided to summing node 28 . A yaw rate proportional gain (K p{dot over (ψ)} ) is similarly applied to the yaw rate error ({dot over (ψ)} ERR ), and the resultant component provided to summing node 28 . The various gains in the PD control of feedback control block 27 are vehicle specific calibration values. Particularly preferred yaw rate proportional gain (K p{dot over (ψ)} ), is characterized as functions of vehicle speed (V x ), and vehicle lateral acceleration (α y ). More particularly, the general character of the yaw rate proportional gain (K p{dot over (ψ)} ), is such that the gain increases with increasing vehicle speed and increases with increasing absolute value of vehicle lateral acceleration. This general character of a preferred yaw rate proportional gain (K p{dot over (ψ)} ) is further illustrated in the table of FIG. 3 . Similarly with respect to the yaw rate derivative gain (K d{dot over (ψ)} ), the gain preferably is characterized as function of vehicle speed (V x ), and vehicle lateral acceleration (α y ). And, more particularly, the general character of the yaw rate derivative gain (K d{dot over (ψ)} ) is such that the gain increases with increasing vehicle speed and increases with increasing absolute value of vehicle lateral acceleration. Particularly preferred lateral velocity proportional gain (K pVy ) is also characterized as function of vehicle speed (V x ), and vehicle lateral acceleration (α y ). And, more particularly, the general character of the lateral velocity proportional gain (K p{dot over (ψ)} ), is also such that the gain increases with increasing vehicle speed and increases with increasing absolute value of vehicle lateral acceleration. Similarly with respect to the lateral velocity derivative gain (K dVy ), the gain preferably is also characterized as function of vehicle speed (V x ), and vehicle lateral acceleration (α y ). And, more particularly, the general character of the lateral velocity derivative gain (K dVy ) is such that the gain increases with increasing vehicle speed and increases with increasing absolute value of vehicle lateral acceleration.
[0026] Closed loop suspension feedback control as described immediately above is particularly responsive to the types of relatively rapid, transient and severe changes is road conditions that may have an undesirable destabilizing influence upon the vehicle, particularly a vehicle already under some form of vehicle stability control as described herein above.
[0027] Feedforward control block 29 is used in calculating the suspension feedforward commands 14 for input to the command arbitration block 15 . Vehicle lateral acceleration (α y ), vehicle speed (V x ), steering wheel angle (δ) and damper positions (P n ) are provided to feedforward control block 29 . Preferably, the feedforward control block 29 implements the well-known skyhook suspension model utilizing a fictitious inertial grounding of the damper in determining the resultant suspension feedforward command 14 .
[0028] Understeer/oversteer behavior block 31 includes vehicle yaw rate ({dot over (ψ)}), vehicle lateral acceleration (α y ), vehicle speed (V x ) and steering wheel angle (δ) inputs for use in determining resultant signals identifying current vehicle understeer/oversteer conditions. Preferably, the resultant vehicle understeer/oversteer conditions 20 are represented in the form of oversteer and understeer flags which definitively indicate whether there is significant oversteer or understeer behavior or the behavior is indeterminate or insignificant with respect to oversteer or understeer for purposes of the present control. Any suitable method for characterizing vehicle behavior as oversteer or understeer can be utilized. An exemplary preferred determination of such understeer and oversteer flags is set forth in co-pending U.S. patent application Ser. No. 10/978,982 filed Nov. 1, 2004, assigned to the assignee of the present invention, the contents of which are hereby incorporated herein by reference.
[0029] With reference now to FIG. 4 , the damper command arbitration block 15 is presented in further preferred detail. An unsigned (i.e. absolute value or magnitude) suspension feedback command is provided to total damping block 41 to calculate the total damping command which represents an aggregate damping force from all four vehicle corner dampers. Unsigned suspension feedback command and understeer and oversteer flags (K USF , K OSF ) from understeer/oversteer behavior block 31 are provided to block 43 which determines a signed suspension feedback command. By convention, negatively signed commands correspond to understeer whereas positively signed commands correspond to oversteer. The signed suspension feedback command is then provided to a gain block 45 whereat the ratio of front and rear split (i.e. distribution) of total damping force is calculated (F/R split command). The total damping command from block 41 and the F/R split command from block 45 are then provided to F/R distribution block 47 to calculate the total front suspension damping force and the total rear suspension damping force commands. It is generally well understood in the art that understeer behavior can be improved with a damping distribution weighted toward the rear of the vehicle and oversteer behavior can be improved with a damping distribution weighted toward the front of the vehicle. Side-to-side distribution block 49 next determined from the total front suspension damping force and the total rear suspension damping force commands the respective side-to-side distribution of damping force. In the present example, the distribution is simply 50% to each of the respective vehicle corner dampers associated with the corresponding front and rear damping force commands. The output from the side-to-side distribution block 49 comprises four corner specific suspension feedback damping commands (LF, RF, LR and RR).
[0030] The four corner specific suspension feedback damping commands are provided to damper motion resolver block 51 . Additionally, damper motion resolver block 51 includes vehicle yaw rate ({dot over (ψ)}) and the suspension feedforward commands from the feedforward control block 29 . The damper motion resolver block 51 determines damper motion dependant damping force commands in accordance with the criticality of the damper motion to the feedback control maintaining vehicle stability in light of potentially destabilizing ride events. The four corner specific suspension feedback damping commands are therefore further resolved into jounce and rebound commands for the control of the damping forces at the respective vehicle corner dampers.
[0031] In a preferred embodiment, the suspension feedforward command will be used to command the damping force for the corners and non-critical damper motion combinations. And, the suspension feedback command will be used to command the damping force for the corners and critical damper motion combinations. The matrix of FIG. 5 illustrates the critical and non-critical corner damper and motion combinations. For example, the feedback control in a vehicle executing a right turn maneuver experiencing an oversteer event would exhibit increasing suspension damper feedback commands corresponding to the front corners and decreasing suspension damper feedback commands corresponding to the rear corners in order to arrest the oversteer event. In contrast, a vehicle executing a right turn maneuver experiencing an understeer event would exhibit increasing suspension damper feedback commands corresponding to the rear corners and decreasing suspension damper feedback commands corresponding to the front corners in order to arrest the understeer event. Since the vehicle is in a right turn, the control critical damper motion and vehicle corner combinations are, as set forth in FIG. 5 , jounce for the left front and rear corners and rebound for the right front and rear corners. Similarly for the right turn, the control non-critical damper motion and vehicle corner combinations are, as set forth in FIG. 5 , rebound for the left front and rear corners and jounce for the right front and rear corners. The damper command arbitration block 15 would implement the feedback commands to the control critical damper motion and vehicle corner combinations and implement the feedforward commands to the control non-critical damper motion and vehicle corner combinations. The matrix combinations of FIG. 5 may be implemented, for example, through vehicle calibration tables corresponding, for example, to vehicle turning direction and vehicle stability control flags. By the present invention, the closed loop damper control is implemented only on the vehicle corner dampers and in the direction of damper motion critical to the yaw dynamics of the vehicle thereby minimizing the effects of such control on potentially destabilizing ride events which may occur during the application of the closed loop control.
[0032] The invention has been described with respect to certain exemplary embodiments. However, it is to be understood that various modifications and alternative implementations of the invention without departing from the scope of the invention as defined in the following claims. | A vehicle comprises a semi-active suspension including controllably adjustable suspension dampers. Open loop and closed loop damper commands are determined for each damper and, depending upon turning direction and damper motion, each damper is controlled with one of the open loop and closed loop damper commands. | 1 |
FIELD OF INVENTION
[0001] The present invention relates to DNAs encoding anti-apoptotic protein and a recombinant 30K protein. More particularly, the present invention is directed to novel anti-apoptotic DNAs obtained from silkworm and a recombinant 30K protein.
DESCRIPTION OF THE RELATED ART
[0002] Apoptosis is a normal physiologic process that leads to individual cell death. This process of programmed cell death is involved in a variety of normal and pathogenic biological events and can be induced by a number of unrelated stimuli.
[0003] Changes in the biological regulation of apoptosis also occur during aging and are responsible for many of the conditions and diseases related to aging. Recent studies of apoptosis have implied that a common metabolic pathway leading to cell death may be initiated by a wide variety of signals, including hormones, serum growth factor deprivation, chemotherapeutic agents, ionizing radiation, and infection by human immunodeficiency virus (HIV) (Wyllie (1980) Nature 284:555-556; Kanter et al. (1984) Biochem. Biophys. Res. Commun. 118:392-399)
[0004] Apoptosis occurs sporadically in all tissues throughout life and is a normal everyday occurrence; however, disproportionate apoptosis, either excessive or deficient may cause serious diseases.
[0005] Many researchers have found that several extant diseases associated with apoptosis, particularly relates to cancer and autoimmune disease which were caused by deficiency in apoptosis, and dementia and Alsheimer's disease which were caused by surplus apoptosis, and so called a degenerative disease and AIDS.
[0006] Subsquent researches have been developed for clinical trial to treat above described by means of these anti-apoptotic gene and proteins, or to use factors intervening signal transduction, that induces apoptosis. These researches were concentrated on regulation of apoptosis, induction of apoptosis, and biological mechanism.
[0007] Recently, it has been known to the public that several genes such as Bcl-2 family inhibit the apoptosis effectively.
[0008] In actual, the study has been preceded to inhibit the necrosis and apoptosis of PC12 cell induced by amyloid peptide related to the demetia of the aged (Neurosci of Apoptosis Protein:IAP). Also, to treat cancer, antisense technology of bcl-2, hsp27 has been tried. Especially, treatment by anti-bcl-2 is known to be effective in lymph tumor (J. Natl, Cancer Inst. 89,998(1997), Lancet 349,1137(1997)).
[0009] By several result of study until now, as many regulative factors of apoptosis have found, technology using regulator or genome information of it has been developed from two points of view.
[0010] One point is related to the study for treatment of the disease induced by cell death. Second point is related to the study of cell culture improving cell-production by inhibiting apoptosis. These studies have been done by using bcl-2 family proteins and genes.
[0011] The present inventors have conducted intensive researches in regard to anti-apoptotic factor existing in silkworm hemolymph.
[0012] As a result, the present inventors have discovered a novel method of fractionation, seperation, purificaton of proteins obtained by silkworm hemolymph, which are capable to substitute for conventional anti-apoptotic proteins encoded by genes such as bcl-2, and that productivity of the recombinant protein and the viability of host cells increase in insect/baculovirus system with adding silkworm hemolymph to the culture medium (Biotechnol. Prog., 15, 1028 (1999)).
[0013] Also, the present inventors have found that silkworm hemolymph has inhibitory factor of apoptosis, and found that silkworm hemolymph inhibits not only virus-induced apoptosis but also apoptosis induced by various chemicals. Moreover, silkworm hemolymph also inhibits human cell apoptosis.
[0014] The present inventor has also found these active factor is a kind of protein, which is seperated from silkworm hemolymph (Korean Patent Application No. 10-2001-0010717, Biochem. Biophys. Res. Commun., 285, 224 (2001)). The corresponding genes are obtained by Polymerase Chain Reaction (PCR) with the primers designed using information of the above purificated protein, and the gene sequence is analyzed.
[0015] The result of the gene sequence analysis indicated that the gene is so called “30K protein” of which function had not yet been known. The 30k protein group consists of five proteins and have the sequence Id. No.1 to 5, respectively.
[0016] Also it had been known to the public that 30K proteins have common characteristics in amino acid composition and immunological activity as well as molecular weight and they are a group of structurally related proteins with a molecular mass of approximately 30,000 Da.
[0017] The genes encoding the 30K proteins were remarkably different from the anti-apoptotic proteins such as bcl-2 family, which had been known to the public.
[0018] The object of the present invention is to provide anti-apoptotic protein originating from silkworm hemolymph. To accomplish the object efficiently, recombinant DNA technology is used to produce useful recombinant proteins in the present invention.
[0019] The pET-22b(+) carrying the 30K protein gene is introduced into E. coli BL(DE3). The 30K protein obtained from recombinant cell is proven to have an effect on inhibiton of apoptosis.
[0020] According to the present invention, the anti-apoptotic protein enables us to produce pharmaceuticals and health care food. For example, the anti-apoptotic recombinant protein is effective to dementia and Alsheimer's disease, which may be caused by surplus apoptosis, and so called a degenerative disease and AIDS as treatment. Also, the anti-apoptotic recombinant protein of the present invention is applied to food additives and cell-culture medium additives for improving productivity of incubating cells. On the basis of the above discoveries, the inventors could have accomplished the present invention.
[0021] Korean Patent Application No. 10-2001-0010717, No. 10-2002-0059686 are referenced in this application in order to more fully describe the state of the art to which this invention pertains. The disclosure of each of these publications and patent documents is incorporated by reference herein.
SUMMARY OF THE INVENTION
[0022] Therefore, the primary purpose of the present invention is to provide DNA SEQ. ID. No. 1 encoding the 30Kc6, DNA SEQ. ID. No. 2 encoding the 30Kc12, DNA SEQ. ID. No. 3 encoding the 30Kc19, DNA SEQ. ID. No. 4 encoding the 30Kc21 and DNA SEQ. ID. No. 5 encoding the 30Kc23.
[0023] It is an another object of the present invention to provide anti-apoptotic recombinant proteins comprising an amino acid sequence set forth as SEQ. ID. No.6, ID. No.7, ID. No.8, ID. No.9 and ID. No.10.
[0024] It is a still another object of the present invention to provide an anti-apoptotic pharmaceutical preparation comprising a therapeutically effective amount of the recombinant anti-apoptotic protein in a pharmaceutically acceptible carrier.
[0025] It is a yet another object of the present invention to provide an anti-apoptotic health food, additive for culture medium and food supplement comprising the recombinant protein.
[0026] It is a further object of the present invention to provide a recombinant expression vector comprising the DNA of SEQ. ID. No.1 encoding anti-apoptotic 30Kc6 protein, ID. the DNA of SEQ. No.2 encoding anti-apoptotic 30Kc12 protein, the DNA of SEQ. ID. No.3 encoding anti-apoptotic 30Kc19 protein, ID. the DNA of SEQ. No.4 encoding anti-apoptotic 30Kc21 protein and ID. the DNA of SEQ. No.5 encoding anti-apoptotic 30Kc23 protein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The above objects and other advantages of the present invention will become more apparent by describing in detail a preferred embodiment thereof with reference to the attached drawings, in which:
[0028] FIG. 1A to FIG. 1C are the photographs of electrophoresis, which indicate that the recombinant 30K protein expressed in E. coli BL21 (DE3) (A), BL21 (DE3) (B) and purified recombinant 30K protein (C).
[0029] FIG. 2A to FIG. 2B are the graphs which show the viability of host cell measured 7 days after virus infection in the media supplemented with the recombinant 30K protein described in the above FIG. 1( c ).
[0030] FIG. 3A to FIG. 3D are the FACS analytic chromatogram, which show the effect of 30K protein on actinomycin D-induced insect cell apoptosis. Except for (a), the cells were treated with 200 ng/ml actinomycin D for 13 h and apoptosis was analyzed by flow cytometry. (A) Sf9 cells not treated with actinomycin D, (B) Sf9 cells cultured in the medium containing 10% FBS, (C) Sf9 cells cultured in the medium containing 5% FBS and 5% hemolymph, and (D) Sf9 cells cultured in the medium containing 5% FBS and 0.2 mg/ml recombinant 30K protein.
[0031] FIG. 4 A( a ) to FIG. 4 A(C) are the photographs which show the effect of 30K protein on staurosporine-induced human cell apoptosis. HeLa cells were treated with 600 nM staurosporine for 12 h and apoptosis was analyzed by fluorescence microscopy using Hoechst 33258 fluorescent dye. (A): (a) Cells cultured in the medium containing 5% FBS and 5% hemolymph. (c) Cells cultured in the medium containing 5% FBS and 0.2 mg/ml recombinant 30K protein.
[0032] FIG. 4B is the graph, which indicates percentage of apoptotic cells represented in (B) was determined by counting the number of apoptotic cells, which were detected by the method used in (A).
DETAILED DESCRIPTION OF THE INVENTION
[0033] Cell death is categorized as either apoptotic or necrotic. Apoptosis is a physiological cell death, which is morphologically distinguishable from necrosis.
[0034] Necrotic cells are characterized by an overall increase in size, mild clumping of chromatin and cell lysis.
[0035] However, apoptosis is different from necrosis where healthy cells are destroyed by external processes, such as inflammation. Apoptosis is a kind of voluntary, programmed death of cells that is under genetic control. The cell's own genes play an active role in its demise and is accompanied by the condensation of nuclei and cytoplasm, the loss of microvilli, convolution of the plasma membrane, and nuclear and cell segmentation.
[0036] Therefore, above objection of the present invention is achieved by providing an anti-apoptotic recombinant anti-apoptotic protein and DNAs encoding anti-apoptotic 30Kc6, 30Kc12, 30K19, 30K21, and 30K23 protein. It enables apoptosis to be inhibited effectively in animal cells and human cells.
[0037] In one embodiment of the present invention, there is provided anti-apoptotic protein synthesized by genetic recombination technology using gene of protein separated from silkworm homolymph.
[0038] DNAs of SEQ. ID. No.1 to 5 encoding anti-apoptotic 30Kc6, 30Kc12, 30K19, 30K21, and 30K23 protein, are obtained from silkworm, repsectively.
[0039] A silkworm hemolymph has been used effectively in biological researches. The production of recombinant protein in an insect cell baculovirus system was increased by supplementing the medium with silkworm hemolymph. Silkworm hemolymph increases baculovirus-infected insect cell longevity.
[0040] Moreover, it has been shown that silkworm hemolymph inhibits apoptosis in insect, mammalian, and human cell systems. These results indicate that silkworm hemolymph contains a component that inhibits apoptosis.
[0041] More recently, this anti-apoptotic fraction was isolated from silkworm hemolymph and characterized by the present inventors.
[0042] The fraction of silkworm hemolymph with the highest activity was found to contain 30K proteins, which are a specific type of plasma protein called “storage proteins”. These proteins constitute a group of structurally related proteins of approximate molecular weight 30,000 Da. The 30K protein group consists of five proteins, which have common characteristics in amino acid composition and immunological activity as well as molecular weight.
[0043] The 30K protein encoded by the 30Kc6 gene of the present invention was expressed in Escherichia coli and purified. E.coli BL21 (DE3) was used as the host for gene expression in the present invention.
[0044] Total RNA was isolated from silkworm tissue using RNA isolation kit, and total cDNA pool was obtained by RT-PCR using an oligo-dT primer. The 30K protein cDNA was amplified from the cDNA pool by PCR using specific primers. Then the amplified PCR products were cloned into E. coli expression vector, pET-22b(+). During this step a signal sequence contained in 30Kc6 was removed, and the vector was designed to express the 30K protein with a 6 x His tag at its C-terminal. E.coli BL21 (DE3) was used as the host for gene expression.
[0045] Hereinafter, the present invention will be described in greater detail with reference to the following examples. The examples are given for illustration of the invention and not intended to be limiting the present invention.
EXAMPLE 1
[0046] Plasmid Containing 30K Protein cDNA Construction
[0047] The 30Kc6(GenBank Accession No.: X07552) protein cDNA was amplified by PCR with a temperature profile of 95° C. for 1 min, 56° C. for 1 min, and 72° C. for 1.5 min.
[0048] The forward and reverse primers were 50-AGA CAT ATG ACA CTT GCA CCA AGA ACT-30 and 50-CAA CTC GAG GTA GGG GAC GAT GTA CCA-30, respectively, which contain the NdeI and XhoI sites, respectively. The forward primer contains ATG for methionine, which is necessary for the initiation of translation in E. coli.
[0049] The amplified PCR products were cloned into a NdeI-XhoI site in E.coli expression vector, pET-22b(+). During this step, we removed a signal sequence contained in 30Kc6. The pET-22b(+) carrying 30Kc6 was designed to express the 30K protein with a 6x His tag at its C-terminal.
EXAMPLE 2
Protein Expression, Purification, and Refolding
[0050] The pET-22b(+) carrying 30Kc6 without signal sequence, was introduced into E. coli strain BL21(DE3) and BL21(DE3)pLysE. The transformed bacteria were grown to OD600 of 0.5, induced with 0.5 mM isopropyl-β-D-thiogalactopyranoside(IPTG), and then incubated for 4 h. The cells were harvested by centrifugation and resuspended in 4ml of lysis buffer (10 mM Tris-HCl, 150 mM NaCl, and 1 mM EDTA, pH 8.0) containing 1 mM phenylmethylsulfonyl fluoride (PMSF) for each 100 ml of culture.
[0051] Lysozyme (0.5 mg/ml) was added and the mixture was incubated on ice for 30 min. The suspended cells were disrupted by sonication (Vibracell, 4 times, each for 15 sec) and centrifuged at 4° C. The precipitate containing inclusion bodies was solubilized in 6 M guanidine hydrochloride overnight at 4° C. This solution was loaded on a Ni 2+ -charged HisTrap column (Amersham Bioscience) and the column was washed with buffer containing 6 M urea and 20 mM imidazole several times to remove the nonspecific binding.
[0052] Refolding of the bound protein was performed in an FPLC (Bio-Rad, Biologic HR) using a linear urea reverse gradient (6 M to 0 M). The total volume and flow rate of the buffer used in the linear gradient were 30 ml and 0.5 ml/min, respectively.
[0053] Finally, the refolded protein was eluted with elution buffer containing 500 mM imidazole. The eluted 30K protein was desalted into the distilled water to remove the imidazole using a HiTrap desalting column (Amersham Bioscience) and concentrated using a lyophilizer.
EXAMPLE 3
Quantitation of Protein
[0054] The purity of the protein obtained was determined by scanning the 30K protein band on SDS-PAGE gel using Total Lab v1.10 (Nonlinear Dynamics). The total protein concentration was measured using a Modified Lowery Protein Determination Kit (Peterson's Modification of the Micro-Lowery Method; Sigma Chemical Co., St. Louis, Mo.).
EXAMPLE 4
Cell Culture for Anti-Apoptotic Activity Assay
[0055] Spodoptera frugiperda (Sf9) cells were cultivated in a Grace medium (Gibco) supplemented with 10% fetal bovine serum (FBS, Gibco), 0.35 g/L NaHCO3, and antibiotic-antimycotic (Gibco) at 28° C.
[0056] HeLa cells were cultivated in DMEM (Dulbecco's modified Eagle's medium, Gibco) supplemented with 10% fetal bovine serum (FBS, Gibco), Hepes, NaHCO3 (2.02 g/L), and penicillin/streptomycin (Gibco). The cells were incubated at 37° C. in humidified air atmosphere with 5% CO2. The recombinant 30Kc6 protein expressed in E. coli , or whole silkworm hemolymph as a control, was added to the culture medium to investigate the effects on apoptosis. Collection and pre-treatment of silkworm hemolymph has been described elsewhere in detail [E. J. Kim, W. J. Rhee, T. H. Park, Isolation and characterization of an apoptosis-inhibiting component from the hemolymph of Bombyx mori , Biochem. Biophys. Res. Commun. 285 (2001) 224-228.]. The collected hemolymph was heat-treated at 60° C. for 30 min and then chilled, and centrifuged. The supernatant filtered with a 0.2-μm membrane filter was used as a medium supplement.
[0057] Either the baculovirus AcMNPV ( Autographa californica multiple nuclear polyhedrovirus) or actinomycin D (Sigma) was used as an apoptosis inducer for Sf9 cells. For the baculovirus infection, the medium was aspirated and a virus stock solution was added.
[0058] A multiplicity of infection (MOI) of 13 was used for all the experiments. After incubating for 1 h, the virus solution was replaced with the medium used before the infection. Actinomycin D dissolved in sterilized water (100 μg/ml) was used to induce apoptosis at a final concentration of 200 ng/ml in each growth medium.
[0059] Staurosporine was used as an apoptosis inducer for HeLa cells. Staurosporine dissolved in DMSO (300 μM) was used to induce apoptosis at a final concentration of 600 nM in each growth medium.
EXAMPLE 5
[0060] N-Terminal Amino Acid Sequencing of Recombinant 30K proteins
[0061] SDS-PAGE was transferred to a PVDF (polyvinylidene difluoride) membrane in transfer buffer (192 mM glycine/25 mM Tris/20% methanol/0.037% SDS) for 90 min at 90 mA using a Bio-Rad Trans Blot SD Semidry Transfer Cell.
[0062] After the transfer, the membrane was stained with ponceau S (0.2% ponceau S in 1% acetic acid) and destained with deionized water. The stained band was then cut out and air-dried. Amino acid sequencing was carried out using the Precise Protein Sequencing System (Applied Biosystems).
EXAMPLE 6
Apoptosis Assay
[0063] For the assay of cell viability, cell numbers were counted under an optical microscope using a hemocytometer and viable cells were detected using the trypan blue exclusion test. Since dead cells absorb trypan blue (Sigma), they can be identified under an optical microscope.
[0064] The cell viability was defined by the ratio of the viable cell number to the total cell number. For the analysis of apoptotic cells accompanying DNA fragmentation, cell nuclei were stained with 10 μg/ml Hoechst 33258 in phosphate-buffered saline (PBS, pH7.4) for 20 min and then observed using a fluorescence microscope (TE300, Nikon) with a UV filter.
[0065] For the quantitative assay of apoptosis, flow cytometric analysis was performed. Cells were collected and washed twice with PBS (pH 7.4). The cell pellets were resuspended in cold 70% ethanol for fixation and stored at −20° C. until the FACS analysis. The fixed cells were washed with PBS, incubated with 100 g/ml RNase at 37° C. for 1 h, and stained with 50 μg/ml propidium iodide for 15 min. A FACSCalibur flow cytometer (Becton Dickinson) was used for this assay.
EXAMPLE 7
[0066] Culture Condition of Recombinant E. coli Containing 30K Gene
[0067] The medium consisted of 20 g of yeast extract, 10 g of casamino acid, 0.24 g of MgSO4·7H20, 0.01 g of CaCl2, 3 g of KH2PO4, 2.5 g of (NH4)2HPO4, 5 g of glucose, and 200 mg of ampicillin per liter in distilled water (pH 6.8). Seed culture was grown in a 500 ml flask containing 80 ml of medium in a shaking incubator at 37° C., at 250 rpm for 12 h. Batch culture was carried out in a 2.5 L jar fermentor containing 1 L of medium.
[0068] The pH was maintained at 6.8 by adding 5N HCl and 50% (v/v) NH4OH, and the dissolved oxygen concentration was maintained above 10% air saturation by controlling the agitation speed. Isopropylthio-β-D-galactoside (IPTG) was added to the cultures to a final concentration of 1 mM, and culture continued for 20 h.
EXAMPLE 8
Preparation of Recombinant 30Kc12 Protein
[0069] The pET-22b(+) carrying 30Kc12 (GenBank Accession No.: X07553), instead of the pET-22b(+) carrying 30Kc6 of Example 2, is introduced into E.coli strain BL21(DE3) and BL21(DE3)pLysE. The transformed bacteria thus prepared, are treated by the process described in Example 2 to prepare the recombinant anti-apoptotic protein 30Kc12.
EXAMPLE 9
Preparation of Recombinant 30Kc19 Protein
[0070] The pET-22b(+) carrying 30Kc19 (GenBank Accession No.: X07554), instead of the pET-22b(+)carrying 30Kc6 of Example 2 is introduced into E.coli strain BL21(DE3) and BL21(DE3)pLysE. The transformed bacteria thus prepared, are treated by the process described in Example 2 to prepare the recombinant anti-apoptotic protein 30Kc19.
EXAMPLE 10
Preparation of Recombinant 30Kc21 Protein
[0071] The pET-22b(+) carrying 30Kc21 (GenBank Accession No.: X07555), instead of the pET-22b(+)carrying 30Kc6 of Example 2, is introduced into E.coli strain BL21(DE3) and BL21(DE3)pLysE. The transformed bacteria thus prepared, are treated by the process described in Example 2 to prepare the recombinant anti-apoptotic protein 30Kc21.
EXAMPLE 11
Preparation of Recombinant 30Kc23 Protein
[0072] The pET-22b(+) carrying 30Kc23 (GenBank Accession No.: X07556), instead of the pET-22b(+) carrying 30Kc6 of Example 2, is introduced into E.coli strain BL21(DE3) and BL21(DE3)pLysE. The transformed bacteria thus prepared, are treated by the process described in Example 2 to prepare the recombinant anti-apoptotic protein 30Kc23.
[0073] While the present invention has been described with reference to particular embodiment thereof, there can be various modifications on the basis of the spirit of the present invention. | The present invention relates to DNAs encoding anti-apoptotic 30K proteins. More particularly, the present invention is directed to 30K protein genes and a recombinant proteins prepared by using novel anti-apoptotic gene obtained from silkworm. The present invention also provides anti-apoptotic health care food, pharmaceutical preparation, additive for cell culture medium, and food supplement. | 2 |
This application claims the benefit of Provisional Application Ser. No. 60/020,385, filed on Jun. 25, 1996.
This invention relates to novel indazole analogs. The compounds are selective inhibitors of phosphodiesterase (PDE) type IV and the production of tumor necrosis factor (TNF), and as such are useful in the treatment of asthma, arthritis, bronchitis, chronic obstructive airway disease, psoriasis, allergic rhinitis, dermatitis, and other inflammatory diseases, central nervous system disorders such as depression and multi-infarct dementia, AIDS, septic shock and other diseases involving the production of TNF. This invention also relates to a method of using such compounds in the treatment of the foregoing diseases in mammals, especially humans, and to pharmaceutical compositions containing such compounds.
Since the recognition that cyclic adenosine phosphate (AMP) is an intracellular second messenger (E. W. Sutherland, and T. W. Rall, Pharmacol. Rev., 12, 265, (1960)), inhibition of the phosphodiesterases has been a target for modulation and, accordingly, therapeutic intervention in a range of disease processes. More recently, distinct classes of PDE have been recognized (J. A. Beavo et al., Trends in Pharm. Sci. (TIPS), 11, 150, (1990)), and their selective inhibition has led to improved drug therapy (C. D. Nicholson, M. S. Hahid, TIPS, 12, 19, (1991)). More particularly, it has been recognized that inhibition of PDE type IV can lead to inhibition of inflammatory mediator release (M. W. Verghese et al., J. Mol. Cell Cardiol., 12 (Suppl. II), S 61, (1989)) and airway smooth muscle relaxation (T. J. Torphy in "Directions for New Anti-Asthma Drugs," eds S. R. O'Donnell and C. G. A. Persson, 1988, 37 Birkhauser-Verlag). Thus, compounds that inhibit PDE type IV, but which have poor activity against other PDE types, would inhibit the release of inflammatory mediators and relax airway smooth muscle without causing cardiovascular effects or antiplatelet effects. It has also been disclosed that PDE IV inhibitors are useful in the treatment of diabetes insipidus (Kidney Int. 37:362, 1990; Kidney Int. 35:494) and central nervous system disorders such as depression and multi-infarct dementia (PCT international application WO 92/19594 (published Nov. 12, 1992)).
TNF is recognized to be involved in many infectious and auto-immune diseases (W. Friers, Fed. of Euro. Bio. Soc. (FEBS) Letters, 285, 199, (1991)). Furthermore, it has been shown that TNF is the prime mediator of the inflammatory response seen in sepsis and septic shock (C. E. Spooner et al., Clinical Immunology and Immunopathology, 62, S11, (1992)).
SUMMARY OF THE INVENTION
The present invention relates to compounds of the formula I ##STR2## and to pharmaceutically acceptable salts thereof, wherein: R is H, C 1 -C 6 alkyl, --(CH 2 ) m (C 3 -C 7 cycloalkyl), --(CH 2 ) m (C 3 -C 9 heterocyclyl), wherein m is 0 to 2, (C 1 -C 6 alkoxy)C 1 -C 6 alkyl, C 2 -C 6 alkenyl, or --(Z 1 ) b (Z 2 ) c (C 6 -C 10 aryl) wherein b and c are independently 0 or 1, Z 1 is C 1 -C 6 alkylene or C 2 -C 6 alkenylene, and Z 2 is O, S, SO 2 , or NR 10 , and wherein said R groups are optionally substituted by one or more substituents independently selected from the group consisting of halo, hydroxy, C 1 -C 5 alkyl, C 2 -C 5 alkenyl, C 1 -C 6 alkoxy, C 3 -C 6 cycloalkoxy, trifluoromethyl, nitro, --CO 2 R 10 , --C(O)NR 10 R 11 , --NR 10 R 11 and --SO 2 NR 10 R 11 ;
R 1 is H, C 1 -C 7 alkyl, C 2 -C 3 alkenyl, phenyl, C 3 -C 7 cycloalkyl, or (C 3 -C 7 cycloalkyl)C 1 -C 2 alkyl, wherein said alkyl, alkenyl and phenyl R 1 groups are optionally substituted by 1 to 3 substituents independently selected from the group consisting of methyl, ethyl, trifluoromethyl, and halo;
R 2 is 2-oxo-4-pyrrolyl, pyrazolyl, 2-oxo-3,4-dihydro-5-pyrimidyl, 2-oxo-3,4-dihydro-4-pyrimidyl, 2-oxo-tetrahydro-4-pyrimidyl, 2-oxo-tetrahydro-5-pyrimidyl, 2-oxo-4-pyrimidyl, or 2-oxo-5-pyrimidyl, wherein each of said R 2 groups is optionally substituted by 1 to 4 R 6 groups;
or R 2 is ##STR3## wherein, in said formulas (Ia)-(It), q is 0 or 1 in formula (Ib), n is 0 to 2 in formula (Ic), and the dashed lines appearing in formulas (Ib), (Id), (Ig), (Ih), (Ii), (Ij) and (Io) represent a double bond or a single bond;
X 1 is 0 or S;
X 2 , in formula (Ik) and where the dashed line in formula (Ij) represents a double bond, is CR 5 , CR 6 , CR 16 , or COC(O)NR 9 R 12 , or, where the dashed line in formula (Ij) represents a single bond, X 2 is CR 5 R 9 , CR 6 R 9 , or CR 16 R 9 ;
X 3 is C(═Z 3 ), C(S) or CR 6 R 10 ;
X 4 is --(CH 2 ) m -- wherein m is 0 to 2;
X 5 is a bond or --CH 2 --;
X 6 is --CH 2 -- or --C(O)--;
R 3 is H, hydroxy, C 1 -C 4 alkoxy, --CHR 7 (O) q (CH 2 ) m A wherein q is 0 or 1 and m is 0 to 2;
R 4 is H, hydroxy, C 1 -C 4 alkyl, C 1 -C 2 alkoxy, --OC(O)CH 3 , C 2 -C 3 alkenyl or (phenyl)C 1 -C 2 alkyl;
R 5 is H, hydroxy, --(CH 2 ) m A wherein m is 0 to 2, C 1 -C 6 alkyl or C 2 -C 3 alkanoyl, wherein said alkyl group is optionally substituted by 1 to 3 subtituents independently selected from halo, nitro, --NR 10 R 11 , --CO 2 R 10 , --OR 10 , --OC(O)R 10 , --C(O)R 10 , cyano, --C(═Y)NR 10 R 11 , --NR 10 C(═Y)NR 10 R 11 , --NR 10 C(═Y)R 10 , --NR 10 C(O)OR 10 , --C(NR 10 )NR 10 R 11 , --C(NCN)NR 10 R 11 , --C(NCN)SR 10 , --NR 10 SO 2 R 10 , --S(O) m R 10 wherein m is 0 to 2, NR 10 SO 2 CF 3 , --NR 10 C(O)C(O)NR 10 R 11 , --NR 10 C(O)C(O)OR 10 , imidazolyl, and 1-(NHR 10 )-2-imidazolyl;
each R 6 is independently selected from the group consisting of H, halo, cyano, R 13 , cyclopropyl optionally substituted by R 9 , --OR 10 , --CH 2 OR 10 , --NR 10 R 12 , --CH 2 NR 10 R 12 , --C(O)OR 10 , --C(O)NR 10 R 12 , --CH═CR 9 R 9 , --C.tbd.CR 9 and --C(═Z 3 )H;
R 7 is H, --C(O)R 8 , imidazolyl, pyrazolyl, triazolyl, tetrazolyl, oxazolyl, isoxazolyl, oxadiazolyl, thiadiazolyl, thiazolyl, oxazolidinyl, thiazolidinyl or imidazolidinyl;
each R 8 is independently --OR 10 , --NR 10 R 12 or R 13 ;
each R 8 is independently H, halo, or C 1 -C 4 alkyl optionally substituted by 1 to 3 fluorines;
each R 10 and R 11 are independently selected from hydrogen and C 1 -C 4 alkyl;
each R 12 is independently --OR 10 or R 10 ;
R 13 is C 1 -C 4 alkyl;
each R 14 is independently selected from the group consisting of halo, nitro, cyano, --NR 10 R 16 , --NR 16 R 12 , --C(═Z 3 )R 8 , --S(O) m R 13 wherein m is 0 to 2, --OR 12 , --OC(O)NR 10 R 12 , --C(NR 12 )NR 10 R 12 , --C(NR 10 )SR 13 , --OC(O)CH 3 , --C(NCN)NR 10 R 12 , --C(S)NR 10 R 12 , --NR 12 C(O)R 17 , --C(O)R 17 , oxazolyl, imidazolyl, thiazolyl, pyrazolyl, triazolyl and tetrazolyl;
each R 15 is independently hydrogen or C 1 -C 4 alkyl optionally substituted by 1 to 3 fluorines;
each R 16 is independently H, R 13 , --C(O)R 13 , --C(O)C(O)R 9 , --C(O)NR 10 R 12 , --S(O) m R 13 wherein m is 0 to 2, --C(NCN)SR 13 , --C(NCN)R 13 , --C(NR 12 )R 13 , --C(NR 12 )SR 13 , or --C(NCN)NR 10 R 12 ;
each R 17 is independently R 13 , --C(O)R 13 , oxazolidinyl, oxazolyl, thiazolyl, pyrazolyl, triazolyl, tetrazolyl, imidazolyl, imidazolidinyl, thiazolidinyl, isoxazolyl, oxadiazolyl, thiadiazolyl, morpholinyl, piperidinyl, piperazinyl or pyrrolyl wherein each of said R 17 heterocyclic groups is optionally substituted by one or two C 1 -C 2 alkyl groups;
R 18 is H, C 1 -C 5 alkyl, C 2 -C 5 alkenyl, benzyl, or phenethyl;
R 19 is H, C 1 -C 5 alkyl, C 1 -C 5 alkanoyl, or benzoyl;
R 20 is H, C 1 -C 4 alkyl, carboxy, aminocarbonyl, C 1 -C 6 alkyl optionally substituted by carboxy, --(CH 2 ) m C(O)(C 1 -C 6 alkoxy), or --(CH 2 ) m (C 6 -C 10 aryl) wherein m is 0 to 2;
R 21 is H, C 1 -C 6 alkyl, --C(═Y)R 22 , --C(═Y)NHR 22 , --C(O)OR 22 , or --(CH 2 ) n X 7 (pyridyl) wherein n is 0 to 5 and X 7 is a bond or --CH═CH--, and wherein said pyridyl moiety is optionally substituted by halo;
R 22 is C 1 -C 6 alkyl, C 3 -C 8 cycloalkyl, --(CH 2 ) m (C 6 -C 10 aryl) or --(CH 2 ) n X 7 (pyridyl) wherein n is 0 to 5 and X 7 is a bond or --CH═CH--, and wherein said pyridyl moiety is optionally substituted by halo;
R 23 is H, R 15 , C 1 -C 3 alkyl substituted by hydroxy, or (C 1 -C 3 alkyoxy)C 1 -C 3 alkyl;
R 24 is H, R 15 , carboxy, (C 1 -C 3 alkyoxy)C 1 -C 3 alkyl, C 3 -C 7 cycloalkyl or C 1 -C 5 alkyl substituted by --NR 10 R 11 ;
or R 23 and R 24 are taken together to form --CH 2 OCH 2 OCH 2 --;
R 25 is H, hydroxy, C 1 -C 4 alkyl optionally substituted by hydroxy, --C(O)R 10 , --NR 10 R 11 , --(CH 2 ) m NHC(O)R 10 , --(CH 2 ) m NHC(O)R 3 , --(CH 2 ) m CO 2 R 10 , --(CH 2 ) m C(O)NR 10 R 11 , --(CH 2 ) m C(O)N(OH)R 10 , --(CH 2 ) m SO 2 NR 10 R 11 , --(CH 2 ) m PO 3 H 2 , --(CH 2 ) m SO 2 NHC(O)R 13 or --(CH 2 ) m SO 2 NHC(O)(phenyl), wherein m is 0 to 4;
R 26 is H, C 1 -C 4 alkyl, phenyl, --NR 10 R 11 , or --NR 10 (C 1 -C 4 alkanoyl);
R 27 is R 10 , --CH 2 CO 2 R 13 or --CH 2 C(O)NR 10 R 11 ;
R 28 is --C(O)R 10 , --C(O)(C 6 -C 10 aryl), --C(O)(C 3 -C 9 heteroaryl), --CO 2 R 10 , --C(O)NR 10 R 11 , cyano, nitro, --CH 2 OH, --NR 10 SO 2 R 10 , --NHSO 2 (C 6 -C 10 aryl), --NHCO 2 (C 1 -C 4 alkyl), --NR 10 C(O)R 10 or --NHCO 2 (C 6 -C 10 aryl);
R 29 is R 15 , cyano, carboxy, formyl, --C(O)R 10 , or C 1 -C 4 alkanoyl;
R 30 is cyano, --NR 10 R 11 , --SO 2 (C 1 -C 4 alkyl), --SO 2 (C 1 -C 10 aryl), --C(O)R 10 , --C(O)(C 6 -C 10 aryl), --C(O)(C 3 -C 9 heteroaryl), --C(O)NR 10 R 11 , or --CO 2 R 10 ;
R 31 and R 32 are each independently H, cyano, nitro, --CO 2 R 10 , --C(O)NR 10 R 11 , --CH 2 OH, --C(O)R 10 , --NHCO 2 R 10 , or --NHSO 2 R 10 ;
A is pyridyl, morpholinyl, piperidinyl, imidazolyl, thienyl, pyrimidyl, thiazolyl, phenyl or naphthyl, wherein each of said A groups is optionally substituted by 1 or 2 R 14 groups or by 1 R 15 group;
Z 3 is O, NR 12 , NOR 10 , N(CN), C(CN) 2 , CR 10 NO 2 , CR 10 C(O)OR 13 , CR 10 C(O)NR 10 R 11 , C(CN)NO 2 , C(CN)C(O)OR 13 or C(CN)C(O)NR 10 R 11 ; and,
Y is O or S.
Specific embodiments of the compounds of formula I include those wherein R is cyclopentyl or cyclohexyl, R 1 is C 1 -C 2 alkyl, preferably ethyl, R 2 is a substituent of formula (Ia) wherein X 1 is O and R 6 and R 3 are both H.
Other specific embodiments of the compounds of formula I include those wherein R is cyclopentyl or cyclohexyl, R. is C 1 -C 2 alkyl, preferably ethyl, R 2 is a substituent of formula (Ib) wherein X 1 is O, q is 1, the dashed line indicates a single bond, and R 4 and R 5 are both H.
Other specific embodiments of the compounds of formula I include those wherein R is cyclopentyl or cyclohexyl, R 1 is C 1 -C 2 alkyl, preferably ethyl, R 2 is a substituent of formula (Id) wherein the dashed line indicates a single bond, R 20 is methyl and R 21 is H or --C(O)NR 10 R 11 .
Other specific embodiments of formula I include those compounds wherein R is cyclopentyl or cyclohexyl, R 1 is C 1 -C 2 alkyl, preferably ethyl, R 2 is a moiety of formula (Io) wherein the dashed line represents a single bond, X 6 is --CH 2 --, and R 10 and R 27 are both H.
Other specific embodiments of formula I include those compounds wherein R is cyclopentyl or cyclohexyl, R 1 is C 1 -C 2 alkyl, preferably ethyl, R 2 is a moiety of formula (Ip) wherein R 31 and R 32 are both H, R 28 is --C(O)R 10 , --CO 2 R 10 , --C(O)(C 6 -C 10 aryl), cyano, nitro, --C(O)NR 10 R 11 , --NR 10 C(O)R 10 , or --NR 10 SO 2 R 10 , R 29 is R 10 or --C(O)R 10 , R 6 is H and R 30 is --CO 2 R 10 , cyano or --C(O)R 10 . Other specific compounds within this group include those wherein R 6 , R 31 , and R 32 are H, R 30 is --CO 2 CH 3 , R 28 is --C(O)CH 3 and R 29 is --CH 3 .
Other specific embodiments of the compounds of formula I include those wherein R 2 is a substituent of formula (Ic), (Ie), (If), (Ig), (Ih), (Ii), (Ij), (Ik), (Il), (Im), (In), (Iq), (Ir), (Is) or (It).
Specific preferred compounds include the following:
racemic 4-(1-Cyclopentyl-3-ethyl-1H-indazol-6-yl)-pyrrolidine-2-one;
(+)-4-(1-Cyclopentyl-3-ethyl-1H-indazol-6-yl)-pyrrolidine-2-one;
(-)-4-(1-Cyclopentyl-3-ethyl-1H-indazol-6-yl)-pyrrolidine-2-one;
and pharmaceutically acceptable salts of said compounds.
Other specific preferred compounds include the following:
racemic 4-(1-Cyclohexyl-3-ethyl-1H-indazol-6-yl)-pyrrolidine-2-one;
(+)4-(1-Cyclohexyl-3-ethyl-1H-indazol-6-yl)-pyrrolidine-2-one;
(-)-4-(1-Cyclohexyl-3-ethyl-1H-indazol-6-yl)-pyrrolidine-2-one;
and pharmaceutically acceptable salts of said compounds.
The present invention further relates to a pharmaceutical composition for the inhibition of phosphodiesterase (PDE) type IV or the production of tumor necrosis factor (TNF) comprising a pharmaceutically effective amount of a compound according to formula I, as defined above, or a pharmaceutically acceptable salt thereof, and a pharmaceutically acceptable carrier.
The present invention further relates to a method for the inhibition of phosphodiesterase (PDE) type IV or the production of tumor necrosis factor (TNF) by administering to a patient an effective amount of a compound according to formula I, as defined above, or a pharmaceutically acceptable salt thereof.
The present invention further relates to a pharmaceutical composition for the prevention or treatment of asthma, joint inflammation, rheumatoid arthritis, gouty arthritis, rheumatoid spondylitis, osteoarthritis, and other arthritic conditions; sepsis, septic shock, endotoxic shock, gram negative sepsis, toxic shock syndrome, acute respiratory distress syndrome, cerebal malaria, chronic pulmonary inflammatory disease, silicosis, pulmonary sarcoidosis, bone resorption diseases, reperfusion injury, graft vs. host reaction, allograft rejections, fever and myalgias due to infection, such as influenza, cachexia secondary to infection or malignancy, cachexia secondary to human acquired immune deficiency syndrome (AIDS), AIDS, HIV, ARC (AIDS related complex), keloid formation, scar tissue formation, Crohn's disease, ulcerative colitis, pyresis, multiple sclerosis, type 1 diabetes mellitus, diabetes insipidus, autoimmune diabetes, systemic lupus erythematosis, bronchitis, chronic obstructive airway disease, psoriasis, Bechet's disease, anaphylactoid purpura nephritis, chronic glomerulonephritis, inflammatory bowel disease, leukemia, allergic rhinitis, dermatitis, depression or multi-infarct dementia, comprising a pharmaceutically effective amount of a compound according to formula I, as defined above, or a pharmaceutically acceptable salt, thereof together with a pharmaceutically acceptable carrier.
This invention further relates to a method of treating or preventing the foregoing specific diseases and conditions by administering to a patient an effective amount of a compound according to formula I, as defined above, or a pharmaceutically acceptable salt thereof.
The term "halo", as used herein, unless otherwise indicated, means fluoro, chloro, bromo or iodo. Preferred halo groups are fluoro, chloro and bromo.
The term "alkyl", as used herein, unless otherwise indicated, includes saturated monovalent hydrocarbon radicals having straight, cyclic or branched moieties.
The term "alkoxy", as used herein, unless otherwise indicated, includes -O-alkyl groups wherein alkyl is as defined above.
The term "alkanoyl", as used herein, unless otherwise indicated, includes --C(O)-alkyl groups wherein alkyl is as defined above.
The term "cycloalkyl", as used herein, unless otherwise indicated, includes saturated monovalent cyclo hydrocarbon radicals including cyclobutyl, cyclopentyl and cycloheptyl.
The term "aryl", as used herein, unless otherwise indicated, includes an organic radical derived from an aromatic hydrocarbon by removal of one hydrogen, such as phenyl or naphthyl.
The term "heterocyclyl", as used herein, unless otherwise indicated, includes aromatic and non-aromatic heterocyclic groups containing one or more heteroatoms each selected from O, S and N. The heterocyclic groups include benzo-fused ring systems and ring systems substituted with an oxo moiety. An example of a C 3 heterocyclic group is thiazolyl, and an example of a C 9 heterocyclic group is quinolinyl. Examples of non-aromatic heterocyclic groups are pyrrolidinyl, piperidino, morpholino, thiomorpholino and piperazinyl. Examples of aromatic heterocyclic groups are pyridinyl, imidazolyl, pyrimidinyl, pyrazolyl, triazolyl, pyrazinyl, tetrazolyl, furyl, thienyl, isoxazolyl and thiazolyl. Heterocyclic groups having a fused benzene ring include benzimidazolyl.
The term "heteroaryl", as used herein, unless otherwise indicated, includes aromatic heterocyclic groups wherein heterocyclic is as defined above.
The phrase "pharmaceutically acceptable salt(s)", as used herein, unless otherwise indicated, includes salts of acidic or basic groups which may be present in the compounds of formula I.
Certain compounds of formula I may have asymmetric centers and therefore exist in different enantiomeric forms. This invention relates to the use of all optical isomers and stereoisomers of the compounds of formula I and mixtures thereof. The compounds of formula I may also exist as tautomers. This invention relates to the use of all such tautomers and mixtures thereof.
DETAILED DESCRIPTION OF THE INVENTION
The following reaction schemes 1-3 illustrate the preparation of the compounds of the present invention. Unless otherwise indicated, R and R 1 in the reaction schemes are defined as above. ##STR4##
The preparation of compounds of formula I can be carried out by one skilled in the art according to one or more of the synthetic methods outlined in schemes 1-3 above and the examples referred to below. In step 1 of scheme 1, the carboxylic acid of formula II, which is available from known commercial sources or can be prepared according to methods known to those skilled in the art, is nitrated under standard conditions of nitration (HNO 3 /H 2 SO 4 , 0° C.) and the resulting nitro derivative of formula III is hydrogenated in step 2 of scheme 1 using standard hydrogenation methods (H 2 --Pd/C under pressure) at ambient temperature (20-25° C.) for several hours (2-10 hours) to provide the compound of formula IV. In step 3 of scheme 1, the amino benzoic acid of formula IV is reacted with a base such as sodium carbonate under aqueous conditions and gently heated until mostly dissolved. The reaction mixture is chilled to a lower temperature (about 0° C.) and treated with sodium nitrate in water. After about 15 minutes, the reaction mixture is slowly transferred to an appropriate container holding crushed ice and a strong acid such as hydrochloric acid. The reaction mixture is stirred for 10-20 minutes and then added, at ambient temperature, to a solution of excess t-butyl thiol in an aprotic solvent such as ethanol. The reaction mixture is acidified to a pH of 4-5 through addition of an inorganic base, preferably saturated aqueous Na 2 CO 3 , and the reaction mixture is allowed to stir at ambient temperature for 1-3 hours. Addition of brine to the reaction mixture, followed by filtration, provides the sulfide of formula V.
In step 4 of scheme 1, the sulfide of formula V is converted to the corresponding indazole carboxylic acid of formula VI by reacting the sulfide of formula V with a strong base, preferably potassium t-butoxide, in dimethyl sulfoxide (DMSO) at ambient temperature. After stirring for several hours (14 hours), the reaction mixture is acidified with a strong acid, such as hydrochloric or sulfuric acid, and then extracted using conventional methods. In step 5 of scheme 1, the indazole carboxylic acid of formula VI is converted to the corresponding ester of formula VII by conventional methods known to those skilled in the art. In step 6 of scheme 1, the compound of formula VIII is provided through alkylation of the ester of formula VII by subjecting the ester to conventional alkylation conditions (strong base/various alkylating agents and, optionally, a copper catalyst such as CuBr 2 ) in a polar aprotic solvent, such as tetrahydrofuran (THF), N-methylpyrrolidinone or dimethylformamide (DMF), at ambient or higher temperature (25-200° C.) for about 6-24 hrs, preferably about 12 hours. In step 7 of scheme 1, the compound of formula VIII is converted to the corresponding alcohol of formula IX by following conventional methods known to those skilled in the art for reducing esters to alcohols. Preferably, the reduction is effected through use of a metal hydride reducing agent, such as lithium aluminum hydride, in a polar aproptic solvent at a low temperature (about 0° C.). In step 8 of scheme 1, the alcohol of formula IX is oxidized to the corresponding aldehyde of formula X according to conventional methods known to those skilled in the art. For example, the oxidation can be effected through use of a catalytic amount of tetrapropylammonium perrutenate and excess N-methylmorpholine-N-oxide, as described in J. Chem. Soc., Chem. Commun., 1625 (1987), in an anhydrous solvent, preferably methylene chloride.
Scheme 2 provides an alternative method of preparing the aldehyde of formula X. In step 1 of scheme 2, the compound of formula XI is nitrated using conventional nitration conditions (nitric and sulfuric acid) to provide the compound of formula XII. In step 2 of scheme 2, the nitro derivative of formula XII is reduced to the corresponding amine of formula XIII according to conventional methods known to those skilled in the art. Preferably, the compound of formula XII is reduced to the amine of formula XIII using anhydrous stannous chloride in an anhydrous aprotic solvent such as ethanol. In step 3 of scheme 2, the amine of formula XIII is converted to the corresponding indazole of formula XIV by preparing the corresponding diazonium tetrafluoroborates as described in A. Roe, Organic Reactions, Vol. 5, Wiley, New York, 1949, pp. 198-206, followed by phase transfer catalyzed cyclization as described in R. A. Bartsch and I. W. Yang, J. Het. Chem. 21, 1063 (1984). In step 4 of scheme 2, alkylation of the compound of formula XIV is performed using standard methods known to those skilled in the art (i.e. strong base, polar aprotic solvent and an alkyl halide) to provide the N-alkylated compound of formula XV. In step 5 of scheme 2, the compound of formula XV is subjected to metal halogen exchange employing an alkyl lithium, such as n-butyl lithium, in a polar aprotic solvent, such as THF, at low temperature (-50° C. to 100° C. (-78° C. preferred)) followed by quenching with DMF at low temperature and warming to ambient temperature to provide the aldehyde intermediate of formula X.
Scheme 3 illustrates the preparation of compounds of formula I wherein R and R 1 are as defined above and R 2 is a substituent of formula (Ia) and X 1 is O. In step 1 of Scheme 3, aldehyde intermediate X is reacted in a polar anhydrous solvent, such as toluene, with diethylmalonate in the presence of an organic base, such as piperidine. The reaction mixture is heated to reflux and water that is produced during the reaction is collected using a Dean-Stark trap. The reaction is run for about 12-30 hours to provide the malonic acid diethyl ester intermediate XVI.
In step 2 of Scheme 3, the malonic acid diethyl ester intermediate XVI is treated with one equivalent of sodium cyanide at ambient temperature (20-25° C.) in an anhydrous polar solvent, such as ethanol, to provide, after acidic work up, the cyano intermediate XVII. In step 3 of Scheme 3, the cyano intermediate XVII is cyclized to pyrrolidin-2-one derivative XVIII by following a four step procedure. First, the cyano intermediate XVII is hydrogenated at high pressure (20-50 psi) using a metal catalyst, such as platinum, and an acidic solvent, such as acetic acid. Second, the intermediate from the first step is heated to reflux in the presence of an organic base, such as triethylamine, in an aprotic organic solvent, such as toluene, for about 10-24 hours. Third, the intermediate from the second step is treated with a strong base, such as sodium hydroxide, in a polar protic solvent, such as an alcohol, preferably ethanol, and heated to reflux for about 30 minutes to an hour. Fourth, the intermediate from the third step is heated to a high temperature, preferably 150-200° C., under an inert atmosphere for 15-30 minutes or until all bubbling has ceased. The crude product can be purified to provide the pyrrolidin-2-one derivative XVIII using standard chromatographic methods known to those skilled in art.
The pyrrolidin-2-one derivative XVIII is racemic and can be separated (or resolved) to its corresponding individual enantiomers using separation techniques known to those skilled in the art. Such methods are described in J. March, Advanced Organic Chemistry, (4th Edition, J. Wiley & Sons), 1992, pages 118-125. In step 4 of Scheme 3, such a resolution is accomplished using a chiral HPLC resolution method as described in Example 2, referred to below.
The compounds of formula I can also be prepared following one or more synthetic methods that are disclosed in published patent applications or issued patents. In particular, using the intermediates described in Schemes 1-3, referred to above, in particular the intermediates of formulas VIII, X, XV and XVIII, those skilled in the art can prepare the compounds of formula I using analogous synthetic methods that have been described for compounds in which a phenyl ring is substituted for the indazole ring in the compounds of formula I. Such analogous synthetic methods are disclosed in U.S. Pat. No. 5,270,206 (issued Dec. 14, 1993) and the following published patent applications: EP 428313 (published Feb. 2, 1994); EP 511865 (published Nov. 4, 1992); EP 671389 (published Mar. 30, 1995); Japanese published application no. 7215952 (published Aug. 15, 1995); Japanese published application no. 7017952 (published Jan. 20, 1995); PCT application WO 87/06576 (published Nov. 5, 1987); PCT application WO 91/07178 (published May 30, 1991); PCT application 91/15451 (published Oct. 17, 1991); PCT application WO 91/16303 (published Oct. 31, 1991); PCT application WO 92/07567 (published May 14, 1992); PCT application 92/19594 (published Nov. 12, 1992); PCT application 93/07111 (published Apr. 15, 1993); PCT application WO 93/07141 (published May 15, 1993); PCT application 94/12461 (published Jun. 9, 1994); PCT application WO 95/08534 (published Mar. 30, 1995); PCT application WO 95/14680 (published Jun. 1, 1995); and PCT application WO 95/14681 (Jun. 1, 1995). The foregoing United States patent and each of the foregoing published patent applications are incorporated herein by reference in their entirety. Each of the foregoing published PCT applications designates the United States.
Specifically, the compounds of formula I wherein R 2 is 2-oxo-4-pyrrolyl, pyrazolyl, 2-oxo-3,4-dihydro-5-pyrimidyl, 2-oxo-3,4-dihydro-4-pyrimidyl, 2-oxo-tetrahydro-4-pyrimidyl, 2-oxo-tetrahydro-5-pyrimidyl, 2-oxo-4-pyrimidyl, or 2-oxo-5-pyrimidyl can be prepared by following analogous synthetic methods disclosed in WO 87/06576, which is referred to above. The compounds of formula I wherein R 2 is a substituent of formula (Ia) can be prepared by following analogous synthetic methods disclosed in WO 87/06576, WO 91/16303, WO 94/12461, WO 92/19594, or WO 93/07141, each of which is referred to above. The compounds of formula I wherein R 2 is a substituent of formula (Ib) can be prepared by following analogous synthetic methods disclosed in WO 87/06576, U.S. Pat. No. 5,270,206, WO 94/12461, WO 92/17567, WO 91/07178, or EP 428313, each of which is referred to above. The compounds of formula I wherein R 2 is a substituent of formula (Ic) can be prepared by following analogous synthetic methods disclosed in WO 87/06576, referred to above. The compounds of formula I wherein R 2 is a substituent of formula (Id) can be prepared by following analogous synthetic methods disclosed in EP 511865, referred to above. The compounds of formula I wherein R 2 is a substituent of formula (Ie) or (If) can be prepared by following analogous synthetic methods disclosed in WO 87/06576 or WO 94/12461, each of which is referred to above. The compounds of formula I wherein R 2 is a substituent of formula (Ig) or (Ih) can be prepared by following analogous synthetic methods disclosed in WO 87/06576, which is referred to above. The compounds of formula I wherein R 2 is a substituent of formula (Ii) can be prepared by following analogous synthetic methods disclosed in WO 91/15451 or WO 93/07111, each of which is referred to above. The compounds of formula I wherein R 2 is a substituent of formula (Ij) or (Ik) can be prepared by following analogous synthetic methods disclosed in WO 93/07111, which is referred to above. The compounds of formula I wherein R 2 is a substituent of formula (Il) can be prepared by following analogous synthetic methods disclosed in WO 95/14680 or WO 95/14681, each of which is referred to above. The compounds of formula I wherein R 2 is a substituent of formula (Im) or (In) can be prepared by following analogous synthetic methods disclosed in Japanese published application no.7215952, which is referred to above. The compounds of formula I wherein R 2 is a substituent of formula (Io) can be prepared by following analogous synthetic methods disclosed in Japanese published application no. 7017952, which is referred to above. The compounds of formula I wherein R 2 is a substituent of formula (Ip) can be prepared by following analogous synthetic methods disclosed in WO 95/08534 or EP 671389, each of which is referred to above. The compounds of formula I wherein R 2 is a substituent of formula (Iq), (Ir), (Is), or (It) can be prepared by following analogous synthetic methods disclosed in WO 87/06576, which is referred to above.
The compounds of formula I that are basic in nature are capable of forming a wide variety of different salts with various inorganic and organic acids. Although such salts must be pharmaceutically acceptable for administration to animals, it is often desirable in practice to initially isolate the compound of formula I from the reaction mixture as a pharmaceutically unacceptable salt and then simply convert the latter back to the free base compound by treatment with an alkaline reagent and subsequently convert the latter free base to a pharmaceutically acceptable acid addition salt. The acid addition salts of the base compounds of this invention are readily prepared by treating the base compound with a substantially equivalent amount of the chosen mineral or organic acid in an aqueous solvent medium or in a suitable organic solvent, such as methanol or ethanol. Upon evaporation of the solvent, the desired solid salt is readily obtained. The desired acid addition salt can also be precipitated from a solution of the free base in an organic solvent by adding to the solution an appropriate mineral or organic acid. Cationic salts of the compounds of formula I are similarly prepared except through reaction of a carboxy group, such as where R 24 is carboxy, with an appropriate cationic salt reagent such as sodium, potassium, calcium, magnesium, ammonium, N,N'-dibenzylethylenediamine, N-methylglucamine (meglumine), ethanolamine, tromethamine, or diethanolamine.
For administration to humans in the curative or prophylactic treatment of inflammatory diseases, oral dosages of a compound of formula I or a pharmaceutically acceptable salt thereof (the active compounds) are generally in the range of 0.1 to 1000 mg daily for an average adult patient (70 kg), in single or divided doses. The active compounds can be administered in single or divided doses. Individual tablets or capsules should generally contain from 0.1 to 100 mg of active compound, in a suitable pharmaceutically acceptable vehicle or carrier. Dosages for intravenous administration are typically within the range of 0.1 to 10 mg per single dose as required. For intranasal or inhaler administration, the dosage is generally formulated as a 0.1 to 1% (w/v) solution. In practice the physician will determine the actual dosage which will be most suitable for an individual patient and it will vary with the age, weight and response of the particular patient. The above dosages are exemplary of the average case but there can, of course, be individual instances where higher or lower dosage ranges are merited, and all such dosages are within the scope of this invention.
For administration to humans for the inhibition of TNF, a variety of conventional routes may be used including orally, parenterally, topically, and rectally (suppositories). In general, the active compound will be administered orally or parenterally at dosages between about 0.1 and 25 mg/kg body weight of the subject to be treated per day, preferably from about 0.3 to 5 mg/kg, in single or divided doses. However, some variation in dosage will necessarily occur depending on the condition of the subject being treated. The person responsible for administration will, in any event, determine the appropriate dose for the individual subject.
For human use, the active compounds of the present invention can be administered alone, but will generally be administered in an admixture with a pharmaceutical diluent or carrier selected with regard to the intended route of administration and standard pharmaceutical practice. For example, they may be administered orally in the form of tablets containing such excipients as starch or lactose, or in capsules either alone or in admixture with excipients, or in the form of elixirs or suspensions containing flavoring or coloring agents. They may be injected parenterally; for example, intravenously, intramuscularly or subcutaneously. For parenteral administration, they are best used in the form of a sterile aqueous solution which may contain other substance; for example, enough salts or glucose to make the solution isotonic.
Additionally, the active compounds may be administered topically when treating inflammatory conditions of the skin and this may be done by way of creams, jellies, gels, pastes, and ointments, in accordance with standard pharmaceutical practice.
The therapeutic compounds may also be administered to a mammal other than a human. The dosage to be administered to a mammal will depend on the animal species and the disease or disorder being treated. The therapeutic compounds may be administered to animals in the form of a capsule, bolus, tablet or liquid drench. The therapeutic compounds may also be administered to animals by injection or as an implant. Such formulations are prepared in a conventional manner in accordance with standard veterinary practice. As an alternative the therapeutic compounds may be administered with the animal feedstuff and for this purpose a concentrated feed additive or premix may be prepared for mixing with the normal animal feed.
The ability of the compounds of formula I or the pharmaceutically acceptable salts thereof to inhibit PDE IV may be determined by the following assay.
Thirty to forty grams of human lung tissue is placed in 50 ml of pH 7.4 Tris/phenylmethylsulfonyl fluoride (PMSF)/sucrose buffer and homogenized using a Tekmar Tissumizer® (Tekmar Co., 7143 Kemper Road, Cincinnati, Ohio 45249) at full speed for 30 seconds. The homogenate is centrifuged at 48,000× g for 70 minutes at 4° C. The supernatant is filtered twice through a 0.22 μm filter and applied to a Mono-Q FPLC column (Pharmacia LKB Biotechnology, 800 Centennial Avenue, Piscataway, N.J. 08854) pre-equilibrated with pH 7.4 Tris/PMSF Buffer. A flow rate of 1 ml/minute is used to apply the sample to the column, followed by a 2 ml/minute flow rate for subsequent washing and elution. Sample is eluted using an increasing, step-wise NaCl gradient in the pH 7.4 Tris/PMSF buffer. Eight ml fractions are collected. Fractions are assayed for specific PDE IV activity determined by [ 3 H]cAMP hydrolysis and the ability of a known PDE IV inhibitor (e.g. rolipram) to inhibit that hydrolysis. Appropriate fractions are pooled, diluted with ethylene glycol (2 ml ethylene glycol/5 ml of enzyme prep) and stored at -20° C. until use.
Compounds are dissolved in dimethylsulfoxide (DMSO) at a concentration of 10 mM and diluted 1:25 in water (400 μM compound, 4% DMSO). Further serial dilutions are made in 4% DMSO to achieve desired concentrations. The final DMSO concentration in the assay tube is 1%. In duplicate the following are added, in order, to a 12×75 mm glass tube (all concentrations are given as the final concentrations in the assay tube).
i) 25 μl compound or DMSO (1%, for control and blank)
ii) 25 μl pH 7.5 Tris buffer
iii) [ 3 H]cAMP (1 μM)
iv) 25 μl PDE IV enzyme (for blank, enzyme is preincubated in boiling water for 5 minutes)
The reaction tubes are shaken and placed in a water bath (37° C.) for 20 minutes, at which time the reaction is stopped by placing the tubes in a boiling water bath for 4 minutes. Washing buffer (0.5 ml, 0.1M 4-(2-hydroxyethyl)-1-piperazine-ethanesulfonic acid (HEPES)/0.1 M naci, pH 8.5) is added to each tube on an ice bath. The contents of each tube are filed to an AFF-Gel 601 column (Biorad Laboratories, P.O. Box 1229, 85A Marcus Drive, Melvile, N.Y. 11747) (boronate affinity gel, 1 ml bed volume) previously equilibrated with washing buffer. [ 3 H]cAMP is washed with 2×6 ml washing buffer, and [ 3 H]5'AMP is then eluted with 4 ml of 0.25M acetic acid. After vortexing, 1 ml of the elution is added to 3 ml scintillation fluid in a suitable vial, vortexed and counted for [ 3 H]. ##EQU1## IC 50 is defined as that concentration of compound which inhibits 50% of specific hydrolysis of [ 3 H]cAMP to [ 3 H]5'AMP.
The ability of the compounds I or the pharmaceutically acceptable salts thereof to inhibit the production TNF and, consequently, demonstrate their effectiveness for treating disease involving the production of TNF is shown by the following in vitro assay:
Peripheral blood (100 mis) from human volunteers is collected in ethylenediaminetetraacetic acid (EDTA). Mononuclear cells are isolated by FICOLL/Hypaque and washed three times in incomplete HBSS. Cells are resuspended in a final concentration of 1×10 6 cells per ml in pre-warmed RPMI (containing 5% FCS, glutamine, pen/step and nystatin). Monocytes are plated as 1×10 6 cells in 1.0 ml in 24-well plates. The cells are incubated at 37° C. (5% carbon dioxide) and allowed to adhere to the plates for 2 hours, after which time non-adherent cells are removed by gentle washing. Test compounds (10 μl) are then added to the cells at 3-4 concentrations each and incubated for 1 hour. UPS (10 μl) is added to appropriate wells. Plates are incubated overnight (18 hrs) at 37° C. At the end of the incubation period TNF was analyzed by a sandwich ELISA (R&D Quantikine Kit). IC 50 determinations are made for each compound based on linear regression analysis.
The following Examples illustrate the invention.
PREPARATION 1
1-Cyclopentyl-3-ethyl-1H-indazole-6-carboxylic acid methyl ester
A. 3-Nitro-4-propyl-benzoic acid. 9.44 g (57.5 mmol, 1.0 equiv) of 4-propylbenzoic acid were partially dissolved in 50 mL concentrated H 2 SO 4 and chilled in an ice bath. A solution of 4.7 mL (74.7 mmol, 1.3 equiv) concentrated HNO 3 in 10 mL concentrated H 2 SO 4 was added dropwise over 1-2 min. After stirring 1 hour at 0° C., the reaction mixture was poured into a 1 L beaker half full with ice. After stirring 10 min., the white solid that formed was filtered, washed 1× H 2 O, and dried to give 12.01 g (100%) of the title compound: mp 106-109° C.; IR (KBr) 3200-3400, 2966, 2875, 2667, 2554, 1706, 1618, 1537, 1299, 921 cm -1 ; 1 H NMR (300 MHz, DMSO-d 6 ) δ 0.90 (t, 3H J=7.4 Hz), 1.59 (m, 2H), 2.82 (m, 2H), 7.63 (d, 1H, J=8.0 Hz), 8.12 (dd, 1H, J=1.7, 8.0 Hz), 8.33 (d, 1H, J=1.7 Hz); 13 C NMR (75.5 MHz, DMSO-d 6 ) δ 14.2, 23.7, 34.2, 125.4, 130.5, 132.9, 133.6, 141.4, 149.5, 165.9; Anal. calcd for C 10 H 11 NO 4 .1/4H 2 O: C, 56.20; H, 5.42; N, 6.55. Found: C, 56.12; H, 5.31; N, 6.81.
B. 3-Amino-4-propyl-benzoic acid. A mixture of 11.96 g (57.2 mmol) 3-nitro-4-propyl-benzoic acid and 1.5 g 10% Pd/C, 50% water wet, in 250 mL CH 3 OH was placed on a Parr hydrogenation apparatus and shaken under 25 psi H 2 at ambient temperature (20-25° C.). After 1 hours, the reaction mixture was filtered through Celite®, and the filtrate concentrated and dried to give 9.80 g (96%) of a pale yellow crystalline solid: mp 139.5-142.5° C.; IR (KBr) 3200-2400, 3369, 3298, 2969, 2874, 2588, 1690, 1426, 1260, 916, 864 cm -1 ; 1 H NMR (300 MHz, DMSO-d 6 ) δ 0.90 (t, 3H, J=7.2 Hz), 1.52 (m, 2H), 2.42 (m, 2H), 5.08 (br s, 2H), 6.96 (d, 1H, J=7.8 Hz), 7.05 (dd, 1H, J=1.7, 7.8 Hz), 7.20 (d, 1H, J=1.7 Hz), MS (Cl, NH 3 ) m/z 180 (M+H + , base); Anal. calcd for C 10 H 13 NO 2 .1/3H 2 O: C, 64.85; N, 7.89; N, 7.56. Found: C, 64.69; H, 7.49; N, 7.86.
C. 3-Carboxy-6-propyl-benzenediazo t-butyl sulfide. A mixture of 8.80 g (49.1 mmol, 1.0 equiv) 3-amino-4-propyl-benzoic acid and 2.34 g (22.1 mmol, 0.45 quiv) sodium carbonate in 55 mL H 2 O was heated gently with a heat gun until mostly dissolved. The reaction mixture was chilled in an ice bath, and a solution of 3.73 g (54.0 mmol, 1.0 equiv) sodium nitrite in 27 mL H 2 O was added dropwise. After 15 minutes, the reaction mixture was transferred to a dropping funnel and added over 10 minutes to a beaker containing 55 g of crushed ice and 10.6 mL concentrated HCl. After stirring 10 minutes, the contents of the beaker were transferred to a dropping funnel and added over 5 minutes to a room temperature solution of 5.31 mL (47.1 mmol, 0.96 equiv) t-butyl thiol in 130 mL ethanol. The pH was adjusted to 4-5 by addition of saturated aqueous Na 2 CO 3 solution, and the reaction mixture was allowed to stir 1 hour at ambient temperature (20-25° C.). 200 mL brine were added, and the mixture was filtered. The solid was washed 1× H 2 O and dried overnight to give 12.25 g (89%) of a brown/rust colored powder (caution-stench): mp 102° C. (dec); IR (KBr) 3200-2400, 2962, 2872, 2550, 1678, 1484, 1428, 1298, 1171 cm -1 ; 1 H NMR (300 MHz, DMSO-d 6 ) δ 0.84 (t, 3H, J=7.3 Hz), 1.48 (m, 2H), 1.55 (s, 9H), 2.42 (m, 2H), 7.29 (d, 1H, J=1.6 Hz), 7.50 (d, 1H, J=8.0 Hz), 7.86 (dd, 1H, J=1.7, 7.9 Hz), 13.18 (br s, 1H); MS (thermospray, NH 4 OAc) m/z 281 (M+H+, base); Anal. calcd for C 14 H 20 N 2 O 2 S: C, 59.96; H, 7.19; N, 9.99. Found: C, 59.71; H, 7.32; N, 10.02.
D. 3-Ethyl-1H-indazole-6-carboxylic acid. A solution of 12.0 g (42.8 mmol, 1.0 equiv) 3-carboxy-6-propyl-benzenediazo t-butyl sulfide in 150 mL DMSO was added dropwise over 15 minutes to an ambient temperature solution of 44.6 g (398 mmol, 9.3 equiv) potassium t-butoxide in 200 mL dimethylsulfoxide (DMS0). After stirring 2 hours at ambient temperature, the reaction mixture was poured into 1.5 L of 0° C. 1N HCl, stirred 5 minutes, then extracted 2×350 mL ethyl acetate. The ethyl acetate extracts (caution-stench) were combined, washed 2×250 mL H 2 O, and dried over MgSO 4 . Filtration, concentration of filtrate and drying gave a tan solid, which was triturated with 1 L of 1:3 Et 2 O/Hexanes and dried to give 7.08 g (87%) of a tan crystalline powder: mp 248-251° C.; IR (KBr) 3301, 3300-2400, 2973, 2504, 1702, 1455, 1401, 1219 cm -1 ; 1 H NMR (300 MHz, DMSO-d 6 ) δ 1.31 (t, 3H, J=7.6 Hz), 2.94 (q, 2H, J=7.6 Hz), 7.63 (dd, 1H, J=1.1, 8.4 Hz), 7.81 (d, 1H, J=8.4 Hz), 8.06 (d, 1H, J=1.1. Hz), 12.95 (br s, 1H); MS (Cl, NH 3 ) m/z 191 (M+H+, base); Anal. calcd for C 10 H 10 N 2 O 2 : C, 63.14; H, 5.30; N, 14.73. Found: C, 62.66; H, 5.42; N, 14.80.
E. 3-Ethyl-1H-indazole-6-carboxylic acid methyl ester. 8.78 g (45.8 mmol, 1.1 equiv) 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride were added in one portion to an ambient temperature solution of 7.92 g (41.6 mmol, 1.0 equiv) 3-ethyl-1H-indazole-6-carboxylic acid, 16.9 mL (416 mmol, 10 equiv) methanol and 5.59 g (45.8 mmol, 1.1 equiv) dimethylaminopyridine (DMAP) in 250 mL CH 2 Cl 2 . After 18 hours at room temperature, the reaction mixture was concentrated to 150 mL, diluted with 500 mL ethyl acetate, washed 2×100 mL 1N HCl, 1×100 mL H 2 O, 1×100 mL brine, and dried over Na 2 SO 4 . Filtration, concentration of filtrate and drying gave 7.8 g of a brown solid, which was purified on a silica gel column (30% to 50% ethyl acetate/hexane gradient) to give 6.41 g (75%) of a tan solid: mp 107-1080C; IR (KBr) 3100-2950, 1723, 1222 cm -1 ; 1 H NMR (300 MHz, CDCl 3 ) δ 8.19 (m, 1H), 7.7-7.8 (m, 2H), 3.96 (s, 3H), 3.05 (q, 2H, J=7.7 Hz), 1.43 (t, 3H, 7.7 Hz); MS (Cl, NH 3 ) m/z 205 (M+H + , base); Anal. calcd for C 11 H 12 N 2 O 2 : C, 64.70; H, 5.92; N, 13.72. Found: C, 64.88; H, 6.01; N, 13.96.
F. 1-Cyclopentyl-3-ethyl-1H-indazole-6-carboxylic acid methyl ester. 1.17 g (29.4 mmol, 1.05 equiv) sodium hydride, 60% oil dispersion, were added in one portion to an ambient temperature solution of 5.7 g (27.9 mmol, 1.0 equiv) 3-ethyl-1H-indazole-6-carboxylic acid methyl ester in 125 mL anhydrous DMF. After 20 min., 3.89 mL (36.6 mmol, 1.3 equiv) cyclopentyl bromide were added dropwise, and the reaction mixture allowed to stir overnight at room temperature. The mixture was then poured into 1 L H 2 O and extracted 3×450 mL ethyl acetate. The organic extracts were combined, washed 3×400 mL H 2 O, 1×200 mL brine, and dried over Na 2 SO 4 . Filtration, concentration of filtrate and drying gave an amber oil, which was purified on a silica gel column (10% ethyl acetate/hexanes, gravity) to give 5.48 g (72%) of a clear oil: 1 H NMR (300 MHz, CDCl 3 ) δ 8.16 (d, 1H, J=1.0 Hz), 7.7 (m, 2H), 5.00 (quintet, 1H, J=7.5 Hz), 3.97 (s, 3H), 3.01 (q, 2H, J=7.6 Hz), 2.2 (m, 4H), 2.0 (m, 2H), 1.8 (m, 2H), 1.39 (t, 3H, J=7.6 Hz); HRMS calcd for C 16 H 20 N 2 O 2 : 272.1526. Found: 272.15078.
G. (1-Cyclopentyl-3-ethyl-1H-indazol-6-yl)-methanol. 7 ml (7.0 mmol, 1.0 equiv) lithium aluminum hydride, 1.0 M solution in THF, were added to a 0° C. solution of 1.02 g (7.05 mmol, 1.0 equiv) 1-cyclopentyl-3-ethyl-1H-indazole-6-carboxylic acid methyl ester in 50 mL anhydrous THF. After 20 minutes, 1 mL methanol was added cautiously, then the reaction mixture was poured into 500 mL of 5% H 2 SO 4 and extracted 3×50 mL ethyl acetate. The organic extracts were combined, washed 2×40 mL H 2 O, 1×40 mL brine, and dried over Na 2 SO 4 . Filtration, concentration of filtrate, and drying gave 1.58 g of a clear oil, which was purified on a silica gel column to give 1.53 g (89%) clear oil: IR (CHCl 3 ) 3606, 3411, 3009, 2972, 2875, 1621, 1490 cm -1 ; 1 H NMR (300 Mhz, CDCl 3 ) δ 7.65 (d, 1H, J=8.0 Hz) 7.42 (s, 1H), 7.06 (dd, 1H, J=1.0, 8.2 Hz), 4.92 (quintet, 1H, J=7.7 Hz), 4.84 (s, 2H), 2.98 (q, 2H, J=7.6 Hz), 2.2 (m, 4H), 2.0 (m, 2H), 1.7 (m, 3H), 1.38 (t, 3H, J=7.6 Hz); MS (thermospray, NH 4 OAc) m/z 245 (M+H + . base); HRMS calcd for C 15 H 20 N 2 O+H: 245.1654. Found: 245.1675.
H. 1-Cyclopentyl-3-ethyl-1H-indazole-carbaldehyde. 106 mg (0.301 mmol, 0.05 equiv) tetrapropylammonium perruthenate (VII) were added to a room temperature suspension of 1.47 g (6.02 mmol, 1.0 equiv) (1-cyyclopentyl-3-ethyl-1H-indazol-6-yl)methanol, 1.06 g (9.03 mmol, 1.5 equiv) N-methylmorpholine N-oxide and 3.01 g 4A molecular sieves in 12 mL anhydrous CH 2 Cl 2 . After 20 minutes the reaction mixture was filtered through a short column of silica gel (eluted with CH 2 Cl 2 ). Fractions containing product were concentrated, and the residue chromatographed on a silica gel column (15% ethyl acetate/hexanes, flash) to give 924 mg (63% of a pale yellow solid: mp 41° C.; IR (KBr) 3053, 2966, 2872, 2819, 1695 cm -1 ; 1 H NMR (300 MHz, CDCl 3 ) δ 10.13 (s, 1H), 7.93 (d, 1H, J-0.9 Hz), 7.77 (d, 1H, J=8.4 Hz), 7.60 (dd, 1H, J=1 .2, 8.4 Hz), 5.00 (quintet, 1H, J=7.5 Hz), 3.01 (q, 2H, J=7.6 Hz), 2.2 (m, 4H), 2.0 (m, 2H), 1.7 (m, 2H), 1.39 (t, 3H, J=7.5 Hz); MS (Cl, NH 3 ) m/z 243 (M+H+, base); Anal. calcd for C 15 H 18 N 2 O: C, 74.35; H, 7.49; N, 11.56. Found: C, 74.17; H, 7.58; N, 11.79.
PREPARATION 2
1-Cyclorentyl-3-ethyl-1H-indazole-6-carbaldehyde
A. 4-Bromo-2-nitro-1-propyl-benzene. 125 g (628 mmol, 1.0 equiv) 1-bromo-4-propyl-benzene were added in one portion to a 10° C. solution of 600 mL conc. H 2 SO 4 and 200 mL H 2 O. With vigorous mechanical stirring, an ambient temperature mixture of 43.2 mL (691 mmol, 1.1 equiv) conc. HNO 3 (69-71%, 16M) in 150 mL conc. H 2 SO 4 and 50 mL H 2 O was added dropwise over 30 minutes. The ice bath was allowed to warm to ambient temperature, and the reaction stirred at room temperature for 68 hours. The reaction mixture was poured into a 4 L beaker, loosely packed full with crushed ice. After stirring 1 hour, the mixture was transferred to a 4 L separatory funnel and extracted 4×800 mL isopropyl ether. The organic extracts were combined, washed 3×800 mL H 2 O, 1×500 mL brine, and dried over Na 2 SO 4 . Filtration, concentration of filtrate and drying gave 150 mL of a yellow liquid, which was purified by silica gel chromatography (2 columns, 3 kg silica gel each, 2% ethyl acetate/hexanes) to afford 63.9 g (42%) of a yellow liquid. The desired regioisomer is the less polar of the two, which are formed in a 1:1 ratio. bp 108° C., 2.0 mm; IR (CHCl 3 ) 3031, 2966, 2935, 2875, 1531, 1352 cm -1 ; 1 H NMR (300 MHz, CDCl 3 ) δ 8.01 (d, 1H, J=2.1 Hz), 7.62 (dd, 1H, J=2.1, 8.3 Hz) 7.23 (d, 1H, J=8.3 Hz), 2.81 (m, 2H), 1.67 (m, 2H), 0.98 (t, 3H, J=7.4 Hz); 13 C NMR (75.5 MHz, CDCl 3 ) a 13.94, 23.74, 34.43, 119.6, 127.4, 133.3, 135.7, 136.4, 149.8; GCMS (El) m/z 245/243 (M+.), 147 (base); HRMS calcd for C 9 H 10 NO 2 Br+H: 243.9973. Found: 243.9954.
B. 5-Bromo-2-propyl-phenylamine. 121 g (639 mmol, 3.0 equiv) of stannous chloride (anhydrous) were added in one portion to a room temperature solution of 51.9 g (213 mmol, 1.0 equiv) 4-bromo-2-nitro-1-propyl-benzene in 1200 mL absolute ethanol and 12 mL (6 equiv) H 2 O. After 24 hours at room temperature, most of the ethanol was removed on a rotary evaporator. The residue was poured into a 4 L beaker, 3/4 full with crushed ice and H 2 O. 150 g of NaOH pellets were added portionwise, with stirring, until the PH=10 and most of the tin hydroxide has dissolved. The mixture was divided in half, and each half extracted 2×750 mL ethyl acetate. All four ethyl acetate extracts were combined, washed 1×500 mL each 1N NaOH, H 2 O, and brine, then dried over Na 2 SO 4 . Filtration, concentration of filtrate and drying gave a yellow liquid, which was purified on a 1.2 kg silica gel column (1:12 ethyl acetate/hexanes) to give 41.83 g (92%) of a pale yellow liquid: IR (CHCl 3 ) 3490, 3404, 3008, 2962, 2933, 2873, 1620, 1491 cm -1 ; 1 H NMR (300 MHz, CDCl 3 ) δ 6.8-6.9 (m, 3H), 3.90 (br s, 2H), 2.42 (m, 2H), 1.62 (m, 2H), 0.99 (t, 3H, J=7.3 Hz); GCMS (El) m/z 215/213 (M+.), 186/184 (base); Anal. calcd for C 9 H 12 NBr: C, 50.49; H, 5.65; N, 6.54. Found: C, 50.77; H, 5.70; N, 6.50.
C. 6-Bromo-3-ethyl-1H-indazole. 49.22 g (230 mmol, 1.0 equiv) 5-bromo-2propyl-phenylamine were placed in a 3 L flask and chilled in an ice bath. A 0° C. solution of 57.5 mL (690 mmol, 3.0 equiv) conc. HCl in 165 mL H 2 O was added, and the resulting solid mass which formed was ground up until a fine white suspension resulted. 100 mL more H 2 O were added, then a solution of 15.9 g (230 mmol, 1.0 equiv) sodium nitrite in 75 mL H 2 O was added dropwise over 10 minutes. The ice bath was removed, and the reaction allowed to stir at room temperature for 30 minutes. The reaction mixture was then filtered through a sintered glass funnel, precooled to 0° C. The filtrate was chilled in an ice bath, and with mechanical stirring, a 0° C. solution/suspension of 32.8 g (313 mmol, 1.36 equiv) ammonium tetrafluorobrate in 110 mL H 2 O was added dropwise over 10 minutes. The thick white suspension which formed (aryl diazonium tetrafluoroborate salt) was allowed to stir 1.5 hours at 0° C. The mixture was then filtered, and the solid washed 1×200 mL 5% aq. NH 4 BF 4 (cooled at 0° C.), 1×150 mL CH 3 OH (cooled to 0° C.), then 1×200 mL Et 2 O. Drying at high vacuum, ambient temperature for 1 hour gave 54.47 g (76%) of the diazonium salt, an off-white solid.
1500 mL of ethanol free chloroform were placed in a 3-neck flask, then 34.16 g (348 mmol, 2.0 equiv) potassium acetate (powdered and dried) and 2.3 g (8.7 mmol, 0.05 equiv) 18-crown-6 were added. After 10 minutes, the diazonium salt was added in one portion, and the reaction mixture allowed to stir at room temperature under nitrogen atmosphere for 18 hours. The mixture was then filtered, the solid washed 2× with CHCl 3 , and the filtrate concentrated to give 47 g of crude product (brown crystals). Silica gel chromatography (1.2 kg silica gel, ethyl acetate/hexanes gradient 15%, 20%, 40%) gave 21.6 g (55% for second step, 42% overall) of tan crystals: mp 112-114° C.; IR (KBr) 3205, 3008, 2969, 2925, 1616, 1340, 1037 cm -1 ; 1 H NMR (300 MHz, CDCl 3 ) δ 9.86 (br s, 1H), 7.61 (d, 1H, J=1.3 Hz), 7.57 (d, 1H, J=8.4 Hz), 7.24 (dd, 1H, J=1.5, 8.6 Hz), 2.99 (q, 2H, J=7.6 Hz), 1.41 (t, 3H, J=7.6 Hz); MS (Cl, NH 3 ) m/z 227/225 (M+H + , base); Anal. calcd for C 9 H 9 N 2 Br: C, 48.02; H, 4.03; N, 12.45. Found: C, 48.08; H, 3.87; N, 12.45.
D. 6-Bromo-1-cyclopentyl-3-ethyl-1H-indazole. 2.46 g (61.4 mmol, 1.05 equiv) sodium hydride, 60% oil dispersion, were added in 0.5 g portions to a 100C solution of 13.17 g (58.5 mmol, 1.0 equiv) 6-bromo-3-ethyl-1H-indazole in 500 mL anhydrous DMF. The mixture was stirred at ambient temperature for 20 minutes, then a solution of 8.8 mL (81.9 mmol, 1.4 equiv) cyclopentyl bromide in 10 mL anhydrous DMF was added dropwise. After 18 hours, the reaction mixture was poured into 2 L H 2 O and extracted 2×1 L ethyl acetate. The organic extracts were combined, washed 2×750 mL H 2 O, 1×500 mL brine, and dried over Na 2 SO 4 . Filtration, concentration of filtrate and drying gave 20.7 g of crude product, which was purified on a silica gel column (1.1 kg silica gel, 3% ethyl acetate/hexanes) to give 10.6 g (62%) of an amber liquid: IR (CHCl 3 ) 2972, 2875, 1606, 1501, 1048 cm -1 ; 1 H NMR (300 mHz, CDCl 3 ) δ 7.56 (d, 1H, J=1.3 Hz), 7.52 (d, 1H, J=8.7 Hz), 7.17 (dd, 1H, J=1.5, 8.5 Hz), 4.83 (quintet, 1H, J=7.6 Hz), 2.96 (q, 2H, J=7.6 Hz), 2.15 (m, 4H), 2.0 (m, 2H), 1.65 (m, 2H), 1.36 (t, 3H, J=7.7 Hz); MS (thermospray, NH 4 OAc) m/z 295/293 (M+H+, base); Anal. calcd for C 14 H 17 N 2 Br: C, 57.35; H, 5.84; N, 9.55. Found: C, 57.48; H, 5.83; N, 9.90.
E. 1-Cyclopentyl-3-ethyl-1H-indazole-6-carbaldehyde. 11.6 mL (28.4 mmol, 1.0 equiv) n-BuLi, 2.45 M in hexanes, were added to a -78° C. solution of 8.32 g (28.4 mmol, 1.0 equiv) 6-bromo-1-cyclopentyl-3-ethyl-1H-indazole in 200 mL anhydrous THF. After 30 min. at -78° C., 8.8 mL (114 mmol, 4.0 equiv) anhydrous DMF were added dropwise, and the reaction mixture was allowed to stir an additional 30 minutes at -78° C. The mixture was warmed to room temperature over 1 hour, then 125 mL 1N HCl were added. After stirring for 10 minutes, most of the THF was removed on a rotary evaporator. The residue was diluted with 500 mL H 2 O, and extracted 2×250 mL ethyl acetate. The organic extracts were combined, washed 1×100 mL H 2 O, 1×100 mL brine, and dried over Na 2 SO 4 . Filtration, concentration of filtrate and drying gave a yellow oil, which was purified on silica gel column (15% ethyl acetate/hexanes, gravity) to give 4.70 g (68%) of a yellow crystalline solid: 1 H NMR (300 MHz, CDCl 3 ) identical to the spectrum of the title compound from Preparation 1.
EXAMPLE 1
Racemic 4-(1-Cyclopentyl-3-ethyl-1H-indazol-6-yl)-pyrrolidine-2-one
A. 2-(1-Cyclopentyl-3-ethyl-1H-indazol-6-ylmethylene)-malonic acid diethyl ester
A mixture of 3.74 g (15.4 mmol, 1.0 equiv) 1-cyclopentyl-3-ethyl-1H-indazole-6-carbaldehyde, 2.33 mL (15.4 mmol, 1.0 equiv) diethyl malonate, and 1.52 mL (15.4 mmol, 1.0 equiv) piperidine in 60 mL anhydrous toluene was heated to reflux. A dean-Stark trap was used to drive the reaction to completion. After 24 hours, the reaction mixture was cooled to room temperature and the toluene removed on a rotary evaporator. The residue was diluted with 500 mL ethyl acetate and washed 2×150 mL saturated aqueous NH 4 Cl, 1×150 mL H 2 O, 1×150 mL brine, and dried over Na 2 SO 4 . Filtration, concentration of filtrate and drying gave 6.87 g crude product, which was purified on a silica gel column (10% ethyl acetate/hexanes, flash) to give 3.01 g (51%) of a yellow oil: IR (CHCl 3 ) 2974, 2940, 2874, 1724, 1257 cm -1 ; 1 H NMR (300 MHz, CDCl 3 ) δ 7.87 (s, 1H), 7.63(d, 1H, J=8.4 Hz), 7.52 (s, 1H), 7.15 (dd, 1H, J=1.4, 8.4 Hz), 4.88 (quintet, 1H, J=7.6 Hz), 4.3 (m, 4H), 2.96 (q, 2H, J=7.6 Hz), 2.15 (m, 4H), 2.0 (m, 2H), 1.7 (m, 2H), 1.3 (m, 9H); MS (Cl, NH 3 ) m/z 385 (M+H + , base); Anal. calcd for C 22 H 28 N 2 O 4 : C, 68.74; H, 7.34; N, 7.27. Found: C, 68.50; H, 7.15; N, 7.23.
B. 2-[Cyano-(1-cyclopentyl-3-ethyl-1H-indazol-6-yl)-methyl]-malonic acid diethyl ester. 375 mg (7.65 mmol, 1.0 equiv) sodium cyanide were added in one portion to room temperature solution of 2.94 g (7.65 mmol, 1.0 equiv) 2-(1-cyclopentyl-3-ethyl-1H-indazol-6-ylmethylene)-malonic acid diethyl ester in 50 mL absolute ethanol. After 14 hour room temperature, the reaction mixture was concentrated on a rotary evaporator and the residue diluted with 500 mL ethyl acetate. 200 mL H 2 O were added, and the mixture acidified to pH 3 with 1N HCl. The layers were separated, and the organic layer was washed 1×100 mL H 2 O, 1×100 mL brine, and dried over Na 2 SO 4 . Filtration, concentration of filtrate and drying gave an orange oil, which was purified on a silica gel column (15%-25% ethyl acetate/hexanes gradient) to give 2.84 g (90%) of a clear oil: IR (CHCl 3 ) 3032, 2974, 2941, 2875, 2250, 1752, 1736, 1244 cm -1 ; 1 H NMR (300 MHz, CDCl 3 ) δ 7.67 (d, 1H, J=8.4 Hz), 7.41 (s, 1H), 7.04 (dd, 1H, J=1.4, 8.4 Hz), 4.89 (quintet, 1H, J=7.6 Hz), 4.66 (d, 1H, J=9.5 Hz), 4.3 (m, 2H), 4.1 (m, 2H), 3.96 (d, 1H, J=9.5 Hz), 2.97 (q, 2H, J=7.6 Hz), 2.15 (m, 4H), 2.0 (m, 2H), 1.36 (t, 3H, J=7.5 Hz), 1.30 t, 3H, J=7.1 Hz), 1.06 (t, 3H, J=7.1 Hz); MS (Cl, NH 3 ) m/z 412 (M+H + , base); Anal. calcd for C 23 H 29 N 3 O 4 : C, 67.13; H, 7.10; N, 10.21. Found: C, 67.29; H, 6.97; N, 10.06.
C. Racemic 4-(1-Cyclopentyl-3-ethyl-1H-indazol-6-yl)-pyrrolidine-2-one. 3.0 g platinum (IV) oxide and 35 mL acetic acid were placed on a Parr® hydrogenation apparatus and shaken under 45 psi H 2 at room temperature for 1 hour. 2.79 g (6.78 mmol, 1.0 equiv) 2-[cyano-(1-cyclopentyl-3-ethyl-1H-indazol-6-yl)-methyl]-malonic acid diethyl ester were added, dissolved in 40 mL acetic acid, then the mixture was shaken under 45 psi H 2 at room temperature for 3 hours. The reaction mixture was filtered through celite®, and the filtrate concentrated on a rotary evaporator and azeotroped 3× with toluene. Drying at high vacuum, room temperature gave 3.37 g of a yellow oil. This oil was dissolved in 100 mL toluene, 10 mL triethylamine were added, and the mixture heated to reflux under nitrogen atmosphere. After 17 hours, the reaction mixture was cooled to room temperature, and the toluene removed on a rotary evaporator. The residue was dissolved in 250 mL ethyl acetate and washed 3×50 mL 1N HCl, 1×50 mL H 2 O, 1×50 mL brine, and dried over Na 2 SO 4 . Filtration, concentration of filtrate and drying gave 2.84 g of an amber oil. This second oil was dissolved in 60 mL ethanol and 20 mL 1N NaOH were added. After 30 minutes of reflux, the reaction mixture was cooled to room temperature and concentrated on a rotary evaporator. The residue was diluted with 200 mL H 2 O, acidified to pH=2 with 1N HCl, and extracted 2×100 mL ethyl acetate. The organic extracts were combined, washed 1×50 mL H 2 O, 1×50 mL brine, and dried over Na 2 SO 4 . Filtration, concentration of filtrate and drying brine, and dried over Na 2 SO 4 . Filtration, concentration of filtrate and drying gave 2.45 g of a tan amorphous solid. This solid was heated in an oil bath to 180° C. (external) under nitrogen atmosphere. After 20 minutes at 180° C., all bubbling had ceased, and the brown liquid which formed was cooled to room temperature. As it cooled, it crystallized as a tan solid. Silica gel chromatography (5% CH 3 OH/CH 2 Cl 2 , flash) gave 1.41 g of a white solid, which was recrystallized from ethyl acetate/hexanes to give 1.21 g (60% overall) white silvery flakes: mp 197-198° C.; IR (KBr) 3197, 3093, 2967, 2874, 2818, 1705, 1682 cm -1 ; 1 H NMR (300 MHz, CDCl 3 ) δ 7.65 (d, 1H, J=8.2 Hz), 7.23 (s, 1H), 6.99 (dd, 1H, J=1.4, 8.3 Hz), 6.09 (br s, 1H), 4.89 (quintet, 1H, J=7.7 Hz), 3.85 (m, 2H), 3.5 (m, 1H), 2.97 (q, 2H, J=7.6 Hz), 2.85 (m, 1H), 2.55 (m, 1H), 2.14 (m, 4H), 2.0 (m, 2H), 1.7 (m, 2H), 1.37 (t, 3H, J=7.5 Hz); MS (Cl, NH 3 ) m/z 298 (M+H + , base); Anal. calcd for C 19 H 23 N 3 O: C, 72.69; H, 7.80; N, 14.13. Found: C, 72.39; H, 7.84; N, 14.33.
EXAMPLE 2
(+)-4-(1-Cyclopentyl-3-ethyl-1H-indazol-6-yl)-pyrrolidine-2-one and (-)-4-(1-cyclopentyl-3-ethyl-1H-indazol-6-yl)-pyrrolidine-2-one
958 mg of racemic 4-(1-cyclopentyl-3-ethyl-1H-indazol-6-yl)-pyrrolidine-2-one were resolved chromatographically on a 5 cm id×50 cm long Chiracel OD column. The mobile phase was 88:12 heptane:isopropanol with 0.05% diethylamine as additive. The feed for each cycle was 60 mg racemate in 4 mL isopropanol. The flow rate was 70 mL/min and the separation was monitored at 230 nm. The two peaks eluted at 50 and 55 minutes. The heart cuts of the 50 and 55 minutes. The heart cuts of the 50 minutes peak were pooled and assayed at 96% ee. This fraction (8L) was concentrated, and the residue purified on a silica gel column (5% CH 3 OH/CH 2 Cl 2 , flash) to give 371 mg of a white solid, which was recrystallized from ethyl acetate/hexanes to give 295 mg of silvery-white flakes: mp 132-135° C.; IR (KBr) 3204, 3097, 2967, 2873, 1702 cm -1 ; 1 H NMR (300 MHz, CDCl 3 ) δ 7.65 (d, 1H, J=8.4 Hz), 7.23 (s, 1H), 6.99 (dd, 1H, J=1.2, 8.3 Hz), 5.94 (br s, 1 H0, 4.89 (quintet, 1H, J=7.6 Hz), 3.85 (m, 2H), 3.49 (m, 1H), 2.98 (q, 2H, J=7.7 Hz), 2.8 (m, 1H), 2.6 (m, 1H), 2.2 (m, 4H), 2.0 (m, 2H), 1.7 (m, 2H), 1.37 (t, 3H, J=7.4 Hz); MS (Cl, NH 3 ) m/z 298 (M+H + , base); Anal. calcd for C 18 H 23 N 3 O: C, 72.69; H, 7.80; N, 14.13. Found: C, 72.41; H, 7.87; N, 14.17; [a]D=-34.3° C. (c=1.15, CHCl 3 ). The heart cuts of the 55 minutes peak were pooled and assayed at 94% ee. This fraction (13 L) was concentrated, and the residue purified on a silica gel column (5% CH 3 OH/CH 2 /Cl 2 flash) to give 400 mg of a white solid, which was recrystallized from ethyl acetate/hexanes to give 256 mg of white crystals: mp 132.5-135.5° C.; IR (KBr) 3203, 3097, 2967, 2872, 1703 cm -1 ; 1 H NMR (300 MHz, CDCl 3 ) δ 7.65 (d, 1H, J=8.4 Hz), 7.23 (s, 1H), 6.99 (dd, 1H, J=1.2, 8.3 Hz), 5.94 (br s, 1H), 4.89 (quintet, 1H, J=7.6 hz), 3.85 (m, 2H), 3.49 (m, 1H), 2.98 (q, 2H, J=7.7 Hz), 2.8 (m, 1H), 2.6 (m, 1H), 2.2 (m, 4H), 2.0 (m, 2H), 1.7 (m, 2H), 1.37 (t, 3H, J=7.4 Hz); MS (Cl, NH 3 ) m/z 298 (M+H + , base); Anal. calcd for C 18 H 23 N 3 O: C, 72.69; H, 7.80; N, 14.13. Found: C, 72.76; H, 7.94; N, 14.20; [a]D=+32.9° (c=1.19, CHCl 3 ). | The invention relates to compounds of the formula I ##STR1## and pharmaceutically acceptable salts thereof, wherein R, R 1 , and R 2 , are as defined herein. The invention further relates to pharmaceutical compositions containing, and methods of using, the compounds of formula I, or acceptable salts thereof, for the inhibition of phosphodiesterase (PDE) type IV or the production of tumor necrosis factor (TNF) in a mammal. | 2 |
CROSS REFERENCE To RELATED APPLICATIONS
[0001] This application is related to U.S. patent applications Ser. No. ______ (Attorney Docket No. 100.840US01) having a title of “MODULARIZED RADIO FREQUENCY BAND COMPONENTS ON REMOVABLE DOORS” (also referred to here as the “'840 Application”), Ser. No. ______ (Attorney Docket No. 100.834US01) having a title of “CLAMSHELL CHASSIS ASSEMBLY” (also referred to here as the “'834 Application”), and Ser. No. ______ (Attorney Docket No. 100.-8315US01) having a title of “A MULTI-FUNCTIONAL HINGE” (also referred to here as the “831 Application”) which are each filed on even date herewith. The '840, '834, and '831 Applications are hereby incorporated herein by reference.
BACKGROUND
[0002] For many years outdoor electronic enclosures have been mounted on utility poles high above the ground. To access the enclosure for repairs or maintenance a serviceperson is usually lifted in the boom of a boom truck to the height of the enclosure. From the elevated boom the serviceperson can generally only access what is within an arm's reach, because a boom, once elevated, has minimal if any capability for lateral movement. If, for example, the enclosure has an access door on each of its four sides, the boom may provide the operator with access to at most three sides of the enclosure. The fourth side has limited access, because it is mounted to the pole and is generally on the side of enclosure opposite of the boom.
[0003] Typically the only means of access to components located on or near this fourth side of the enclosure is by completely removing the enclosure from the pole, or by opening one of the other access doors and reaching through the enclosure. Both of these options present problems. For example, the enclosures are often large, heavy, and securely mounted to the pole, all which make removing the enclosure no small task. The enclosure is typically connected to some type of power source, requiring trained technicians to disconnect. Also, if the enclosure provides some type of service, such as telecommunications coverage, power distribution, security or monitoring, removing the enclosure can have a negative impact on the system. Additionally, enclosures generally make efficient use of internal space, resulting in many cables running about. This makes it difficult or impossible to reach through the enclosure.
[0004] For the reasons stated above, and for other reasons stated below which will become apparent to those skilled in the art upon reading and understanding the present specification, there is a need in the art for a mechanism that provides easy access to the pole side of a mounted enclosure.
SUMMARY
[0005] The above-mentioned problems of current systems are addressed by embodiments of the present invention and will be understood by reading and studying the following specification. The following summary is made by way of example and not by way of limitation. It is merely provided to aid the reader in understanding some of the aspects of the invention. In one embodiment, an electronic equipment apparatus is disclosed. The electronic equipment apparatus includes an enclosure for holding electronic equipment. The electronic equipment apparatus also includes a hinged pivot mount, wherein the enclosure is rotatably coupled to the hinged pivot mount.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The present invention can be more easily understood, and further advantages and uses thereof are more readily apparent, when considered in view of the detailed description and the following figures in which:
[0007] FIG. 1 is a perspective view of one embodiment of a pivoting enclosure system in an open position;
[0008] FIG. 2 is another perspective view of the pivoting enclosure system of FIG. 1 in a closed position;
[0009] FIG. 3A is a front view of a pivoting bracket for use in a system similar to FIG. 1 ;
[0010] FIG. 3B is a side view of a pivoting bracket for use in a system similar to FIG. 1 ;
[0011] FIG. 3C is a back view of a pivoting bracket for use in a system similar to FIG. 1 ; and
[0012] FIG. 3D is a top view of a pivoting bracket for use in a system similar to Figure
[0013] In accordance with common practice, the various described features are not drawn to scale but are drawn to emphasize specific features relevant to the present invention. Like reference characters denote like elements throughout the Figures and text.
DETAILED DESCRIPTION
[0014] In the following detailed description, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific illustrative embodiments in which the method and system may be practiced. These embodiments are 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 logical, mechanical and electrical changes may be made without departing from the spirit and scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense.
[0015] Embodiments of the present invention provide for a system for mounting a telecommunications enclosure, or similar enclosure containing electronic devices, to a mounting surface, and enabling the enclosure to pivot relative to the mounting surface.
[0016] With reference now to the figures, FIGS. 1 and 2 illustrate perspective views, shown generally at 100 and 101 respectively, of a pivot mount 106 (pivot bracket) that improves the accessibility of an enclosure 102 and enables enclosure 102 to be mounted to a utility pole 104 . Pivot mount 106 provides secure attachment of enclosure 102 to pole 104 . Notably, pivot mount 106 allows enclosure 102 to partially rotate about an axis relative to pole 104 which exposes a back side 108 (pole side) of enclosure 102 . Access to pole side 108 of enclosure, enables easier upgrades and repairs for maintenance crews accessing components on or near pole side 108 of enclosure 102 .
[0017] As shown in FIG. 1 , enclosure 102 is a telecommunications enclosure, or more specifically, a cabinet holding a plurality of telecommunication devices. In alternate embodiments, enclosure 102 could be any enclosure containing any type of devices, which is mounted to an upright structure and with which it is desirable to have access to the pole side of the enclosure. As it is used here, enclosure 102 includes devices mounted internally, externally, or both. Although FIG. 1 shows enclosure 102 mounted to a utility pole 104 , other mounting surfaces are contemplated as within the scope of the present invention. For example, alternate embodiments include, but are not limited to, a light pole, a tree, a side of a building, or any other upright structure.
[0018] Pivot mount 106 includes a first hinge 112 and a second hinge 113 for coupling enclosure 102 to pole 104 . Hinges 112 , 113 provide the ability to pivot enclosure 102 relative to pole 104 . First hinge 112 is located at the top of enclosure 102 and second hinge 113 is located at the bottom of enclosure 102 . In this embodiment, enclosure 102 has an aperture in both the top and bottom for connecting enclosure 102 to hinges 112 , 113 . One pivot bolt 115 for each hinge 112 , 113 is used to connect enclosure 102 to each hinge 112 , 113 . Each pivot bolt 115 extends through an aperture (not shown) in each hinge 112 , 113 and into the aperture in enclosure 102 . In this embodiment, the apertures in enclosure 102 are threaded and bolts 115 screw into the threaded apertures. Bolts 115 are solidly connected to enclosure 102 , and thus rotate with enclosure 102 as enclosure 102 is pivoted. As enclosure 102 is pivoted, bolts 115 rotationally slide within the apertures of hinges 112 , 113 .
[0019] As known to those skilled in the art, although in this embodiment, an aperture and a bolt 115 are used to connect enclosure 102 to hinges 112 , 113 , other mechanisms for connecting enclosure 102 to hinges 112 , 113 are contemplated as within the scope of this invention. For example, a screw or a pin could be used to connect hinges 112 , 113 to enclosure 102 . Additionally, although for illustration purposes two hinges (e.g. 112 , 113 ) are used to connect to enclosure 102 , the present invention is not intended to be so limited. Notably, a single hinge, or more than two hinges could be used. Also, in other embodiments, a different type of hinge is used. For example, in one embodiment, a single hinge of the type common in household door applications could be used. In this embodiment, one component of the hinge is connected to the side of enclosure 102 , and the other component of the hinge is connected to pivot mount 106 . In this embodiment, both components are aligned and a pin is placed through the components. Alternatively, any other type of hinge could be used as known to those skilled in the art.
[0020] As shown, hinges 112 , 113 define a vertical pivoting axis for enclosure 102 through each of the apertures within hinges 112 , 113 . In this embodiment, enclosure 102 “opens” to the left by pivoting from the position shown in FIG. 1 to the position shown in FIG. 2 . The vertical axis provided by hinges 112 , 113 is located off-centered in enclosure 102 . This positioning of hinges 112 , 113 enables full exposure of pole side 108 when enclosure 102 is pivoted to the open position as shown in FIG. 2 .
[0021] In another embodiment, hinges 112 , 113 are disposed to provide a horizontal pivot axis. In this alternative embodiment, hinges 112 , 113 are connected to opposite lateral sides of enclosure 102 , and enclosure 102 opens either upwards or downwards depending on the point(s) of connection between hinges 112 , 113 and enclosure 102 . In still another alternative embodiment, hinges 112 , 113 are disposed to form a vertical pivot axis as in FIG. 1 ; however, hinges 112 , 113 are connected to enclosure 102 near the center of the top and bottom of enclosure 102 . In this alternative embodiment, enclosure 102 can freely rotate 360 degrees to the degree restricted only by cables other obstacles hindering such rotation.
[0022] In the illustrative embodiment of FIG. 1 , enclosure 102 has a plurality of electrical connectors shown generally at 116 . Electrical connectors 116 are used to connect cables (e.g. fiber optic cables, coaxial cables, power cables, etc.) to enclosure 102 . In this embodiment, connectors 116 are positioned near the vertical pivot axis to minimize the translational distance of travel when enclosure 102 is pivoted. This minimizes the strain on the cables and reduces the amount of slack required when connecting the cables.
[0023] FIGS. 3A , 3 B, 3 C, and 3 D illustrate front, side, back, and top views respectively of one embodiment of a pivot mount 300 which is similar to pivot mount 106 shown in FIGS. 1 and 2 . Pivot mount 300 has a base 302 , a first hinge 304 , and a second hinge 306 . Base 302 has an enclosure face 307 (shown in FIG. 3A ) which is on the side of pivot mount 300 in which the enclosure is adjacent when the enclosure is in the closed position. Enclosure face 307 has a design and shape that fits the pole side 108 of enclosure 102 . In this embodiment, enclosure face 307 of base 302 is flat and planar. The present invention, however, is not intended to be limited to a flat and planar enclosure face 307 . For example, in other embodiment, an enclosure has a rounded side adjacent to enclosure face 307 , and enclosure face 307 of base 302 is similarly rounded to match with the side of the enclosure.
[0024] Base 302 also has a pole face 309 shown in FIG. 3C . Pole face 309 of enclosure 3 C has a design and shape that fits onto pole 104 . In this embodiment, pole face 309 of base 302 has a stabilizer 308 (shown in FIGS. 3B , 3 C, and 3 D) made up of two rails. Each rail of stabilizer 308 extends vertically on base 302 of pivot mount 300 and is spaced apart from the other rail. This allows pivot mount 300 to mount evenly and securely upon pole 104 . When pivot mount 300 is mounted to pole 104 , the rails extend parallel with pole 104 and the curvature of pole 104 is straddled between the two rails. Each rail has a plurality of apertures 310 through which a band clamp 110 (shown in FIGS. 1 and 2 ) is inserted. When pivot mount 300 is mounted to pole 104 , each band clamp 120 extends around pole 104 and through one of the apertures 310 of pivot mount 300 . To secure pivot mount 300 to pole 104 , each band clamp 110 is tightened around pole 104 . This causes stabilizer 308 to place force against pole 104 , thus holding pivot mount 300 to pole 104 . Each band clamp 110 is of sufficient size and strength, such the weight of enclosure 102 and pivot mount 300 are supported.
[0025] FIG. 3B shows a side of pivot mount 300 opposite of hinges 304 , 306 having a lip 312 . Lip 312 of base 302 is used to hold enclosure 102 in a closed position (as shown in FIG. 2 ) when pole side 108 of enclosure 102 is not being accessed. Lip 312 has two apertures 314 which each accept a screw 114 (shown in FIGS. 1 and 2 ). When enclosure is closed, screws 114 are screwed through apertures 310 and are tightened, applying pressure to enclosure 102 and preventing enclosure 102 from unintentionally pivoting out of the closed position. Although in this illustrative embodiment, lip 312 and screws 114 are used as a fastener to hold enclosure 102 in the closed position, the present invention is not intended to be so limited. In other embodiments, enclosure 102 is held in place with a different fastener. For example, enclosure 102 may have apertures into which screws 114 could be inserted to hold enclosure 102 in place, or a pin, strap, mechanical latch, or other mechanism that does or does not use apertures 314 could be used to hold enclosure 102 in place.
[0026] Referring back to FIGS. 1 and 2 , to easily access pole side 108 of enclosure 102 , enclosure 102 is pivoted (opened) to 90 degrees as shown in FIG. 2 . To allow enclosure 102 to pivot from the closed position, screws 114 are removed from apertures 202 in pivot mount 106 . Alternatively, instead of screws 114 , a captive fastener could be used to hold the enclosure in the closed position. In this case the captive fastener would be loosed to disengage from pole side 108 , yet still be held captive within pivot mount 106 . As shown in FIG. 2 , with screws 114 removed, enclosure 102 can pivot freely by manual rotation to an open position. As shown in FIG. 2 , enclosure 102 is opened to approximately 90 degrees from the fully closed position. In other embodiments, however, hinges 112 , 113 could be positioned in other locations to allow pivoting of enclosure 102 of differing degrees as desired for the particular application.
[0027] To protect pole side 108 from the natural elements, and prevent access to pole side 108 , enclosure 102 is pivoted to the closed position. Screws 114 are then screwed through apertures 202 in pivot mount and tightened against enclosure. Although pole side 108 is difficult to access in the closed position, in this embodiment, the other three sides 118 of enclosure 102 are still accessible. For additional security, a mechanical cylinder having a proprietary heat fastener could replace one or both of screws 114 . In other embodiments, an external feature could be included to allow for an external padlock to be used.
[0028] Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement, which is calculated to achieve the same purpose, may be substituted for the specific embodiment shown. This application is intended to cover any adaptations or variations of the present invention. Therefore, it is manifestly intended that this invention be limited only by the claims and the equivalents thereof. | An electronic equipment apparatus is provided. The electronic equipment apparatus includes an enclosure for holding electronic equipment. The electronic equipment apparatus also includes a hinged pivot mount, wherein the enclosure is rotatably coupled to the hinged pivot mount. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to apparatus in the field of undergarments, and in particular, to a device for covering portions of an undergarment that might be exposed through an outer garment with a relatively open back.
2. Description of Related Art
Brassieres come in various styles. Many brassieres have a horizontal strap with releasable closures in the back or in the front which circles the chest of the wearer.
In FIG. 1 outer garment 10 is a top with an open back 12 bordered at the neck with a cinch 10 A. The wearer P is also wearing an undergarment 14 , namely a brassiere (bra) with a backstrap 16 that can be fastened/unfastened at clasp 16 A. Undergarment 18 is shown with the conventional shoulder straps 18 and 20 attached to the left and right, respectively, of backstrap 16 . It will be noticed that backstrap 16 and portions of shoulder straps 18 and 20 are visible through open back 12 .
The bodice of many women's garments in modern style have this open back, which exposes the horizontal bra strap 16 . Exposure of this strap is often considered unattractive or aesthetically unpleasant. Moreover for many of these styles, the exposure of the bra's shoulder straps is also considered aesthetically undesirable.
See also U.S. Pat. Nos. 4,945,576; 5,144,696; 6,406,354; 8,357,025; and 8,469,772; as well as US Patent Application Publication Nos. 2011/0269376; 2012/0045597; and 2012/0324631.
SUMMARY OF THE INVENTION
In accordance with the illustrative embodiments demonstrating features and advantages of the present invention, there is provided a cover for an undergarment having a back strap and a pair of shoulder straps. The cover includes a casing for covering the back strap. The casing is adapted to extend from one of the pair of shoulder straps to the other.
In accordance with another aspect of the present invention, a method is provided for covering a back strap of an undergarment having a pair of shoulder straps. The method employs a casing. The method includes the step of placing the casing about the back strap to cover it at least partially. Another step is extending the casing along the back strap from one of the shoulder straps to the other. The method also includes the step of donning an outer garment over the undergarment.
By employing apparatus and methods of the foregoing type, a novel cover is provided for covering portions of an undergarment that might be exposed through the open back of an outer garment. For example, one can cover the backstrap of a brassiere that would otherwise be exposed through a garment that has a relatively open back. To install the cover, the backstrap, when open, is threaded into a tubular cover. The backstrap can then be closed and the cover stretched to reach from one shoulder strap to the other. This cover can be made of an attractive material and can be adorned with decorative elements, so others see a relatively attractive article instead of a utilitarian and less-than-attractive rear bra strap.
The cover may be fastened to the shoulder straps to ensure full coverage from shoulder strap to shoulder strap. In one case snaps are attached to the rim of the openings of a tubular cover. At each end the snaps may be pulled past the shoulder strap to a position just above the bra's backstrap, before being snapped together. This not only provides full coverage, but applies an outward pressure to the shoulder straps, causing them to bow outwardly and slide under portions of the outer garment adjacent to the open back.
In some embodiments the ends of a tubular cover can be fastened to the bra's shoulder straps with a releasable tether. The tether can be affixed to the end of the tubular cover and can wrap around the shoulder strap before being fastened back onto the cover.
In some embodiments a relatively stiff panel is laminated onto an inside face of the cover. This panel tends to stretch the cover longitudinally so the cover will bear against the bra's shoulder straps.
Some bras are fastened in the front and therefore the backstrap does not open. In that case the cover may have a longitudinal split that allows the cover to be wrapped around the backstrap before closing the cover along the longitudinal split. The closure at the longitudinal split may be a zipper, snaps, or other means.
BRIEF DESCRIPTION OF THE DRAWINGS
The above brief description as well as other objects, features and advantages of the present invention will be more fully appreciated by reference to the following detailed description of illustrative embodiments in accordance with the present invention when taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a rear elevational view of a person wearing an outer garment over an undergarment, in accordance with the prior art.
FIG. 2 is perspective view of a cover in accordance with principles of the present invention;
FIG. 3 is a perspective view of the cover of FIG. 2 installed on an undergarment;
FIG. 4 is a cross-sectional view taken along line 4 - 4 of FIG. 3 ;
FIG. 5 is a rear elevational view of a person wearing an undergarment outfitted with a cover as shown in FIG. 4 , the cover being adorned with decorative elements;
FIG. 6 is a fragmentary, perspective of one end of a cover that is an alternate to that shown in the above Figures;
FIG. 7 is fragmentary, perspective of one end of the cover of FIG. 6 shown installed on an undergarment;
FIG. 8 is a cross-sectional view of a cover that is an alternate to that shown in the above Figures;
FIG. 9 is a cross-sectional view of a cover that is an alternate to that shown in the above Figures;
FIG. 10 is a cross-sectional view of a cover that is an alternate to that shown in the above Figures;
FIG. 11 is a plan view of a cover that is an alternate to that shown in the above Figures;
FIG. 12 is a fragmentary, elevational view of one end of the cover of FIG. 11 that is folded but unfastened; and
FIG. 13 is fragmentary, perspective of one end of the cover of FIG. 11 shown installed on an undergarment.
DETAILED DESCRIPTION
Referring to FIG. 2 , the illustrated cover 22 is a tubular casing (also referred to as a tube or jacket) with an opposing pair of openings 24 . Cover 22 can be made from any of a variety of fabrics, including knit or weaved fabrics, plastic sheets or sheets made from entangled fibrous material. To give cover 22 some stretchability, some embodiments may use knit nylon or polyester blended with spandex. In some cases the cover 22 will be fabrics of nylon, polyester or other fibers that stretch due to the design of the knit. Other embodiments may use rubberized materials or flexible plastics such as polyethylenes and thermoplastic polyurethanes. Any of the forgoing material may be blended or laminated together to form a composite. In particular the outer surface of cover 22 may have a pleasant appearance and may be a layer of actual or imitation cotton, silk, chiffon, crepe, denim, etc. In some cases the outer surface of cover 22 may be a smooth surface suitable for printing, embossing, coloring, receiving appliques or charms, etc.
A pair of fasteners 26 A and 26 B are installed near the annular rim of opening 24 (left end of FIG. 2 ) at locations that are angularly spaced about 120° apart (two o'clock and 10 o'clock positions), although other angular spacings may be employed in other embodiments. A complementary pair of fasteners are installed at the opposite (right) end, again 120° apart, only one of them (fastener 28 A) being visible in this Figure. Fasteners 26 A, 26 B, and 28 A are releasable snaps.
Cover 22 is adorned with a number of decorative elements 22 A. While elements 22 A are illustrated as small round objects, in some embodiments they may be larger objects with an arbitrary outline. Elements 22 A may be plastic emblems, metal studs, stickers, decals, printed indicia, small mirrors, three dimensional typographic characters, sequins, relief images, real or artificial jewels (precious or semiprecious), etc. In some cases elements 22 A may be molded items depicting celebrities, historic buildings, sports equipment, team logos, classic automobiles, common household items, pets, etc. In some cases, the decorative elements may be a single element that spans across cover 22 , banner-like. In still other cases, cover 22 can be a fabric (or a fabric sheath) with a pleasant color or pattern, and will not have separate, distinct decorative elements.
In some cases, elements 22 A may be LEDs or other types of lights that are illuminated continuously or intermittently. These lights can flash randomly to produce a twinkling effect or can be illuminated in a sequence to produce a ticker tape effect. If densely packed, these lights can be used to produce images that are either static, changing, or animated.
In some embodiments the cover 22 may have a different appearance on the opposite side and may be reversed, right to left, or rotated 180° along its axis to present this other appearance. In addition, in some embodiments the inside of cover 22 may have a different appearance and the cover may be turned inside out to present that other appearance. In still other embodiments, the appearance of cover 22 may be varied by using a replaceable skin that is secured by adhesive, hook and loop fasteners, etc.
To facilitate an understanding of the principles associated with the foregoing apparatus, its operation will be briefly described with reference to FIGS. 1-5 . In FIG. 3 previously mentioned back strap 16 ( FIG. 1 ) is shown threaded through cover 22 and emerging from its opposite ends 24 . This threading is achieved by opening back strap 16 at clasp 16 A and threading one side of the unclasped back strap through cover 22 , before closing clasp 16 A and stretching the cover so it reaches between shoulder straps 18 and 22 .
Snaps 26 A and 26 B ( FIGS. 2 and 3 ) are then pulled past shoulder strap 18 and snapped together above back strap 16 . Likewise, snap 28 A and its mate are snapped together above back strap 16 and to the outside of shoulder strap 20 . Thus, snap 26 A and its mate (snap 28 A and its mate) form a passageway for shoulder strap 18 ( 20 ) and another passageway for back strap 16 . These passageways are also referred to as annular entranceways.
This installation of cover 22 may be performed while back strap 16 is located dorsally as shown in FIG. 1 . Alternatively, the installation may be performed with back strap 16 positioned anteriorly. After this installation, bra 14 will be spun azimuthally 180°, before lifting into place shoulder straps 18 and 20 and the bra's front cups (not shown).
The fastened positions of snaps 26 A and 28 A and their mates tends to stretch the portion of opening 24 around shoulder straps 18 and 20 and the resulting tension tends to push the shoulder straps outwardly and down toward the back strap 16 . This is accompanied by wrinkling in regions W. Consequently, shoulder straps 18 and 20 bow outwardly causing them to slide behind outer garment 10 either completely (as in FIG. 5 ), or partially. Therefore, open back 12 no longer reveals straps 16 , 18 and 20 , and reveals instead the pleasantly decorated cover 22 .
Referring now to FIGS. 6 and 7 , alternative cover 122 may be a tube formed of materials as previously described. However, cover 122 has a fastener that is different from that described above. Specifically, a separate pair of tethers 130 are attached to each of the opposing ends 124 of cover 122 . The proximal end of tether 130 is affixed to cover 122 by stitches, staples, rivets, adhesive, or the like. Snap element 132 A on the distal end of tether 130 is designed to snap onto its mate 132 B on the opposite side of cover 122 .
As before, back strap 16 may be undone and threaded into cover 122 before closing the strap 16 at clasp 16 A. Cover 122 is then stretched to shoulder straps 18 and 22 and held in place using tethers 130 . Specifically, tether 130 is routed around the outside of shoulder strap 20 as shown in FIG. 7 . Only shoulder strap 20 is shown in FIG. 7 but the other shoulder strap 18 is tethered in a complementary fashion.
Installation of tethers 130 tends to stretch the portion of opening 124 around shoulder straps 18 and 22 and the resulting tension tends to push the shoulder straps outwardly and down toward the back strap 16 . As before, shoulder straps 18 and 20 bow outwardly causing them to slide behind an outer garment (garment 10 of FIG. 5 ). Therefore, the pleasantly decorated cover 122 is exposed, but not the associated bra components.
Referring to FIG. 8 , alternative cover 222 may be a tube formed of the previously described materials and may have either the fastener of FIG. 3 or 6 . Cover 222 has a stiffener 238 in the form of a panel attached to the inside of the cover by adhesives, stapling, riveting, etc. Stiffener 238 may also be secured by placement in pockets formed in the cover 222 .
Stiffener 238 will have some flexibility, but will be able to stretch cover 222 to reach the shoulder straps (shoulder straps 18 and 20 of FIG. 1 ). Stiffener 238 may have a rectangular outline, but other outlines are anticipated as well. In some cases, the upper corners of stiffener 238 may be notched to provide clearance for the shoulder straps. The right and left end of stiffener 238 may be shaped to actually engage the shoulder straps and push them outwardly to conceal the straps below an outer garment. (See FIG. 5 , showing concealment of shoulder straps). Stiffener 238 may be a sheet of plastic, metal, cardboard, composite materials, etc. In some embodiments the stiffener may be made as a row of flexible rods that are held together by glue, welds, a sheath, etc.
Cover 222 may be installed over back strap 16 in the manner described above, with stiffener 238 positioned to push the shoulder straps outwardly.
In some cases the bra will not have a clasp at the back strap, but will instead be clasped in the front. The embodiment of FIG. 9 will accommodate such a bra. In FIG. 9 cover 322 is shown as a tube with a longitudinal split 340 . Specifically, the longitudinal edges of split 340 overlap and are held together with snap elements 342 A and 342 B. Snap elements 342 A and 342 B may be a series of snaps equidistantly spaced along longitudinal split 340 . In this embodiment snap elements 342 A and 342 B are located on the inward side (skin side) of cover 322 , and decorative elements 322 A are attached on the outside. In some embodiments snap element 342 A may have a decorative head and will be positioned to the outside.
Cover 322 may be installed by wrapping it around back strap 16 and then closing snap elements 342 A and 342 B. This installation may take place before the bra is donned and secured by closing the bra's front clasp (not shown).
Referring to FIG. 10 , cover 422 is a tubular structure with a longitudinal split 440 that may be closed with a zipper, shown as complementary elements 444 A and 444 B secured to opposite edges of the longitudinal split. Cover 422 may be installed as previously described in connection with FIG. 9 , except that split 440 is closed by closing the zipper 444 A/ 444 B in the conventional manner.
Referring to FIG. 11 , the inside of alternate cover 522 is shown as a rectangular panel formed of any of the materials previously mentioned. The long upper edge and long lower edge of cover 522 is referred to as a first and a second longitudinal edge, respectively. The four corners of cover 522 are shown sharp, but may be rounded in some embodiments.
In a manner to be described presently, cover 522 may be rolled and closed using female snaps 542 A and male snaps 542 B to form a tube with a longitudinal split (similar to cover 322 of FIG. 9 ) FIG. 11 shows the sockets of snaps 542 A and the base of snaps 542 B, that is, the reverse side of snaps 542 B have the lugs that will connect to the sockets of snaps 542 A. Snaps 542 A and 542 B are referred to herein as closure devices that are part of a closure.
Because it may not be sufficiently strong, the material of cover 522 is overlaid with reinforcing strip 547 before installing snaps 542 B. Strip 547 may be cloth, plastic, or other material adequate to reinforce snaps 542 B. The opposite edge of cover 522 has a reinforcing strip 548 that is placed in the fold of hem 522 B before installing snaps 542 A. Remaining in the fold of hem 522 B, reinforcing strip 548 extends to a position near the corners of cover 522 to reinforce female corner snaps 546 A (a closure implement whose socket side is visible in this view).
The purpose of the foregoing snaps is to form a tubular cover having at each end, a pair of passageways (such passageways are shown in FIG. 3 with snap 26 A dividing opening 24 into two passageways for straps 16 and 18 ). In principle, the division into a pair of passageways could be performed with four snaps: two snaps at an end of cover 522 to form the tube, and two more to divide the tube opening into two passageways. That much snap hardware would tend to crowd the end of cover 522 , reducing the stretchability of the cover and leaving little room for the passage of a bra's backstrap and shoulder strap.
Instead, this embodiment gives previously mentioned snap 546 A two separate connection points, namely, snap fastener 546 B and aperture 550 . Specifically, two apertures 550 are formed in the corners opposite snaps 546 A and are reinforced with peripheral stitches 550 A, similar to a buttonhole. Male snaps 546 B (lug side shown in this view) are spaced from snaps 546 A about one quarter of the way toward apertures 550 . The snaps 546 B are installed on reinforcing strips 549 , which lie on cover 522 .
As will be described presently, cover 522 can be folded to embrace a backstrap (e.g. the portion of backstrap 16 of FIG. 3 between shoulder straps 18 and 20 ). Referring specifically to FIG. 12 , cover 522 is initially folded lengthwise so that at each end, snap 546 B is aligned with aperture 550 .
Comparing the progression from FIG. 12 to FIG. 13 , cover 522 has been folded a second time, halfway between snaps 542 A and 542 B before fastening those snaps together to form a tubular structure for capturing the bra's backstrap 16 .
The opening 524 at the end of cover 522 ( FIG. 13 ) is stretched to accommodate backstrap 16 and shoulder strap 20 . Specifically, the portion of cover 522 below elements 546 B and 550 is stretched to accommodate backstrap 16 . Likewise, the portion of cover 522 above elements 546 B and 550 is stretched to accommodate shoulder strap 20 . With cover 522 stretched in this manner and straps 16 and 20 positioned as shown in FIG. 13 , snap 546 A may be folded down to connect to the lug of snap 546 B protruding through aperture 550 .
The foregoing stretching produces tension that tends to outwardly bow and conceal shoulder strap 20 in the manner previously described (see for example FIG. 3 ).
FIG. 13 shows installation around right shoulder strap 20 , and a complementary installation will be performed on the left shoulder strap (similar to that shown in FIG. 3 ). FIG. 13 shows the inward facing side of cover 522 , although in some embodiments this side can face outwardly. As before, the outwardly facing side of cover 522 can be adorned with decorative elements (not shown).
Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. | A cover can be installed on an undergarment having a back strap and a pair of shoulder straps. The cover has a casing for covering the back strap. The casing is adapted to extend from one of the pair of shoulder straps to the other. An outer garment can be worn over the undergarment that is fitted with the cover. | 0 |
[0001] This application is a Divisional of U.S. patent application Ser. No. 10/706,948, filed Nov. 14, 2003, the contents of which are hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of semiconductor devices and manufacture, and more particularly, to multi-channel devices.
BACKGROUND OF THE INVENTION
[0003] A conventional MOSFET operates by driving current through the channel region between the source and drain of a device. The conductivity of the channel region is modulated by the application of a voltage on the conducting gate above the channel surface and insulated from it. Efforts are ongoing within many MOS integrated circuit manufacturing companies as well as at many universities and government laboratories to improve the speed and available drive currents with MOSFETs to reduce their power consumption, and to improve their reliability and radiation hardness for applications in harsher remote environments, including space.
[0004] One of the goals in semiconductor processing is to maximize the use of the available silicon area. This allows increased miniaturization of the electronic circuitry. In particular, it is desirable to maximize the drive current for a given silicon area. This has included devices in which multiple gates are provided. For example, dual gate devices in which the drive current is doubled for a given silicon area have been created. Further improvements in maximizing the drive current for a given silicon area are desirable.
SUMMARY OF THE INVENTION
[0005] There is a need for providing a MOSFET in which the transistor drive is increased, while reducing gate leakage current and gate capacitance. Due to the requirements for miniaturization, such as the push towards sub-45 nm ULSI (ultra large scale integration). This increase in current drive should be obtained without an increase in device size or change in layout design.
[0006] These and other needs are met by embodiments of the present invention that provide a multiple-channel semiconductor device comprising a first insulator layer on a substrate and a first channel region on the first insulator layer. A second insulator layer is provided on the first channel region. A second channel region is on the second insulator layer, and a third insulator layer is on the second channel region. A gate electrode is provided on the third insulator layer.
[0007] The present invention thus provides a device that has a gate electrode and multiple channel regions which allow for increased drive current without an increase in device size.
[0008] The earlier stated needs are also met by embodiments of the present invention which provide a method of forming a multiple-channel semiconductor device comprising the steps of forming a stack on a substrate, this stack including at least two lightly doped channel regions vertically separated from each other and from the substrate by insulator layers. A gate electrode of the stack is separated from the channel regions by a insulator layer. An oxide layer is formed on the sidewalls of the gate electrode and source and drain regions are formed that contact sidewalls of the channel regions. Gate electrode spacers are formed on the oxide liner on the gate electrode.
[0009] The methods of the invention allow for formation of a multiple-channel device that does not occupy a greater amount of real estate than previous devices, but yet provides more drive current than conventional devices. The method may find particular utility in sub-45 nm applications, for example.
[0010] The foregoing and other 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
[0011] FIG. 1 depicts a stack formed in accordance with embodiments of the present invention after an etching of layers has been performed to create the stack.
[0012] FIG. 2 depicts the structure of FIG. 1 following a thermal oxidation process and a source and drain extension implant, in accordance with embodiments of the present invention.
[0013] FIG. 3 depicts the structure of FIG. 2 following a lightly doped silicon deposition and a heavily doped silicon deposition, in accordance with embodiments of the present invention.
[0014] FIG. 4 shows the structure of FIG. 3 after a silicon spacer etch has been performed, in accordance with embodiments of the present invention.
[0015] FIG. 5 depicts the structure of FIG. 4 following the formation of an oxide or nitride spacer on the gate electrode and silicon spacers.
[0016] FIG. 6 shows the structure of FIG. 5 after a source and drain implantation and the formation of a silicide region in the gate electrode, in accordance with embodiments of the present invention.
[0017] FIG. 7 shows an alternative embodiment of the present invention that follows FIG. 2 in a process flow, and in which raised source and drain structures are formed in accordance with embodiments of the present invention.
[0018] FIG. 8 depicts the structure of FIG. 7 after formation of an oxide or nitride spacer and silicide region in the gate electrode, in accordance with embodiments of the present invention.
[0019] FIG. 9 depicts layers in an alternate embodiment of the present invention prior to etching of the layers.
[0020] FIG. 10 shows the structure of FIG. 9 after the gate electrode and the hard mask have been etched, in accordance with embodiments of the present invention.
[0021] FIG. 11 shows the structure of FIG. 10 after the formation of a thermal oxide liner on the gate electrode and the deposition of gate electrode spacer material over the gate electrode and the hard mask.
[0022] FIG. 12 depicts the structure of FIG. 11 following a spacer etching to form gate electrode spacers in accordance with embodiments of the present invention.
[0023] FIG. 13 shows the structure of FIG. 12 after a dry etch has been performed to create the stack, in accordance with embodiments of the present invention.
[0024] FIG. 14 shows the structure of FIG. 13 following an extension implantation process, with a wet etch that recesses the stack and a silicon deposition over the stack, in accordance with embodiments of the present invention.
[0025] FIG. 15 shows the structure of FIG. 14 following matching of the silicon layers to form silicon spacers and the formation of a silicide region on the gate electrode, in accordance with embodiments of the present invention.
[0026] FIG. 16 depicts the structure of FIG. 15 following the deposition of nitride or oxide, the etching of the deposited nitride or oxide to form spacers, and source and drain implantation, in accordance with embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0027] The present invention addresses and solves problems related to maximizing the drive current for a given silicon area in the formation of MOSFETs and other semiconductor devices. This is achieved, in part, by the creation of a multiple-channel device having multiple channel regions formed on a substrate, with insulator layers separating the channel regions vertically and from the substrate. The gate electrode is provided on the uppermost channel region, with an insulator layer interposed between the gate electrode and the uppermost channel region. Source and drain regions are formed vertically to contact the multiple channel regions. Verticality of the semiconductor device thus formed provides increased drive current through the multiple channels without increasing the silicon area required for the semiconductor device.
[0028] FIGS. 1-6 describe a method of making a multiple-channel device in accordance with embodiments of the present invention. The description will discuss certain materials and process steps in an exemplary manner, but it should be recognized that these materials and process steps are exemplary only as other materials and process steps may be employed without departing from the scope of the present invention.
[0029] FIG. 1 depicts a stack 10 that has been created on a substrate 12 by a dry etching of layers that have been previously formed. The stack 10 of FIG. 1 includes a first oxide layer 14 a, a lightly doped polysilicon (hereafter silicon) layer 15 , another oxide layer 14 b, a second lightly doped silicon layer 15 , and a third oxide layer 14 c. The third oxide layer 14 c forms a gate oxide layer in FIG. 1 . The stack 10 includes a heavily doped polysilicon channel 16 and a hard mask 18 , on the silicon nitride, for example, or other hard mask material.
[0030] In preferred embodiments of the invention, the silicon in each layer 15 is doped prior to the formation of the next layer. The silicon layers 15 are doped with a first conductivity type, such as p conductivity type, and gate electrode 16 is doped with a second conductivity type, such as n conductivity type. Alternatively, the gate electrode 16 is doped with p type dopants while the silicon in channel regions 15 are doped with n type dopants. Furthermore, the silicon regions 15 and 16 may comprise other semiconductor materials, such as silicon germanium (SiGe).
[0031] Following the formation of the stack 10 , a thermal oxidation process is performed, the results of which are depicted in FIG. 2 . For example, the stack may be exposed to temperatures of between about 900° to 1000° for approximately less than 10 minutes in an environment suitable for oxidation, as is well known. Strict control of the thermal oxidation process is necessary, especially in applications such as sub-45 nm ULSI devices, to prevent the gate electrode 16 from becoming over oxidized. This may readily occur since heavily doped silicon, such as that in the gate electrode 16 , allows oxide to grow much faster than in lightly doped silicon, such as in the channel regions 15 .
[0032] FIG. 2 also shows the formation of source and drain extensions by source and drain extension implants 21 . This may be performed in a conventional manner.
[0033] FIG. 3 shows the structure of FIG. 2 following the sequential deposition of a lightly doped silicon layer 22 and a heavily doped silicon layer 24 . The layers 22 and 24 are doped with the same conductivity type dopant as in the gate electrode 16 . Hence, in the exemplary embodiment being described, the dopant is an n-type dopant. Deposition of the silicon layers 22 and 24 may be performed by chemical vapor deposition (CVD) for example. It is preferred to deposit doped silicon layers rather than attempting to dope by ion implantation the silicon layers after they have been deposited, since control of the implantation process to form a lightly doped region and heavier doped regions is difficult to control in this arrangement. However, it is also possible to perform implanting to achieve the desired doping, and certain embodiments of the invention perform such implanting.
[0034] A silicon etch is then performed to form silicon spacers 26 that include the lightly doped regions 22 and the heavily doped regions 24 . The silicon spacers 26 contact the first and second channel regions 15 but are electrically isolated from the gate electrode 16 by the thermal oxide 20 .
[0035] FIG. 5 shows the structure of FIG. 4 following the deposition of an insulating spacer material and a dry etch procedure that forms spacers 28 over the silicon spacers 26 . The insulating material may be an oxide or nitride or other suitable material, for example.
[0036] FIG. 6 depicts the structure of FIG. 5 after the hard mask 18 has been removed by etching, for example. A portion of the gate electrode 16 is silicided to form a silicide region 30 by conventional silicide techniques, including the deposition of a refractory metal layer and annealing to silicidize a portion of the gate electrode 16 .
[0037] A source and drain implant process is performed in a conventional manner to create source and drain regions 32 in a substrate 12 . The spacers 26 , 28 serve as a mask during the source and drain implant process.
[0038] The arrows in FIG. 6 represent an exemplary electron flow through the multiple channels created in the device of the present invention. Hence, while not increasing the width of the semiconductor device, the multiple channels (three such channels in FIG. 6 embodiment) provide increased electron flow and drive current. Further, gate leakage current and gate capacitance are reduced.
[0039] In certain embodiments of the invention, the gate electrode 16 may be formed of a metal or completely silicidized. The metal gate may be a replacement metal gate, or may be formed initially. Furthermore, one or more of the insulator layers 14 a - 14 c may consist of a high k gate dielectric material, rather than a relatively lower k oxide or other material.
[0040] FIGS. 7 and 8 show structures constructed in accordance with another embodiment of the present invention. Following the thermal oxidation and source and drain extension implant steps of FIG. 2 , FIG. 7 provides for a raised source and drain formation process. This is performed, for example, by growing silicon on the substrate 12 in a known manner, and then etching the silicon to form the raised source and drains 40 .
[0041] In FIG. 8 , an insulating spacer 42 has been formed over the raised source and drains 40 . Spacers 42 are formed from an oxide or nitride, for example. A silicide region 48 is formed on the gate electrode 16 , in a manner as described earlier.
[0042] FIGS. 9-16 depict still another embodiment of the present invention that may be considered especially preferred since it avoids the risks of thermal oxidation that are especially present in very small devices.
[0043] FIG. 9 shows a number of layers on a substrate 50 . The layers include insulator layers 52 , made of an oxide, for example. Other materials may be used, such as high K gate dielectrics, for example. Lightly doped semiconductor channel regions 54 are provided between the insulator layers 52 . A gate electrode layer 56 is provided on the uppermost insulator layer 52 . A hard mask layer 58 is provided on the gate electrode layer 56 . As in earlier described embodiments, the gate electrode layer 56 may be formed from a heavily doped silicon or silicon germanium layer, and the channel layers 54 may be formed of a lightly doped silicon or silicon germanium material. The conductivity types of the dopants in the gate electrode layer 56 and the channel layers 54 are of opposite types. In the described exemplary embodiment, for purposes of explanation and illustration, the gate electrode layer 56 is considered to have been heavily doped with n type dopants, while the channel layers 54 will be considered to have been lightly doped with p-type dopants.
[0044] Following the formation of the layers in FIG. 9 , a dry etching is performed to shape the gate, the results of which are depicted in FIG. 10 . The gate electrode 56 a is thus created, with the dry etching stopping on the gate insulator layer 52 , which forms the uppermost insulator layer in the stack. The hard mask 58 a is also etched at this time. A conventional dry etching technique may be employed.
[0045] FIG. 11 shows the structure of FIG. 10 after a thermal oxide liner 60 has been formed on the gate electrode 56 a to serve as protection for the gate electrode 56 a. Subsequent to the formation of the thermal oxide liner 60 , a second insulator layer, such as nitride, is deposited by CVD, for example.
[0046] A spacer dry etch step is then performed, the results of which are depicted in FIG. 12 . The spacer dry etch stops on the top insulator layer 52 . The dry etch creates gate electrode spacers 64 on the thermal oxide liner 60 . A conventional dry etch process may be employed in this step.
[0047] A second etching procedure is then performed, using a dry etch, to create a stack 66 . The etching employs the gate electrode spacers 64 as a mask, while insulator layers 52 and channel layers 54 are etched. The dry etch is stopped on the bottom insulator layer 52 for control purposes to prevent damage to the silicon substrate 50 .
[0048] FIG. 14 shows the structure of FIG. 13 following an extension implant of the same type dopants as provided in the gate electrode 56 a. The implants create extensions 68 in a substrate 50 . Following the extension implant, a wet etch process is performed that recesses the stack underneath the gate electrode spacer 64 . It also serves to remove a portion of the bottom insulator layer 52 . However, a second wet etch may be performed to remove more of the bottom insulator layer 52 if necessary to cause it to form the structure depicted in FIG. 14 . The recessing of the stack 66 , including channel regions 54 a and insulator regions 52 a, allows the diffusion of the extension implants to reach the channel under the gate electrode 56 a.
[0049] Following the recessing of the stack 66 , a multi-step polysilicon deposition process is performed to subsequently deposit a lightly doped polysilicon layer 70 over the stack 66 , followed by a heavily doped polysilicon layer 72 over the lightly doped polysilicon layer. The dopant conductivity type is the same as in gate electrode 56 a and in the extension implants 68 . In this example, the dopant conductivity type is n-type dopant. The deposition of the polysilicon layer 70 , 72 may be by chemical vapor deposition (CVD) or other appropriate methodologies.
[0050] FIG. 15 shows the structure of FIG. 14 following a dry etch of the silicon layer 70 , 72 to form silicon spacers 76 , having a lightly doped region and a heavily doped region. At this time, silicide can then be formed on the silicon spacers 76 and in the gate electrode 56 a, once the hard mask 58 a has been removed by appropriate etching techniques.
[0051] FIG. 16 depicts the structure of FIG. 15 following the formation of an insulator spacer 80 , made of nitride or oxide or other suitable material, for example. A source and drain implant is then performed to create source and drain regions 82 in the substrate 50 .
[0052] Three separate channel regions 54 b are depicted in the structure of FIG. 16 , providing for a total of four channels (including the channel formed in the substrate 50 ). Hence, it should be clear to those of ordinary skill in the art that the number of channel regions may be varied in different embodiments.
[0053] The present invention thus provides for a semiconductor device and method for making the same that has a greater drive current than previous devices, but without occupying a greater amount of silicon area than conventional devices.
[0054] Although the present invention has been described and illustrated in detail, it is to be clearly understood that the same is by way of illustration and example only and is not to be taken by way of limitation, the scope of the present invention being limited only by the terms of the appended claim. | A multiple-channel semiconductor device has fully or partially depleted quantum wells and is especially useful in ultra large scale integration devices, such as CMOSFETs. Multiple channel regions are provided on a substrate with a gate electrode formed on the uppermost channel region, separated by a gate oxide, for example. The vertical stacking of multiple channels and the gate electrode permit increased drive current in a semiconductor device without increasing the silicon area occupied by the device. | 7 |
DESCRIPTION
1. Technical Field
This invention relates to a guarding assembly and more particularly to a guarding mechanism to will remove material from the surface of a wheel to prevent the build-up of material around a wheel and axle assembly.
2. Background Art
In the operation of construction machinery, especially the type known as a landfill compactor, it is quite common for the machine to traverse terrain that is filled with debris. In the case of a landfill compactor, the machine is driven over trash of all kinds to compact or compress it so that maximum use may be made of the available space on the landfill site.
In many landfill sites, there is an abundance of cable, wire, strands of scrap from manufacturing operations and strands of many other types of material. When operating over this type of material, it is quite common for the teeth of the drum portion-type wheels to become attached to these strands of material as they roll over it. In doing so, the strands of material are caused to revolve with the wheel and many times fall from the upper portion of the wheel, down on the axle. As the movement of the machine continues, the strands can become wrapped around the axle. In some instances, the material will become tightly wrapped around the axle and the wound material will tend to work its way along the axle in the direction of the wheel. This is an area wherein the final drive of the wheel assembly interfaces with the axle. Since the wheel assembly rotates along this interface and the axle does not, a rotational seal is required at this interface to keep dirt out and lubricating fluid within the axle assembly. It is a common and vexatious problem when this material becomes wound around the axle in the area of the seal interface because the strands, by the force of the winding, are forced into the sealed interface. When this happens the integrity of the seal is destroyed creating the need for immediate repair. This not only takes the machine out of production, it is also known to have a deleterious effect on the components of the drive assembly.
The present invention is directed to overcoming one or more of the problems set forth above.
DISCLOSURE OF THE INVENTION
In one aspect of the present invention a guard assembly is provided that includes a frame and an axle assembly that is mounted to the frame. A wheel is provided that has a drum portion that defines an outer surface. The wheel is mounted on the axle assembly for rotation with respect thereto with the inner side of the drum portion positioned adjacent the frame. A guard member, having at least one mounting bracket, is mounted to either the frame or the axle assembly in a manner to position the arm at a location that is radially outwardly adjacent the inner side of the outer surface of the drum portion. A scraping means, having an engagement end portion, is mounted to the mounting bracket defined by the guard member in a manner wherein the engagement end is positioned in overlapping, parallel relation to the outer surface of the drum portion on the inner side thereof.
In another aspect of the present invention, a guard assembly is provided for a machine that has a frame and a pair of first and second axle assemblies mounted to the frame at spaced locations from one another along a centerline of the machine. Each axle assembly has an end portion that extends laterally from opposing sides of said frame. A wheel, having an outer cylindrical surface defined thereon, is mounted to each end portion of the axle assemblies. A first pair of guard members is provided, each having a base portion and a pair of scraping means. The first guard members are mounted to opposite sides of the frame in inwardly adjacent relation to the respective wheels. The respective base portions are positioned in surrounding relation to the respective end portions of the first axle assembly with the scraping means positioned in overlapping, parallel relation to the cylindrical outer surfaces of the respective wheels. A pair of second guard members, also having a pair of scraping means, is mounted to opposite end portions of the second axle assembly between the respective sides of the frame and the respective wheels. The scraping means is positioned in overlapping, parallel relation to the cylindrical outer surfaces of the respective wheels.
With a guard assembly as set forth above, a scraping means is provided between the frame and each of the wheels of a machine and provides a mounting for one or more scraping members. The scraping members are mounted radially outwardly from the surface of the wheel and overlaps the inner portion of the wheel. Being so positioned, the scraping means will remove material from the inner portion of the wheel before it has an opportunity to be carried around the wheel. Further, since the scraping means is positioned on the inner portion of the wheel, the chance for material to revolve with the wheel, fall off on the inner side of the wheel and become wrapped around the axle assembly is greatly reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic side view of a portion of a machine with a guard assembly that embodies the principles of the present invention;
FIG. 2 is a diagrammatic, partially sectioned view of the frame of the machine shown in FIG. 1;
FIG. 3 is a diagrammatic top view taken along lines 3--3 of FIG. 2;
FIG. 4 is a diagrammatic side view, similar to FIG. 2, showing a an alternate embodiment of guard assembly;
FIG. 5 is a diagrammatic, enlarged side view taken along lines 5--5 of FIG. 4; and
FIG. 6 is a diagrammatic, enlarged side view, similar to that of FIG. 5 showing an axle and wheel assembly oscillated with respect to the machine.
BEST MODE FOR CARRYING OUT THE INVENTION
Referring to the drawings, a guard assembly 10 for a machine is shown. The machine includes a frame 12 and a pair of axle assemblies 14 (FIGS. 1-3) and 16 (FIGS. 4-6). The axle assemblies are mounted to the frame 12 in spaced relation to one another along a longitudinal centerline (not shown) that is defined by the machine.
Referring to FIGS. 1-3, it can be seen that axle assembly 14 is mounted to the frame 12 and defines a pair of end portions 18 (one shown) that extend laterally outwardly from the frame. In the embodiment illustrated in FIGS. 1-3, the axle assembly 14 is fixedly mounted to the frame. A wheel 20 is mounted to the end portion 18 of the axle assembly and rotates with respect to the axle assembly and the frame in a well known manner. The wheel has an inner hub portion 22 and an outer drum portion 24 that are concentrically arranged about an axis X defined by the axle assembly 14. An inner and outer side wall extend between the hub and drum portions. In the illustrated embodiment, the drum portion 24 is substantially wider than the hub portion 22 and the side walls are tapered outwardly from the hub portion to a location that is closely adjacent the frame 12. It is to be understood that the hub portion and the drum portion could be the same width and thereby connected by side walls that are substantially straight up and down. The tapered inner side wall 26 is illustrated in FIG. 3. The drum portion 24 defines an outer cylindrical surface 30 that extends across the face of the drum. A plurality of teeth 32 are circumferentially positioned about the surface 30 in rows that are axially spaced between inner and outer sides defined by the outer cylindrical surface. As is best shown in FIG. 3, an innermost row of teeth 38 are spaced from the inner side 34 a preselected distance to provide a space about the drum between the inner side 34 and the first row of teeth.
A first guard member 40 is mounted to the frame 12 on each of an opposing side thereof in an area that is laterally adjacent the wheel 20, between the wheel and the frame. While only one guard assembly is shown in the drawings it is to be understood that the other side of the machine and like components secured to the frame, are a mirror image of those shown and described herein. The guard member 40, which is best shown in FIGS. 2 and 3, is comprised of a generally planar base portion 42 that fits substantially flat against the frame. An outer flange 44, that is generally arcuate in configuration, defines an upper extremity of the base portion 42. The outer flange 44 is positioned radially from the axis X of the axle assembly 14 a distance that positions it inwardly adjacent the drum portion 24 of the wheel. The outer flange has a radius that is substantially the same as that of the drum and is generally centered about the axis X of the axle assembly 14. The outer flange terminates with a pair of end portions 46 and 48. An inner flange 50 is defined on the lower region of the base portion 42 and extends laterally from the frame in a direction toward the hub portion 22 and terminates in closely adjacent proximity to the hub portion. The inner flange 50 is shaped to substantially surround the upper portion of the axle assembly 14 and defines opposing end portions 52 and 54 that are angled toward the frame to connect with the end portions 46 and 48 defined by the outer flange 44. The angled end portions 52 and 54 of the inner flange have an angle that substantially matches that of the taper defined by the inner side wall 26 of the wheel, as illustrated in FIG. 3. A plurality of plates 56 are also secured to each of the inner and outer flanges and extend therebetween at an angle that also is substantially equal to that of the tapered inner side wall 26 to position the plates in closely adjacent parallel relation to the inner side wall.
An arm 58 is mounted to extend from the outer flange 44 and has a pair of opposing end portions that terminate in a pair of mounting brackets 60 and 62. The mounting brackets extend radially outwardly beyond the drum portion 24 of the wheel 20 and define a backing plate 64 (FIG. 3). The backing plate extends laterally in overlapping relation to the outer cylindrical surface 30 but is spaced radially therefrom a preselected distance.
A scraping means 66 in the form of a plate member 68 is adapted for mounting to each of the backing plates 64. The scraping plate 68 has an angled engagement end portion 70 that defines an engagement surface 72 (FIG. 2) that extends from a substantially centrally disposed mounting portion 74. The mounting portion further defines a substantially centrally disposed, elongated slot 76 (FIG. 3). The slot 76 receives a plurality of fastening members 78 such as threaded fasteners that adjustably mount the scraping plate to the backing plate. Being so mounted the engagement surface 72 is positioned in laterally overlapping relation to the outer cylindrical surface 30. In addition, the elongated slot allows the scraping plate to be moved in a radial direction, toward and away from the outer cylindrical surface of the drum portion 24. This permits the distance between the engagement surface and the drum to be adjusted for proper spacing and/or to accommodate for any wear of the scraping plate that may occur as a result of normal operation.
Referring now to FIGS. 4-6, a second embodiment of the guard assembly 10 is shown. In this configuration, the wheel 20' is mounted to an axle assembly 16 for rotational movement with respect to the axle assembly. The axle assembly, in turn, is pivotally mounted along the longitudinal centerline of the machine. Being so mounted, the axle assembly is allowed to oscillate, with respect to the frame 12. It is a well known practice in some construction machines, such as landfill compactors, that an axle assembly 14 as previously described is mounted on a front portion of the machine, while an oscillating axle assembly 16 is mounted on the rear portion of the machine.
Referring primarily to FIG. 4, it can be seen that a second guard member 82 is mounted to the axle assembly 16 for pivoting movement therewith. The second guard member includes an arm 84 that has generally centrally located mounting portion 86. A pair of end portions 88 and 90 respectively, extend from the mounting portion 86 on opposite sides thereof. A pair of mounting brackets 92 and 94 are mounted to the opposing end portions of the arm, 88 and 90 respectively. The mounting portion 86 is adapted to engage a lower surface 96 defined by the axle assembly 16 and is secured thereto in a well known manner, such as by threaded fasteners or by welding. The mounting of the arm to the axle assembly in this manner positions the mounting brackets 92 and 94 laterally between the frame 12 and the drum portion 24. In addition, the mounting brackets extend radially outwardly from the drum portion.
A scraping means 66', in the form of a pair of scraping plates 68', is mounted to the respective mounting brackets 92 and 94. The scraping plates each have an angled end portion 70' and an elongated slot 76' defined in a central mounting portion 74' thereof. A plurality of threaded fasteners 78' is positioned in the slot 76' and engage the respective mounting brackets to secure the scraping plates to the mounting brackets. The scraping plates 68' are adjustably mounted to permit movement toward and away from the outer cylindrical surface 30' for reasons previously set forth.
As is shown best in FIGS. 5 and 6, the scraping plate 68' is positioned in overlapping relation to the outer cylindrical surface 30' of the drum portion 24'. The scraping plate extends past the inner side 34' of the wheel a distance that will substantially span the distance between the inner side 34' and the innermost row of teeth 38'. Since the second guard member 82 is mounted to the axle assembly 16, the scraping plates 68' are mounted such that they will move with the wheel 20' as it oscillates with respect to the frame. This condition is illustrated in FIG. 6. This places the scraping plates in operating condition at all times during the rotation of the wheel and during axle oscillation.
INDUSTRIAL APPLICABILITY
During the operation of a machine, such as a landfill compactor, it is a common occurrence for stands of material and/or debris to become attached to the teeth 32 of each wheel 20,20' as the machine traverses the landfill site compacting the material. As this occurs, any material that is picked up by the innermost row of teeth 38,38', that is closest to the inner side 34,34' of the outer cylindrical surface 30,30' defined by the wheels, will be removed by the scraping plates 68,68', since they are mounted in overlapping relation to the outer cylindrical surfaces defined by each wheel. The scraping plates defined by either the first or second guard members 40 and 82, are positioned on opposing sides of the wheels and therefore remove material before it has a chance to become entrained about the wheel. This greatly reduces the occurrence of material becoming wound around the respective axle assemblies. With the reduction of material wrapped around the axle, the opportunity for damage to any seal interface positioned along the axle assembly, is also greatly reduced. This not only reduces downtime required to remove the material wrapped around the axle, it also reduces instances of machine failure. This ultimately reduces the maintenance costs associated with machine operation and increases machine reliability and productivity.
Other aspects, objects and advantages of this invention can be obtained from a study of the drawings, the disclosure and the appended claims. | In the operation of machines of the type that are typically designed to traverse terrain having deposits of debris, it is a common problem to have the debris become attached to the wheels of the machine and rotate therewith. In many instances this causes material to become entrained around the axles of the machine requiring continual maintenance and occasionally causing damage to the axle components. In the present invention a guard assembly is provided that defines a scraping member that is positioned in radially inner and laterally overlapping relation to an outer cylindrical surface defined by each wheel. The scraping member function to remove material that may become attached to the wheels during their movement over the terrain. Functioning as such, material is prevented from becoming entrained about the respective axle assemblies of the machine. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is based on and claims the priority of provisional application No. 60/139,708, filed on Jun. 17, 1999 and entitled Well Packer and Method.
FIELD OF THE INVENTION
The present invention relates to the field of downhole tools. More specifically, the invention relates to a device and method for directing bypass lines through a packer and for releasing a packer using flow through at least one of the bypass lines.
BACKGROUND OF THE INVENTION
Completion systems require or may require control lines and telemetering lines that may be either electric, hydraulic, or fiber optic. Using the control lines, various tools may be set or unset, gauges and other equipment may be powered, monitored, and controlled, and other actions may be performed using the control lines.
Well completions typically include a casing extending from a surface wellhead to the producing formation, a production tubing located within the casing, and one or more other completion devices. One such completion device is commonly called a packer and is used to block, pack off, and seal the annulus formed between the casing and the production tubing. Placement of one or more packers in this way directs the production fluid into the production tubing. Packers are also used for other purposes, such as during cementing, gravel packing, and during other procedures.
However, the packer presents an obstacle to the control and telemetering lines and the like (commonly referred to herein as “control lines”), because the control lines are typically run between the tubing and the casing. Accordingly, there is a need for a bypass through the packer to allow communication of the control lines through the packer.
Often, there is a need for a packer that may be set and, at some later time, released. In some cases, it may be necessary to place multiple, spaced packers in a well in which the packers are all set and subsequently released. Typically, the release of such packers is accomplished by pulling the tubing for release or using other mechanical release devices. However, such release devices may inadvertently release by inadvertent pulls on the tubing. Further, there is also a need for packers that may be set and released a plurality of times.
There remains a need for a packer that may be set and unset using, for example, hydraulic means and that provides communication and protection for control lines through the packer.
SUMMARY OF THE INVENTION
The present invention features a hydraulically releasable well packer that has a plurality of bypass passages to allow control lines to pass therethrough. The present invention also provides a release mechanism that is actuated by hydraulic fluid to effect the release of the packer slips and elements. According to another exemplary embodiment, the present invention features a release mechanism that can be reset to allow the repositioning and resetting of the packer in the well with the possibility of subsequent release of the packer.
BRIEF DESCRIPTION OF THE DRAWINGS
The manner in which these objectives and other desirable characteristics can be obtained is explained in the following description and attached drawings in which:
FIGS. 1A-D are cross sectional, side elevational views of the present invention;
FIG. 2 is a cross sectional view of the present invention taken along lines A—A in FIG. 1A;
FIG. 3 is a cross sectional view of the present invention taken along lines B—B in FIG. 1B;
FIG. 4 is a cross sectional view of the present invention taken along lines C—C in FIG. 1B;
FIG. 5 is a cross sectional, side elevational view of the release mechanism in the open position;
FIG. 6 is a cross sectional, side elevational view of the release mechanism in the closed, released position;
FIG. 7 is a cross sectional, side elevational view of an alternative embodiment for the release mechanism in the closed, released position; and
FIG. 8 is a cross sectional, side elevational view of an alternative embodiment for the release mechanism in the open position.
It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention generally provides a releasable well packer 10 having at least one bypass line 12 through the mandrel. The packer 10 preferably includes a release mechanism 14 (see FIGS. 5-8) actuated by applied fluid flow and pressure through a control line 18 extending from the surface and communicating with the packer 10 . In an alternative embodiment, the packer 10 is adapted for multiple setting and multiple releasing of the slips 40 and elements 34 .
FIGS. 1A-D illustrate a first embodiment of the well packer 10 illustrated in four sections extending from the section illustrated in FIG. 1A to the section illustrated in FIG. 1 D. The body 20 of the packer 10 is generally formed of an upper mandrel 22 that is releasably, slideably interconnected to a releasing sleeve 24 and a lower mandrel 26 . The body 20 defines a passageway 28 therethrough that is adapted for coaxial alignment with and fluid communication with a tubing string and includes standard connections for attachment to the tubing string to provide fluid communication therethrough. The upper mandrel 22 is formed of a first upper mandrel component 30 and a second upper mandrel component 32 . The first and second upper mandrel components 30 , 32 are fixedly attached to one another and are hereinafter referred to collectively as the upper mandrel 22 .
Similarly, the lower mandrel 26 is formed of four generally interconnected and associated components that do not move relative to one another. For clarity and ease of description these components are collectively referred to herein as the lower mandrel 26 . Likewise, the upper mandrel 22 , lower mandrel 26 , and releasing sleeve 24 are collectively referred to herein as the body or mandrel 20 . In general, the upper mandrel 22 , lower mandrel 26 , and releasing sleeve 24 are releasably attached to one another and do not move relative to one another until the desired release of slips 40 and element 34 of the packer 10 .
At least one sealing element 34 is disposed about the upper mandrel 22 . The upper position of the sealing elements 34 are established by a shoulder member 36 fixed to the upper mandrel 22 . The lower end of the elements 34 abut an element actuator 38 slideably mounted to the upper mandrel 22 . A plurality of slips 40 are spaced circumferentially about the upper mandrel 22 at a position below the elements 34 and are secured thereto by a slip cage 42 , or other known devices. Slip actuators 44 are slideably mounted to the upper mandrel 22 on either or both longitudinal sides of the slips 40 . Actuators 44 have a ramp surface 46 facing cooperating ramp members 48 of the slips 40 to selectively move the slips 40 radially relative to the mandrel between an inwardly retracted running position and an outwardly extended set position.
Shear pins 50 connect the lower slip actuator 44 to the upper mandrel 22 and the slip cage 42 to the upper and lower slip actuators 44 to prevent the relative movement of the slip actuators 44 and the slip cage 42 to the upper mandrel 22 , and to prevent movement of the slips 40 to the outwardly extended position until the occurrence of a predetermined event shearing the shear pins 50 . The upper slip actuator 44 is fixedly attached to the element actuator 38 . Thus, the element actuator 38 is also held in position relative to the upper mandrel 22 and the elements 34 until the setting of the element 34 is desired. Note that the elements 34 and slips 40 , their positioning, and their general actuation as described are matters of preference and should not be limiting, as other variations are known, e.g., to position the slips 40 in a different orientation relative to the elements 34 .
A setting piston 52 is slideably positioned within the mandrel has an upper end abutting the lower end of the lower slip actuator 44 . A setting port 54 provides fluid communication from the passageway 28 through the mandrel to a lower end of the piston. Seals 56 between the setting piston 52 and the mandrel facilitate actuation of the setting piston 52 in response to pressure applied through the tubing, into the passageway 28 , through the setting port 54 , and to the bottom of the setting piston 52 . A locking member 60 , preferably comprising cooperating wicker threads 62 , restricts the motion of the piston to unidirectional movement in the setting direction (which is upward in the disclosed embodiment). In the disclosed embodiment, the locking member 60 includes a set of wicker threads 62 attached to the setting piston 52 and a cooperating set of wicker threads 62 attached to the lower mandrel 26 .
Accordingly, to set the packer 10 , sufficient pressure is applied through the tubing and the setting port 54 to the bottom of the setting piston 52 to shear the shear pins 50 holding the slip actuators 44 to the mandrel and the slip cage 42 . The setting piston 52 moves upwardly in response to the pressure abutting the lower slip actuator 44 forcing it into the slips 40 . The upward force and motion is transmitted to the upper slip actuator 44 which moves upward moving the element actuator 38 upward. The movement of the slip and element actuators 38 , 44 forces the slips 40 into the extended set position and compresses the elements 34 creating a seal between the packer 10 and the well casing. The upward motion of the components is locked in by the locking member 60 .
A portion of the upper mandrel 22 extends into the lower mandrel 26 . A set of bolts 64 , or detents, attached to the upper mandrel 22 cooperate with mating slots 66 in the lower . mandrel 26 to maintain their relative rotational orientation. The upper mandrel 22 is releasably connected to the releasing sleeve 24 by a shear pin 68 . The upper mandrel 22 is generally releasably connected to the lower mandrel 26 by a set of locking dogs 70 with gripper teeth 72 that mate with gripper teeth 72 on an inner surface 74 of the lower mandrel 26 . The locking dogs 70 have an inner surface 76 abutting an outer surface 78 of the releasing sleeve 24 . Mating profiles 80 , 82 on the inner surface 76 of the dogs 70 and the outer surface 78 of the releasing sleeve 24 allow selective disengagement of the gripper teeth 72 holding the lower mandrel 2640 the locking dog and, thereby the sleeve and upper mandrel 22 . In a first, set position of the releasing sleeve 24 , wherein the shear pin 68 is intact, the profiles 80 , 82 of the locking dogs 70 and the lower mandrel 26 are misaligned to maintain the engagement of the gripper teeth 72 and the relative axial positions of the lower mandrel 26 to the releasing sleeve 24 and the upper mandrel 22 .
Conventionally, to release the packer 10 , a tool is run into the passageway 28 and locked into a profile 88 formed in the releasing sleeve 24 . The releasing sleeve 24 is then mechanically lifted shearing the shear pin 68 connecting the releasing sleeve 24 to the upper mandrel 22 . Further upward movement of the releasing sleeve 24 aligns the profiles 80 , 82 of the releasing sleeve 24 and the locking dogs 70 allowing the locking dogs 70 to move inwardly away from the lower mandrel 26 . Once released, the lower mandrel 26 along with the setting piston 52 connected thereto are free to move downward relative to the upper mandrel 22 releasing the pressure holding the slips 40 and the elements 34 in the set position. The elements 34 and slips 40 are then free to return to the released, retracted position. According to a preferred embodiment of the present invention, hydraulic release mechanism 14 is mounted to selectively force releasing sleeve 24 upward, thus avoiding inadvertent release due to lifting of releasing sleeve 24 (see FIGS. 5 - 8 ).
FIGS. 2 through 4 are cross sectional views of the packer 10 shown in FIG. 1 . In the embodiment shown, the passageway 28 through the mandrel is eccentrically positioned so that the mandrel wall is thicker to one side. One or more bypass lines 12 may then be easily provided through the packer 10 to facilitate the passage of control lines 18 therethrough (see FIG. 4 ). The eccentric design also facilitates alignment with other eccentric downhole tools in the completion string. As shown in FIG. 1, the bypass lines 12 may include a bypass line tubing 84 within the mandrel extending between the upper mandrel 22 and the lower mandrel 26 to provide a sealed passageway therethrough that allows fluid communication through the bypass line 12 , pressure transmission through the bypass line 12 , and that provides a protected passageway for control lines 18 extending therethrough. Fittings 86 at the top and bottom of the bypass lines 12 may be used to seal the bypass lines 12 . In an alternative embodiment, the passageway 28 is positioned concentrically through the mandrel.
FIG. 5 illustrates a preferred embodiment of a hydraulic release mechanism 14 mounted within the lower mandrel 26 that has a releasing piston 90 adapted to actuate the upward releasing motion of the releasing sleeve 24 in response to pressure and flow. For clarity, the figure shows a blown-up version of the release mechanism 14 with a schematic drawing of the interconnecting communication lines. In general, the release mechanism 14 provides a flow responsive valve 92 fixed in an open position by shear pins 94 and closeable by application of flow and pressure. A bleed-off line 96 communicating with the valve prevents the build-up of pressure in the release mechanism 14 when the flow responsive valve 92 is open. When the flow responsive valve 92 is closed, the pressure bleed-off line 96 is closed and pressure may build in the release mechanism 14 . The pressure actuates a releasing piston 90 by moving the piston 90 upward and forcing the releasing sleeve 24 up into the released position. The upward movement of the releasing sleeve 24 causes a release of the slips 40 and elements 34 as previously described. A detailed description of the release mechanism 14 follows.
The lower mandrel 26 defines a cylindrical release mechanism cavity 98 therein that is axially aligned with one of the bypass lines 12 through the packer 10 . A control line 18 communicates a control fluid to the release mechanism cavity 98 from a controllable source of fluid 102 , such as a pump, preferably located at the surface. Preferably, the release mechanism 14 incorporates an accumulator 104 in the control line 18 to enhance the response of the release mechanism 14 to flow conditions provided from the controllable source of fluid 102 .
The flow responsive valve 92 includes a valve cap 106 fixed within the release mechanism cavity 98 . An upper portion of a valve piston 108 is sealably positioned within the valve cap 106 and is releasably attached thereto by shear pins 94 . The control line 18 extends through the valve cap 106 and into a valve bore 110 defined through the valve piston 108 . The valve bore 110 has an enlarged upper portion 112 and a lower portion 114 having a relatively smaller diameter than the upper portion. The change in diameter between the upper portion 112 and the lower portion 114 defines a ball seat 116 . A valve ball 118 maintained within the enlarged upper portion 112 of the valve bore 110 has a lower specific gravity than the fluid in the control line 18 . Thus, the valve ball 118 floats above the ball seat 116 . Further, the diameter of the ball valve is smaller than the diameter of the upper portion 112 , but larger than the diameter of the lower portion 114 . Therefore, the position of the ball seat 116 is unaffected by pressure in the control line 18 and generally remains off seat. A flow of fluid through the control line 18 , however, will act to force the valve ball 118 downward onto the ball seat 116 .
A bleed-off line 96 communicates with the release mechanism cavity 98 at a position below the valve piston 108 . The opposite end of the bleed-off line 96 communicates with the annulus formed between the tubing and the casing with the bleed-off line 96 preferably extending through a separate bypass line 12 through the packer 10 so that the pressure vents above the packer 10 . A check valve 120 in the bleed-off line 96 allows flow from the release mechanism cavity 98 through the bleed-off line 96 only. Therefore, pressure buildup within the release mechanism 14 flows through the flow responsive valve 92 and through the bleed-off line 96 into the annulus of the well. By releasing the pressure within the release mechanism 14 , the actuation of the release mechanism 14 based upon pressure alone is prevented. Requiring flow in addition to pressure prevents unsetting of the packer 10 due to inadvertent pressure increases in the control line 18 . For example, if a surface valve in the control line 18 were inadvertently closed and the control fluid in the control line 18 expanded due to thermal increases, the pressure in the control line 18 would tend to rise. However, the bleed-off line 96 prevents such a situation from releasing the packer 10 .
When a flow of fluid is directed through the control line 18 , the valve ball 118 engages the valve seat 124 . Pressure in the control line 18 builds shearing the shear pins 94 holding the valve piston 108 in place. The pressure forces the valve piston 108 downward so that a piston seat 122 of the valve piston 108 sealably engages and seats on the valve seat located at the bottom of the release mechanism cavity 98 . An optional valve spring 126 helps to hold the valve piston 108 in the seated position in the event of loss of flow. When in the seated position, the valve piston 108 sealably closes the bleed-off line 96 allowing pressure to build in the release mechanism 14 . Specifically, the fluid flows through communication ports 128 in the control line 18 into a pressure cavity 130 defined between the flow responsive valve 92 and the releasing piston 90 in the release mechanism cavity 98 . Once the pressure reaches a sufficient level, the shear pin 68 holding the releasing sleeve 24 to the upper mandrel 22 shears allowing the releasing piston 90 and releasing sleeve 24 to move upward releasing the locking dogs 70 and, ultimately, the packer 10 as previously described. A piston spring 132 biases the releasing piston 90 to an upward, released position. FIG. 6 shows the flow responsive valve 92 closed and the releasing piston 90 and releasing sleeve 24 forced upward to a release position.
Preferably, as shown in FIG. 6, the release mechanism 14 also has a pass through line 134 that provides fluid communication through the release mechanism 14 to additional packers 10 or tools located below the packer 10 . The pass through line 134 is preferably axially aligned with the valve bore 110 . To facilitate such communication, the valve piston 108 defines auxiliary passageways 136 . A first set of auxiliary passageways 136 extend from a position above the valve ball 118 when the valve ball 118 is seated on the ball seat 116 to an exterior of the valve piston 108 . Seals 138 between the valve piston 108 and the valve cap 106 positioned below the first set of auxiliary passageways 136 prevent flow through the first set of auxiliary passageways 136 when the flow responsive valve 92 is open (i.e. before the valve piston 108 has moved down on seat). However, after the valve piston 108 moves on seat, the first set of auxiliary passageways 136 communicate fluid from the communication line to a valve annulus 140 formed between the valve piston 108 and the release mechanism cavity 98 wall. A second set of auxiliary passageways 136 defined in the valve piston 108 and providing communication from an exterior of the valve piston 108 to the valve bore 110 are positioned below the seated valve ball 118 . Therefore, fluid may flow around the seated valve ball 118 , back into the valve bore 110 , and into the pass through line 134 without allowing flow into the bleed-off line 96 .
FIGS. 7 and 8 show an alternative embodiment for the release mechanism 14 that allows resetting of the release mechanism 14 . In this embodiment, the shear pins 94 are replaced by collets 142 which are nondestructive and may be reset into position. Return springs 144 in the release mechanism 14 bias the release mechanism 14 back to a set position upon removal of pressure. This release mechanism 14 may be combined with a packer 10 having modifications in which the shear pins 50 , 68 are replaced by nondestructive type setting members, such as collets. In such an arrangement, the packer 10 may be made to be set, released, and reset a plurality of times.
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 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 word “means” together with an associated function. | A releasable packer has a control line therethrough. A hydraulic release mechanism of the packer is controlled from the surface by application of flow and pressure. A modification of the packer and release mechanism using resettable collets and return springs allows multiple sets and releases of the packer. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention in general relates to a method of and an apparatus for controlling the energization of an electrical load in circumstances where the supply of current is limited and electrical energy reserves have to stay within certain limits, and more particularly to such a method and apparatus for controlling the energizing of an electrical load the current consumption of which exceeds the current generating capability of the electrical system to which it is connected without discharging a storage battery below a predetermined level.
2. Description of the Prior Art
Automotive vehicles are equipped with a current generator or alternator for generating current and with a storage battery. While the current produced by the generating equipment is in normal circumstances sufficient to satisfy all the requirements of the electrical system of the vehicle, it is, nevertheless, limited. For at times the current required by the system may exceed the current generated. In such circumstances the difference may be supplied, at least for a limited time, from the battery.
For instance, the temporary energization of a heatable windshield may add a load to the electrical system which may consume current exceed the generating capability of the generator. The excess would have to be drawn from the battery in a manner well known. However, unless carefully monitored, this could lead to lowering the battery charge to a level too low to restart the engine after it has been cut.
3. Objects of the Invention
Therefore, it is an object of the invention to provide a method of and apparatus for preventing an excessive discharge of a battery.
Another object of the invention resides in the provision of a method and apparatus for preventing excessive discharge of a battery where current required to feed electrical loads is in excess of current generated.
A further object of the invention resides in providing a method and an apparatus for use in an automotive vehicle for preventing excessive current drain from a battery where temporarily activated electrical loads require current in addition to the total capacity the generating equipment is capable of providing.
Yet another object of the invention is to provide a method and an apparatus for monitoring excessive current consumption and temporarily reducing such consumption in response to the charge level of a battery being lowered to a predetermined level.
Still another object of the invention resides in the provision of a method and apparatus for disconnecting an electrical load from an electrical system of an automotive vehicle in response to signals indicating a predetermined level of charge of the battery.
A more general object of the invention resides in the provision of a method and apparatus for establishing values representative of upper and lower charge levels of a battery.
It is also an object of the invention to provide a method of an apparatus for simulating predetermined maximum and minimum charge levels of an electrical storage battery in an automotive vehicle and in response to the minimum charge level to disconnect predetermined current consuming equipment.
Other objects of the invention w ill in part be obvious and will in part appear hereinafter. The invention accordingly comprises a method and apparatus possessing the construction, combination of elements and arrangement of parts which are exemplified in the following detailed disclosure.
SUMMARY OF THE INVENTION
These and other objects are accomplished by a method comprising the steps of measuring the operating time of a vehicle while a high current drain accessory is switched off, deriving from this operating time a value representative of the charge level of the battery, modifying this value while the accessory is switched on, and switching off the accessory when a predetermined threshold value has been reached.
In accordance with the invention the circuitry for practicing the method may comprise means for counting in a first direction to a predetermined first threshold value while the high current drain accessory it not in operation and for counting in the opposite direction to a predetermined second threshold value when the high current drain accessory is operating, and means for disconnecting the high current drain accessory when the second threshold value has been reached.
DESCRIPTION OF THE DRAWING
The novel features which are considered characteristic of the invention are set forth with particularity in the appended claims. The invention itself, however, in respect of its organization and method of operation, together with other objects and advantages of the illustrated embodiment when read in connection with the accompanying drawings, in which:
FIG. 1 schematically depicts a first embodiment of a control circuitry for executing the present invention;
FIG. 2 is an alternate embodiment of a circuit in accordance with the invention; and
FIG. 3 is a third embodiment of a circuit in accordance with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An electrical load, schematically depicted as an electrically heatable windshield 10 is connected to positive and negative terminals 12 and 14, respectively, of a current source. For purposes of this description the current source may comprise a current generator and a storage battery (neither shown) suitably connected to each other and to the positive terminal 12 so that at times the generator may charge the battery and at times either or both may energize the electrical system in a manner well known in the art. A switch 16, for instance a transistor, may selectively open and close the circuit between the positive voltage terminal 12 and the windshield 10 in a manner to be described. Those skilled in the art will appreciate that other electrical loads may take the place of the heatable windshield 10.
Since the current drawn by the windshield 10 in addition to all the other loads of the system may exceed the total current generating capability of the generator, the additional requirement would be drawn from the battery to compensate for the resulting deficiency. However, in order to prevent excessive discharge of the battery in such circumstances, the invention provides for the logic control circuit means as well as a method of its operation to be described.
By way of example, the logic circuit in accordance with the invention shown in FIG. 1 may be arranged as follows: Collector and emitter of the transistor 16 are connected to the positive terminal 12 and the windshield 10, respectively, the base of the transistor 16 being connected, by a line 30, to a driver stage 28 which in turn is connected to the output terminal 26 of an AND gate 20. One input terminal 22 of the AND gate 20 is connected to a manual on-off switch 18. The on-off switch 18 may be used for energizing the windshield 10 in the manner of this invention. Closing the switch 18 results in a logic 1 signal being applied to the input terminal 22 of the AND gate 20.
The other input terminal 24 of the AND gate 20 is inverted and is connected to an output terminal of a one-shot multivibrator 68. The one-shot multivibrator 68 may be triggered by a signal from the output terminal 66 of an up/down counter 64.
The output terminal 26 of the AND gate 20 is also connected, by way of a line 32, to one input terminal 34 of another AND gate 38. The other input terminal 36 of the AND gate 38 is connected to a clock oscillator 70 by way of a line 48.
The output terminal 56 of the AND gate 38 is connected, by a line 58, to the down-count input terminal 60 of the up/down counter 64. The output terminal 56 of the AND gate 38 is also connected to the input of another one-shot multivibrator 72. The output of the multivibrator 72 is in turn connected to an inverted input terminal 42 of a further AND gate 44. The other input terminal 40 of the AND gate 44 is connected to the oscillator 70 by way of line 46, and the output terminal 54 of the AND gate 44 is connected to the up-count terminal 62 of the up/down counter 64 by way of a line 50.
The operation of the control circuit is as follows: The up/down counter 64 comprises a non-volatile memory capable of retaining stored counts after the vehicle has been turned off and the circuit is no longer energized. For purposes of explaining the operation of the circuit it is assumed that the count initially stored in the counter exceeds zero. An initial count of zero is a special condition to be described infra.
When the count in the counter 64 exceeds zero a logic 0 signal is present at its output terminal 66. The one-shot multivibrator 68 cannot therefore be triggered and, with current being switched on, its logic 0 output is inverted to a logic 1 signal at the input terminal 24 of the AND gate 20.
When for purposes of switching on the heatable windshield 10 the manual switch 18 is closed, the input terminal 22 of the AND gate 20 will transition to logic 1. The output of the AND gate 20 will then go to logic 1, and the driver stage 28 will gate the transistor 16 into conduction. Once the transistor 16 is conducting the windshield 10 will be energized by current flowing through it from the positive terminal 12 to the negative terminal 14.
The logic 1 signal from the output terminal of AND gate 20 will also be applied to the input terminal 34 of the AND gate 38 by way of line 32. The other input terminal 36 of the AND gate 38 receives a train of pulses of predetermined frequency from the oscillator 70 by way of line 48. These pulses are applied to the down-count terminal 60 of the up/down counter 64.
By way of line 52 the output 56 of AND gate 38 also triggers the one-shot multivibrator 72. The pulsewidth of the one-shot multivibrator 72 exceeds the pulse frequency of the oscillator 70. Thus, the one-shot multivibrator 72 is triggered by a pulse from the AND gate 38, but before it can revert to its initial state the one-short multivibrator 72 will have received another trigger pulse so that its output remains at logic 1. The logic 1 signal from the one-shot multivibrator 72 is inverted at the input terminal 42 of the AND gate 44. The output 54 of the AND gate 44 thus is a logic 0 signal. By line 50 the logic 0 signal is applied to the up-count terminal 62 of the up/down counter 62.
As soon as the windshield 10 is turned on by closure of the manual switch 18, the counter 64 will commence to count down from its initial count, at the pulse frequency of the oscillator 70.
As soon as the counter 64 has counted down to zero its output 66 changes to a logic 1signal. The logic 1 signal triggers the one-shot multivibrator 68 and its resulting logic 1 output signal will be inverted at the input 24 of the AND gate 20 to a logic 0 signal. Thus, the output of the AND gate 20 changes to a logic 0 signal, and the transistor 16 is turned off. This disconnects the windshield 10 from the current source for the duration of the transition period of the one-shot multivibrator 68. The pulse width or transition period of the multivibrator 68 is a relatively long one lasting, for example, in the order of several minutes.
The logic 0 signal from the AND gate 20 is simultaneously fed to the input terminal 34 of the AND gate 38 by way of line 32. The output 56 of the AND gate 38 therefore transitions to a logic 0 signal.
Thus, the AND gate 38 no longer passes the pulses from the clock oscillator 70 to the down-count input terminal 60 of the counter 64 and to the one-shot multivibrator 72. As a result, the output of the multivibrator 72 transitions to a logic 0 signal which is inverted to a logic 1 signal at the input 42 of the AND gate 44. The latter thus passes the pulses received at its input terminal 40 form the oscillator 70 along line 46 to the up-count terminal 62 of the up/down counter 64 by way of line 50. As long as the AND gate 20 and, therefore, the windshield 10 remain turned off the counter 64 counts up at the same frequency at which it previously counted down.
When at the end of its transition the multivibrator 68 reverts to its logic 0 output signal and the switch 18 is closed, the transistor 16 will be turned on again and heating of the windshield 10 will recommence in the manner described supra.
Accordingly, the windshield 10 is disconnected after an operational interval the length of which is a function of the count in the counter 64 even while the switch 18 is closed. During a period of recuperation determined by the pulsewidth of the one-shot multivibrator 68 the battery may be recharged, before the windshield 10 is automatically turned on again.
In the event the switch 18 is open, the output of the AND gate 20 is at logic 0 because its input terminal 22 is at logic 0. Therefore, the input 34 of the AND gate 38 is also at logic 0 and the up/down counter 64 counts up for reasons described above.
The highest count storable in the non-volatile memory of the counter 64 corresponds substantially to the maximum charge level of the battery. Once the maximum count has been reached the upward count is suspended because the battery cannot be charged beyond its capacity.
On the other hand, a zero count in the memory of the counter represents the lowest level of battery charge tolerable for safe operating conditions of the vehicle. That is to say that even at this low level the battery is powerful enough to start the engine, for instance. Therefore, while the counter is counting down the discharging of the battery is acceptable. Thereafter, the windshield 10 is switched off. If because of prior operating conditions, such as prior operation of the windshield 10, the count in the memory of the counter 64 is low, the apparatus of the invention would limit discharging of the battery for a correspondingly shorter period.
Those skilled in the art will appreciate that the circuit in accordance with the invention may be adapted or modified to suit particular circumstances. For instance, the embodiment depicted in FIG. 2, while being similar to the embodiment of FIG. 1 in major respects, utilizes two clock oscillators 70' and 70" for the purpose of feeding pulse trains of different frequencies to the up-count and down-count terminals 62 and 60 of the counter 64, respectively.
FIG. 3 depicts an embodiment with divider circuits 74 and 76 connected between the output of a single clock oscillator 70 and the inputs 40 and 36 of the AND gates 44 and 38, respectively. Divider circuit 74 divides the pulse frequency of the clock oscillator 70 by a first multiple, X, thereof, and the divider circuit 76 divides the clock frequency by a second multiple, Y, thereof.
Thus, while the embodiment of FIG. 1 provides for counting up and down at substantially identical pulse frequencies, the embodiments of FIG. 2 and 3 permit up and down counts at different frequencies. In this connection, it may in certain circumstances be desirable to count down at a relatively slow rate and to count up at a relatively fast rate, or vice versa. Persons skilled in the art would know which one of the two frequencies in any particular circumstance should be the higher one.
The length of the interval during which the windshield 10 remains switched off during operation of the circuit may be varied by adjusting the transition period of the one-shot multivibrator 68.
Other modes of operation would be possible. For instance, it would also be within the ambit of the invention to vary the pulse frequency fed to input terminals 60 and 62 of the counter 64 as a function of the total electrical load connected to the electrical system at any time, so that as the load increases the frequencies of the up-count and of the down count are respectively increased and decreased, or vice versa. Also, the maximum count storage in the counter 64 may be made adjustable as a function of such operating parameters as ambient temperature, battery size and/or age.
Furthermore, for practicing the invention other circuit configurations would be possible. For instance, operating cycles of the vehicle with the windshield 10 deactivated may be read into a memory and may be multiplied by the current available from the generator after all other loads have been deducted. Operating cycles of the vehicle with the windshield 10 activated would be stored in a second memory and may be multiplied by maximum current drain. The difference between the two values could be fed to a comparator for comparison with a predetermined minimum value. If the minimum value is less than the difference, the windshield would be disconnected, and vice versa.
It will thus be seen that the invention provides for an effective method and apparatus for preventing the discharge of an electrical storage battery below a predetermined minimum level in circumstances in which the current generating capacity lags behind current consumption.
Other embodiments of the invention, including additions, subtractions, deletions and other modifications of the preferred disclosed embodiment will be obvious to those skilled in the art and are within the scope of the appended claims. | A method and apparatus for controlling the consumption of electrical current exceeding the total generating capability of an electrical system and for monitoring the charge of a storage battery between maximum and minimum levels and for disconnecting electrical loads in response to the level reaching the minimum. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to dynamic magnetic information storage and retrieval and, ore particularly, to heads which are magnetoresistive, and to sensors of magnetic fields in general.
2. Description of the Prior Art
Commonly assigned U.S. Pat. No. 3,864,751 of Beaulieu et al for an "Induced Bias Magnetoresistive Read Transducer" shows a magnetoresistive sensor 10 deposited on an insulating layer 12 on a magnetic shield 20. In FIG. 5 of that patent a shunt bias layer 26 of titanium can be provided. The magnetoresistive sensor 10 and the layer 26, if present, are then covered by SiO 2 insulating layers 14 or 27 on which is deposited a bias film 16 of Permalloy. Thus, the magnetoresistive sensor or the layer 26 is separated from the bias layer by SiO 2 which we have discovered can have spurious electrical breakdowns causing variations in resistance which produces spurious signals and can lead to degraded magnetic and electrical characteristics. Previously, it had been thought, as shown by Beaulieu et al and commonly assigned Voegeli U.S. Pat. No. 3,860,965, that the normal provision of insulation was necessary probably in order to prevent degradation of the signal in Beaulieu et al and in order to function in the case of the Voegeli patent and in a publication by O'Day entitled, "Balanced Magnetic Head," IBM Technical Disclosure Bulletin, Vol. 15, No. 9, Feb. 1973, p. 2680.
In addition, Beaulieu et al provides a structure which makes it very difficult to provide contact with the lower magnetoresistive sensor because the conductor requires a discontinuity in the structure, causing Barkhausen noise and potential short circuits.
The fact has been discovered by experimentation that if insulation is used, it must be on the order of 1000A thick or thicker to be reliable whereas magnetic efficiency considerations require an insulation on the order of 200A thick, which leads to the unreliability and degradation characteristics referred to above.
The O'Day U.S. Pat. No. 3,814,863 and Brock et al U.S. Pat. No. 3,813,692 are commonly assigned and both show an MR layer deposited on a substrate covered with a layer of titanium which does not rely on magnetic bias but which uses current flowing through the titanium film to provide the bias instead. This form of bias is less effective because it requires much larger bias currents, thus producing excessive heat, and is critically dependent upon spacing in the gaps.
SUMMARY
In accordance with this invention, the magnetoresistive (MR) film is deposited on a smooth substrate. The sequence of deposition is important for smoothness of the surface on which the MR film is deposited, since smoothness determines the quality of the MR film. A smooth substrate provides a higher quality film with reduced dispersion and lower coercivity. Both are desirable for reduction of Barkhausen noise. An intermediate layer of a thin film of a high resistivity, conductive material, such as titanium, is deposited directly upon the film of magnetoresistive material. The titanium is deposited under low temperature conditions which yield a smooth surface. A thin film of magnetic biasing material is deposited directly upon the intermediate layer.
An object of this invention is to provide a magnetoresistive sensor having a bias layer without spurious electrical breakdowns and with excellent magnetic and electrical characteristics.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A shows a perspective view of a prior art form of magnetoresistive sensor structure (with a top shield and dielectric omitted) interpreted to show what would seem to be the most favorable specific embodiment.
FIG. 1B shows a plan view of the head of FIG. 1A.
FIG. 1C shows a front elevation view of the head of FIG. 1A.
FIG. 2A shows a perspective view of a magnetoresistive sensor structure in accordance with this invention.
FIG. 2B shows a plan view of the head of FIG. 2A.
FIG. 2C shows a front elevational view of the head of FIG. 2A.
FIG. 3 is a plan view of a modification of FIG. 1A.
FIG. 4 is a plan view of another modification of FIG. 1A.
FIG. 5 shows an equivalent electrical circuit for the invention as embodied in FIGS. 2A-2C.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIGS. 1A-C, a modification of the arrangement shown in FIG. 5 of U.S. Pat. No. 3,864,751 of Beaulieu et al is shown. A substrate 20 comprising a magnetic shield is covered with an insulating layer 12. On the layer 12 is vacuum deposited a layer of a magnetoresistive element 10. Upon the layer 10 is deposited a shunt layer 26 which is nonmagnetic but of comparable resistivity and adapted to carry a comparable current composed of a material such as titanium. An insulation layer 27 is deposited upon shunt layer 26, and a layer of a bias film 16 which can be composed of a Permalloy composition (80% Ni, 20% Fe). The Beaulieu et al patent does not deal in detail with the issue of location of the conductor leads 28 and 30 which connect the sensor layer 10 and shunt layer 26 to the current source 24. However, in thin film technologies, such considerations are important. It would appear that the best way to connect layer 10 and 26 to leads 28 and 30 is as shown in FIG. 1, with leads 28 and 30 extending under insulation layer 27 and bias film 16. In order to provide adequate current to the layers 10 and 26, the conductors 28 and 30 must be on the order of 1000A thick which creates a step over which insulation layer 27 and bias layer 16 must extend. This leads to the problem of short circuits through the insulation 27 which is preferably only about 200A thick and which cannot be controlled in thickness very well at edges 29 where the thickness of the leads (about 1000A) should be thicker than the film 27. Note that Beaulieu et al call for insulation layers of about 2000A thickness and yet call for a separation between MR layer 10 and bias layer 16 of only 500 to 1000A, which creates a conflict since the 200A thickness of shunt layer 26, plus a 2000A layer 27 would separate the layers by about 2200A or twice the desired thickness. In any event, there is an additional problem in that extension of bias layer 16 over leads 28 and 30 causes a serious magnetic discontinuity. At edges 29, the bias layer will have a vertical inclination causing discontinuities in magnetic directional orientation which can produce Barkhausen noise attributable to magnetic domains at edges 29.
FIGS. 2A-C show a similar magnetoresistive sensor to that shown in FIGS. 1A-C modified in accordance with this invention. A substrate 60 is coated with dielectric layer 52 composed preferably of glass. A magnetoresistive sensor thin film layer 50 such as Permalloy nickel-iron about 200A-600A thick is deposited by evaporation at a substrate temperature near 250° C on the smooth dielectric layer 52 to provide an excellent magnetoresistor. A thin film 66 about 100A to 200A thick of a high resistivity conductor such as titanium is deposited upon sensor layer 50 at room temperature to reduce grain size of the titanium. Then finally a thin film layer 56 about 140A to 425A thick of a hard or soft magnetic biasing material such as Permalloy nickel-iron, or CoCr is deposited upon film 66. When made from the same material as the magnetoresistive layer 50, layer 56 should be about 0.707 of the thickness of magnetoresistive layer 50. An inverted U-shaped outline is formed by selective etching of all three layers through use of a single photoresist pattern or the equivalent to provide a sensor stripe plus support for the electrical leads 68 and 70 which are deposited upon the legs of the inverted U-shape formed by etching or the equivalent. However, the shape of the MR sensor sandwich can also be a rectangular one with the leads stepping over it. The low temperature technique of depositing the shunt layer 66 results in minimization of the increase in coercivity normally observed in depositing magnetic material over a layer because of the reduced grain size of shunt layer 66.
Note that layer 56 is selected to be thinner than layer 50 when using Permalloy nickel-iron so that it will be saturated and will not be capable of exhibiting the magnetoresistive effect. Such saturation is imposed by the magnetic field generated by the sensor 50 and the shunt layer 66.
Modifications can be made upon the Beaulieu et al patent as shown in FIGS. 1A-C to clarify the way in which the conductors would be connected to the magnetoresistor 10 which is very much left to speculation by the schematic electrical leads shown in that patent. One possibility is that there would be thin film conductors aligned to butt with the edge of the MR sensor 10 but that would be very difficult to achieve because of the extremely small dimensions involved which would make alignment almost impossible. A possible modification based upon the use of a titanium layer on top of MR sensor 10 is shown in FIG. 3 in which the titanium shunt layer 26 extends beyond the upper and lower ends of sensor 10. However, sensor 10 would have to be formed into an inverted U-shaped form prior to deposition of shunt layer 26. Then layer 26 would have to be etched prior to deposition of conductors 28 and 30, insulating layer 27 and bias layer 26. Thus, layer 26 would have its shape formed separately from layer 26 after several intervening steps. The configurations of layers 10 and 16 after etching should be identical and perfectly aligned to avoid substantially increasing Barkhausen noise. Achieving that degree of alignment would impose impossible fabrication problems. From a practical point of view, such alignment is not possible without a procedure whereby the three layers are etched simultaneously as is possible in the arrangements of FIGS. 1A-C and 2A-C. The arrangement of FIG. 3 is also unsatisfactory because it would provide a nonuniform magnetic bias since sensor 10 extends beyond bias layer 16.
FIG. 4 shows another modified arrangement of the Beaulieu et al patent which will eliminate short circuits, but which also suffers the fabrication difficulties of the above-mentioned case.
A question which is immediately raised by placing the shunt and bias layers electrically in parallel with the magnetoresistor as in FIGS. 2A-C is one of the degree to which the parasitic shunt resistances of those layers degrade the signal output.
In FIG. 5, an equivalent electrical schematic circuit for the sandwich of FIGS. 2A-C is shown. A biased magnetoresistor of resistance R without any shunt has an AC output voltage of IΔR where ΔR is the change of resistance caused by a magnetic field, and where the sensing current I is limited by power dissipation considerations (I 2 R).
A biased magnetoresistor of resistance R with a shunt of resistance βR has an output AC voltage of I'ΔRβ/1+β. However, I' can be of a larger value than I since the magneto-resistor-shunt combination can withstand a higher current than the magnetoresistor alone at equal power dissipation I' 2 Rβ/ 1+β).
For the dimensions and materials described above for FIGS. 2A-2C, the value of β is near 1 and I' equals about 1.4I. Therefore, the sensor of FIG. 2A-C provides 70% of the maximum output signal of a magnetoresistor without a shunt. This is considered to be a negligible loss of signal amplitude in view of elimination of the unreliability caused by the breakdown of the thin insulating layers which were required by Beaulieu et al. | A magnetoresistive permalloy film is deposited upon a substrate and coated with a separating layer composed of titanium or a similar high resistivity, conductive material. A soft biasing layer of a material such as permalloy or a hard biasing material such as cobalt chromium is deposited upon the separating layer to complete a sandwich. All layers are coextensive in outline because their outlines are formed by a single etching step. | 8 |
REFERENCE TO CROSS RELATED APPLICATION
[0001] This application is a continuation-in-part of an application filed on Jan. 31, 2007, Ser. No. unknown at this time.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The subject matter disclosed generally relates to the field of semiconductor image sensors.
[0004] 2. Background Information
[0005] Photographic equipment such as digital cameras and digital camcorders may contain electronic image sensors that capture light for processing into still or video images, respectively. Electronic image sensors typically contain millions of light capturing elements such as photodiodes. The photodiodes are arranged in a two-dimensional pixel array.
[0006] FIG. 1 shows an enlarged cross-section of pixels in a pixel array of the prior art. The pixels include first regions 1 constructed from a first type of material, typically p-type, and second regions 2 constructed from a and 2 form p-n junctions of photodiodes. The p-n junctions are reversed biased to form depletion regions between dashed lines 3 and 4 . The photons of incoming light 5 are absorbed to create electron-hole pairs 6 . The electrons move to create an electrical current. The current is ultimately sensed and processed to reproduce the image detected by the image sensor.
[0007] Light at relatively long wavelengths penetrate deep into the photodiodes. Consequently, electrons are formed at the outer edges of the depletion regions. The depletion regions can grow and actually merge in region 7 . The merger of depletion regions electronically couples the adjacent photodiodes in a capacitance manner. A change in voltage of a photodiode receiving light may vary the voltage in an adjacent photodiode not receiving light. This will result in an inaccurate sensing of light in the adjacent photodiode. It would be desirable to provide a pixel structure that would minimize the effects of lateral depletion region growth from impinging on adjacent depletion regions.
BRIEF SUMMARY OF THE INVENTION
[0008] An image sensor with an array of photodiodes that each have a first region constructed from a first type of material and a second region constructed from a second type of material. An insulating region is located between the first and second regions. The second region is offset from the insulating region in a corner region of the photodiode array.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is an illustration of an image sensor of the prior art;
[0010] FIG. 2 is a schematic of an image sensor;
[0011] FIG. 3 is an illustration of a plurality of photodiodes of the image sensor;
[0012] FIG. 4 is an illustration of photodiodes at a corner region of a pixel array of the image sensor;
[0013] FIG. 5 is an illustration of photodiodes at the corner region, with offset barrier regions;
[0014] FIG. 6 is an illustration of photodiodes at the corner region, with offset n-regions.
DETAILED DESCRIPTION
[0015] Disclosed is an image sensor with a plurality of photodiodes that each have a first region constructed from a first type of material and a second region constructed from a second type of material. The photodiodes also have an insulating region between the first and second regions. The photodiodes are arranged in an array. In corner regions of the array, the second regions are offset relative to the insulating regions to capture more photons of incoming light.
[0016] Referring to the drawings more particularly by reference numbers, FIG. 2 shows an image sensor 10 . The image sensor 10 includes a photodiode array 12 that contains a plurality of individual photodiodes 14 . The photodiodes 14 are typically arranged in a two-dimensional array of rows and columns. The array 12 has a center area 16 and corner areas 18 .
[0017] The photodiode array 12 is typically connected to a light reader circuit 20 by a plurality of conductive traces 22 . The array 12 is connected to a row decoder 24 by conductive traces 26 . The row decoder 24 can select an individual row of the array 12 . The light reader 20 can then read specific discrete columns within the selected row. Together, the row decoder 24 and light reader 20 allow for the reading of an individual photodiode 14 in the array 12 . The data read from the photodiodes 14 may be processed by other circuits such as a processor (not shown) to generate a visual display.
[0018] The image sensor 10 and other circuitry may be configured, structured and operated in the same, or similar to, the corresponding image sensors and image sensor systems disclosed in U.S. Pat. No. 6,795,117 issued to Tay, which is hereby incorporated by reference.
[0019] FIG. 3 shows a plurality of photodiode 50 . Each photodiode 50 includes a first region 52 constructed from a first type of material and a second region 54 constructed from a second type of material. By way of example, the first material may be an intermediately doped p-type material and the second regions 52 may be a lightly doped n-type material. The regions 50 and 52 are formed on a substrate 56 . The substrate 56 may be constructed from a lightly doped p-type material.
[0020] Each photodiode 50 may further have a gate 58 and either a source or drain pad 60 formed adjacent to the first region 52 . The gate 58 may be constructed from a heavily doped n-type polysilicon material. The source/drain pad 60 may be constructed from a heavily doped n-type material. The n-type source/drain pads 60 may be separated from the n-type second regions 54 by insulating regions 62 .
[0021] Adjacent to each first region 52 is a barrier region 64 . The barrier region 64 may be constructed from a medium doped p-type material. The photodiodes 50 are reversed biased to create depletion regions generally within lines 66 and 68 . Absorption of light and the formation of electron-hole pairs 70 at relatively long wavelengths of light will occur in the bottom portion of the depletion regions. By way of example, light with wavelengths longer than 650 nanometers tend to become absorbed at the bottom of the depletion regions.
[0022] The barrier regions 64 inhibit lateral growth of the depletion regions in the horizontal directions as represented by dashed lines 72 . This prevents the depletion regions from merging and causing errant voltage variations in adjacent photodiodes. By way of example, the barrier regions may have a depth between 2-4 μm.
[0023] As shown in FIG. 4 , the light rays penetrate the photodiodes at an angle for pixels located at the corner areas 18 of the pixel array. The angle can be as much as 30 degrees. The incident light may be absorbed by material and form electron-hole pairs 70 outside of the second region and in close proximity to an adjacent photodiode. The free electrons may migrate to the adjacent photodiode causing inaccurate photo-detection.
[0024] FIG. 5 is an embodiment where the barrier regions 64 are offset relative to the first regions 52 . The offset barrier regions 64 create a longer path to an adjacent photodiode from the point when incident light is absorbed by the material. The offset may vary from the center of the pixel array, where the light penetrates the photodiodes in a perpendicular direction, to the outer pixels of the array where the light penetrates at a significant angle. The offset may become progressively larger from the center of the pixel array to the outer regions of the array. The offset allows the depletion region to grow laterally in the direction of the incoming light. By way of example, the barrier regions may be offset up to 0.5 μm at the outermost pixels.
[0025] FIG. 6 is an embodiment where both the barrier regions 64 and the second regions 54 are offset relative to the insulating regions 62 . The offset second regions 54 are in-line with the direction of incoming light and capture more photons. The second region offsets may vary from the center of the pixel array, where the light penetrates the photodiodes in a perpendicular direction, to the outer pixels of the array where the light penetrates at a significant angle. The offsets may become progressively larger from the center of the pixel array to the outer regions of the array. By way of example, the barrier and second regions 64 and 54 , may be offset up to 0.5 μm at the outermost pixels.
[0026] The photodiodes may be constructed with known CMOS fabrication techniques. The barrier region 64 may be formed on the substrate 56 . The first regions 52 may be formed on the barrier regions 64 and the gates 58 and pads 60 formed on the regions 52 . The second regions 54 may also be formed on the substrate 56 . The order of formation may vary depending on the processes used to create the image sensor.
[0027] While certain exemplary embodiments have been described and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative of and not restrictive on the broad invention, and that this invention not be limited to the specific constructions and arrangements shown and described, since various other modifications may occur to those ordinarily skilled in the art. | An image sensor with a plurality of photodiodes arranged in an array. A barrier region is disposed between adjacent photodiodes and inhibits depletion region merger between adjacent photodiodes, thereby inhibiting a capacitive coupling between the adjacent photodiodes. | 7 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation of, and clams the benefit of, the applicants' prior parent regular utility patent application, entitled Safety Apparatus and Method of Use, Ser. No. 11/233,675, filed Sep. 22, 2005, now U.S. Pat. No. 7,150,054 which prior parent regular utility patent application claimed the benefit of the applicants' prior U.S. provisional patent application of the same title, Safety Apparatus and Method of Use, Ser. No. 60/719,671, filed Sep. 21, 2005. The contents the above-referenced prior parent regular utility application and prior U.S. provisional patent are hereby incorporated by reference in their entirety.
FIELD
This application concerns a device for orienting a body with respect to another object and method of use. In one embodiment, the application concerns a device for relatively securely orienting a human body, such as a sleeping infant for example, with respect to an adjacent blanket or sheet and method of use.
BACKGROUND
A common problem faced by caregivers and parents of an infant, particularly a young infant, is that the infant typically is unable to keep a blanket over a lower portion of the infant while the infant is asleep. This arises because the infant may move around during sleep or kick off the blanket. This can result in the infant becoming cold during sleep and therefore waking, requiring the attention of an adult to re-cover the infant. In more serious cases, the blanket can be moved up over the face of the infant or the infant may slip down under the blanket thus increasing the risk of overheating and suffocation of the infant.
A further problem commonly faced by caregivers and parents of infants is that the infant may roll over onto its stomach during sleep thus also increasing the risk of suffocation. Also, the infant may roll over during sleep and wedge their face against the side of a cot in which it sleeps, again increasing the risk of suffocation.
Yet another problem for caregivers and parents is the possible loss of oxygen and other problems (such as falling out of bed) that may arise for an infant if it moves toward the sides or headboard of bed.
One solution known in the art is to tuck a blanket tightly around an infant and hope that the infant does not have enough strength to remove the blanket. However, there is a risk that the blanket could be tucked too tight and thus restrict the infant's breathing. A further known solution is to simply not cover the infant during sleep, but provide a very warm room in which the infant can sleep. However, the cost of heating a room to a suitable temperature, and maintaining the same, renders such a solution impractical to most parents. Also, the use of heaters to maintain such a temperature increases the risk of fire thus endangering the infant.
SUMMARY
Certain embodiments of the present invention address one or more of the above mentioned problems and provide a solution which reduces the risk of suffocation to an infant while also reducing the infant's discomfort.
Some embodiments provide a safety device for offering increased safety to a sleeping infant comprising cover means operable to cover at least a portion of an infant and securing means operable to secure at least a portion of an infant to the cover means.
In certain embodiments, the cover means comprise a blanket or sheet. The cover means may be formed of a soft material which may be a fabric material. The cover means may be formed from any natural or synthetic fabric, or any woven or non-woven fabric. Examples of a soft fabric material include brushed cotton and fleece.
In certain embodiments, the securing means are adjustable. The securing means may comprise a support member that may be adapted to fit between the legs of an infant. The support member may comprise a seat that is preferably adapted to support the seat of an infant. The support member may be attached to a first face of the sheet, such as, for example, toward a first end thereof. The support member may comprise a crotch strap or support.
In some embodiments, the securing means comprises strapping means, which strapping means may be adapted to strap an infant to the cover means. The strapping means may comprise a strap, a center section of which may be attached toward a second end of the support member. The securing means can generally triangularly or T-shaped. The securing means may comprise a harness that may fit between an infant's legs and around an infant's waist or torso.
The cover means may comprise at least one aperture. Alternatively, the cover means may comprise at least two apertures. The strapping means may be adapted to pass through the at least one aperture in the cover means. The strapping means can be adapted to pass through the at least two apertures in the cover means.
In some embodiments, the securing means is operable to secure at least a portion of an infant to a first face of the cover means. The securing means can be operable to be adjusted at a second face of the cover means.
The safety device may also further comprise strap retaining means operable to secure the strapping means to the cover means. The strap retaining means can be attached to the second face of the cover means.
In certain embodiments, toward a first end of the strapping means are attachment means operable to removably attach the first end of the strapping means to the strap retaining means. Toward a first end of the strapping means may be strap attachment means operable to removably attach a second end of the strapping means thereto. In addition, toward a second end of the strapping means may be attachment means operable to removably attach the second end of the strapping means to the first end of the strapping means.
In certain embodiments, the safety device is adapted to be attached to or incorporated within a surface, which surface may be substantially planar. In certain embodiments, the surface is a surface upon which an infant sleeps. Alternatively, the safety device may be sized and used with other than infants, in order to more reliably secure a non-infant in position, such as infirm elderly person.
The safety device may be attached to or incorporated within a bed sheet or mattress such that an infant (or other body) may be held in position relative to the bed sheet or mattress by the safety device. The safety device can be attached to or incorporated within a bed sheet or mattress so as to form a pocket. The pocket can be adapted to receive an infant therein and may be locate to maintain the infant in a desired position with respect to the bed or other structure, including the bed sheet.
In some embodiments, the support member is attached to an internal face of the cover means when the safety device is attached to or incorporated within a bed sheet or mattress. By internal face of the cover means it is meant a face of the cover means which directly abuts the mattress or bed sheet. The strapping means may be operable to be secured to an external face of the cover means when the safety device is attached to a mattress or bed sheet (and in this application, the term “sheet” includes blankets as well as conventional bed sheets).
In certain embodiments, a method of securing an infant (or other body) to a surface comprises the steps of: attaching a safety device comprising cover means and securing means to a surface, placing an infant or other body between the safety device and the surface, adjusting the securing means to fit the infant or other body, and securing the infant or other body to the safety device using the securing means. The method may instead or in addition comprise placing a cover on the infant or other body after first placing the infant or other body in the security means, such as a harness, and securing the harness in place. Other methods are disclosed.
In certain embodiments, the surface is a mattress or bed sheet.
All of the above aspects may be combined with any of the features disclosed herein in any combination.
The foregoing is a brief summary of aspects of the various embodiments disclosed in this specification. There are additional aspects that will become apparent as this specification proceeds. In addition, it is to be understood that embodiments of the invention need not include all such aspects or address all issues in the Background above.
BRIEF DESCRIPTION OF THE DRAWINGS
The preferred and other embodiments are shown in the accompanying drawing in which:
FIG. 1 shows a perspective view of a front surface of a safety (or securing) device;
FIG. 2 shows a perspective view of a rear surface of a safety device;
FIG. 3 shows a perspective view of a safety device attached to a mattress cap;
FIG. 4 shows a perspective view of a safety device attached to a fitted bed sheet in a predetermined position (for example to secure an infant adjacent the foot of a bed or at least away from the head or head board of a bed);
FIG. 5 shows a partial cross-sectional view from the top of a safety device attached to a bed sheet, the bed sheet being fitted to a mattress;
FIG. 6 shows a perspective view of a rear surface of a second embodiment of a safety device;
FIG. 7 shows a perspective view of a safety device secured to a fitted mattress with straps penetrating passages in the fitted sheet;
FIG. 8 shows a bottom view of the fitted sheet with the safety device mounted to the fitted sheet as in FIG. 7 ;
FIG. 9 shows a perspective view of an alternative arrangement for securing a safety device to a fitted mattress at the sides of the mattress;
FIG. 10 is a side view showing a method in which a blanket is slid over the bottom end of a mattress with a cover sheet;
FIG. 11 is a perspective view showing insertion of a harness on top of the mattress, in the method of FIG. 10 ;
FIG. 12 is a perspective view showing insertion of an infant between the harness and upper blanket, in the method of FIG. 10 ;
FIG. 13 is a perspective view showing the opposing securing straps of the harness pulled through mating strap passages in the blanket providing for strap locations on opposing sides of the infant's torso, in the method of FIG. 10 ;
FIG. 14 is a perspective view showing a first securing strap secured to a mating hook and pile fastener section on the upper surface of the blanket above the infant's torso, in the method of FIG. 10 ; and
FIG. 15 is a perspective view showing a second securing strap secured to a mating hook and pile fastener section on the upper surface of the first secured strap above the infant's torso, completing the method of FIG. 10 .
In the following Detailed Description section various specially orienting terms are used such as “upper” and “lower.” It is to be understood that such terms are used for convenience in association with the drawings but are not be themselves limiting or requiring of any absolute orientation in space.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2 , a safety device 102 comprises cover means in the form of a rectangular sheet 104 , and a harness 106 . The sheet 104 and the harness 106 are formed of a flexible, soft, and breathable material, such as fleece. It should be appreciated that the sheet 104 and the harness 106 may be made from any suitable material. Factors to consider when choosing a suitable material include the softness of the material, possible irritation to the infant's skin, climate in which the device will be used (i.e., cooling fabrics for warmer climates, etc.) fabrics which will not react to an infant's bodily excretions such as saliva, vomit and urine, etc.
The harness 106 comprises a gusset strap 108 as displayed in FIG. 2 and a securing strap 110 extending perpendicularly away from each side of a first end thereof. The gusset strap 108 of the harness 106 is attached at a second end thereof to a rear face 112 of the sheet 104 . The attachment may be accomplished in a wide variety of ways, such as by stitching or with buttons in mating button holes in the harness, or via other fastening techniques.
The opposing ends of the securing strap 110 pass from the rear face 112 of the sheet 104 to a front face 114 of the sheet 104 via two laterally spaced elongate apertures 116 in the sheet 104 . Therefore, as shown in FIG. 2 , the harness 106 forms a T shape, but other shapes may be utilized.
An alternative embodiment of a harness 206 is shown in FIG. 6 . In this embodiment, the harness 206 has a seat 208 of a shape that an infant can sit in, for example, in the shape of a seat of a pair of briefs. A bottom edge 210 of the seat 208 is secured to the rear face 112 of the sheet 104 . Attached at opposing sides toward the top of the seat 208 are securing straps (not shown) which extend through the apertures 116 and function in the same manner as will be described below. The front face 114 of the sheet 104 fitted with the preferred harness 206 is as described with reference to FIG. 1 below.
The front face 114 of the sheet 104 (as shown in FIG. 1 ) has a securing pad 118 approximately centrally disposed between the two apertures 116 . The securing pad 118 is attached to the sheet 104 by stitching and has female hook and pile fastener on its outer surface, e.g., the pile portion of the hook and pile fastener.
Toward a first end 120 of the securing strap 110 there is attached a portion of hook and pile fastener on each face thereof (not shown), one portion being male hook and pile fastener, the other portion being female hook and pile fastener. Toward a second end 122 of the securing strap there is attached a portion of male hook and pile fastener (not shown).
It is preferred that the male hook and pile fastener (i.e., the hook portion) be attached on the surfaces which are least likely to come into contact with an infant, in use. This is because the texture of the male hook and pile fastener is coarse and may irritate an infant, whereas the female hook and pile fastener (the pile) has a softer texture. This is exemplified by providing the female hock and pile fastener on the securing pad 118 which faces upwards, away from the infant, in use.
The device 102 may be attached to or form part of a mattress or cushion upon which an infant sleeps.
Alternatively, as shown in FIGS. 4 and 5 , the device 102 may be attached to or form part of a fitted bed sheet 126 . In this embodiment, a fitted bed sheet has an upper face 128 and side faces 130 of an appropriate size to fit an infant's mattress 132 . The device 102 may be attached to the upper face 128 of the fitted bed sheet 126 .
The attachment or incorporation of the device 202 onto or into a bed sheet, mattress, cushion etc. should incorporate a pocket 124 as shown in FIGS. 3 , 4 and 5 into which an infant may be placed.
A further alternative (shown in FIG. 3 ) is to form the sheet 104 into a pocket which may be fitted over one end of a mattress already fitted with a bed sheet. The device 102 would therefore be held in place by the weight of the mattress.
The sheet 104 is shown in a preferred rectangular shape, however it should be appreciated that many shapes of sheet could perform the same function in a similar manner.
In use, an infant (not shown) is placed under the sheet 104 such that the gusset strap 108 of the harness 106 sits between the infant's legs and the securing strap 110 around the infant's waist or torso. The ends of the securing strap 110 are then pulled through the apertures 116 so that the infant is pulled toward the rear face 112 of the sheet 104 . The first end 120 of the securing strap 110 is then attached to the securing pad 118 by the hook and pile fastener thereon. The second end 122 of the securing strap 110 is then attached to the first end 120 of the securing strap 110 by the hook and pile fastener between them.
As shown in FIG. 7 , yet another embodiment of the safety or securing device has a harness 200 that is mountable to fitted or other sheet 202 , which is in turn mounted to a bed mattress (not shown). In this embodiment, the harness 200 has a generally semi-triangular or T-shape with three securing straps 204 , 206 , 208 extending from the central body 210 of the harness 200 . Two collinear but opposing securing straps 206 , 208 penetrate mating securing strap passages, 212 , 214 respectively, in the sheet 202 . The mating securing strap passages 212 , 214 are equidistant from the axial center A of the bed mattress, in order to center a body secured by the harness 200 in the axial center of the bed mattress and equally spaced from the opposing lateral sides 216 , 218 and top and bottom sides 220 , 222 of the sheet on the bed mattress.
A center, axially extending securing strap 204 extends from the central body 210 transverse to the opposing securing straps 206 , 208 toward the bottom or foot of the bed 222 . The remote end 224 of the axially extending strap 204 is secured to the bed sheet 220 such as by stitching or other fastening means.
Each of the opposing securing straps, e.g., 204 , extends from its mating securing strap passage, e.g., 212 , between the sheet 202 and underlying mattress (not shown) to then protrude outwardly from mating side strap passage, e.g., 226 , in the associated side 216 of the sheet 202 and underlying bed mattress. The distal, protruding end 228 of the securing strap 204 is then secured to side 216 of the sheet 202 such as by a hook and pile fastener sections matingly mounted between the protruding end 228 and the side 216 of the sheet 202 . Other types of fasteners may also be used. Alternatively, the protruding end 228 may be lengthened and tied to adjacent structure (not shown) such a as a crib gate.
As shown in a somewhat alternative construction in FIG. 8 , the axially extending strap 204 may be adjustable and/or removable rather than fixed to the bed sheet 202 as in FIG. 7 and, for example, extend through a mating strap passage 230 in the bed sheet 202 . The fastening end 232 of the axially extending strap 204 may similarly be secured to the bed sheet 202 by hook and pile or other fasteners (not shown). Alternatively, the axially extending strap 204 may extend through yet an additional passage (not shown), such as in the bottom side 222 of the bed sheet 202 to be secured in the fashion of the opposing securing straps 206 , 208 as shown in FIG. 7 . Numerous other harness securing structures and techniques may be utilized.
For example, in yet another embodiment, the mating side strap passage 226 of FIG. 7 may be enlarged 240 as shown in FIG. 8 . Further, the hook and pile fastener portion 242 secured to the bed sheet 202 may be widened to cover a greater lateral area on the side 216 of the bed sheet 202 . This configuration can allow for lateral adjustment of the mounting or fastening position of the associated opposing or sidewardly extending securing strap 244 . In this manner, the securing strap 244 may be mounted in various locations along the side 216 of the bed 202 and avoid interfering structure such as a crib gate or side bed post (not shown).
The securing harnesses shown in FIGS. 8 and 9 may thus be relatively easily removed from the associated bed sheet and replaced, washed, or repaired as desired. Further, they can be secured in position, to maintain an associated body in position, in a fashion that can be difficult or impossible for an infant, or perhaps other body, to undo the orientation of the harness when secured to the associated bed street or other structure.
In the embodiments of FIGS. 7-9 , the harness is shown unattached to a sheet or blanket. A sheet (meaning herein any other desired cover, such as a blanket as noted above) may be either attached to the harness before or after installation of the harness and in any number of ways. For example, a sheet might be secured in position with respect the harness and associated infant or other body by securing corners of the sheet to a crib gate or other structure. The corners of the sheet may have any number of fastening devices attached to such or other locations. Examples can include straps secured to the sheet location, mating hook and pile fasteners mounted on the straps of mating structures, or button and mating passage fastening structures.
The sheet can be further secured in position in many other ways. One example is to secure the sheet to the harness above the infant or other body by means of mating hook and pile fastener sections mounted to the harness and the mating section of the sheet.
Alternatively, the sheet can include included pocket structure with the harness of FIGS. 7-9 mounted within the pocket to secure an infant or other body within the pocket. The pocket may be created by slip-over sheeting on a mattress, or it may be formed of a section of sheet stitched or otherwise fastened to another sheet.
With reference now to FIGS. 10-15 , one method of utilizing a harness and associated sheet with an infant comprises:
A. sliding a pre-constructed or arranged pocket sheet 300 (such as, as one example, a stretchable fleece blanket in the embodiment of FIGS. 10-15 ) over the bottom or lower end 302 of a mattress pre-covered with an underlying fitted sheet 304 ; B. inserting a somewhat triangularly shaped securing harness 306 between the fitted sheet 304 and mating upper section 308 of the pocket sheet 300 ; C. placing an infant 310 on the upper face 312 of the harness 306 and below the mating upper section 308 of the pocket sheet 300 , with the upper edge 314 of the mating upper section 308 of the pocket sheet 300 extending across the infant's torso 316 spaced from the infant's head 318 and, in this particular embodiment, shoulders 320 ; D. pulling the two opposing securing straps 322 , 324 of the harness 306 through mating strap passages, e.g., 326 , in the sheet 300 providing for strap passage locations on opposing sides 328 , 330 of the infant's torso 316 ; E. securing a first securing strap 322 to a mating hook and pile fastener section 332 on the upper surface 334 of the sheet 300 above the infant's torso; and F. securing the opposing second securing strap 324 to a mating hook and pile fastener section 336 on the upper surface 338 of the first secured strap 322 above the infant's torso 316 .
The infant 310 is thereby secured safely in position on the lower end 302 of the bed mattress generally equidistant from the opposing lateral sides 340 , 342 of the bed mattress.
It can thus be seen that the applicants have provided body orienting device that may, depending on the embodiment utilized, relatively comfortably orient a body, such as a human body, with respect to other objects, particularly when the body is intended to be at rest. In this regard, the embodiments shown herein have shown particular structures for a harness. As noted above, other harness structures or configurations may be used to secure a body in position. For example, the harness may be enlarged to secure larger bodies, such as older children, infirm adults, or certain animals undergoing care.
In the embodiments such as those in which the securing element or harness is used in conjunction with a flexible, relatively thin, fleece sheet secured to a fitted or otherwise relatively secured bed sheet, such as in FIGS. 4 , 5 , and 10 - 15 for example:
reduces the risk of being kicked off or over the infant's head, thereby also reducing the risk of suffocation or breathing of oxygen reduced or depleted air; reduces the risk that the baby may slip down under the blanket, further reducing the risk of overheating or suffocation; reduces the need for excessive heating in the baby's room and further reducing the chance of overheating the baby; allows comforting airflow around the baby as it kicks to maintain a desired body temperature; positions the baby at the foot of the bed and away from the sides, thereby reducing danger of suffocation or breathing of oxygen reduced or depleted air; maintains the baby in the correct sleeping position, comfortably, while reducing the danger sudden infant death syndrome; maintains swaddling of the baby in the a soft harness, promoting increased sleep duration.
All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.
Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.
For example, the harness may be configured to consist of a central body with three corners, and each corner may have extending sections that may wrap around a separate mounting strap and secure to the strap or to themselves by mating hook and pile fastening sections or other fastener devices. In turn, the harness may be mounted to one or more separate, removable, and adjustable mounting straps secured around or to a mounting structure, such as a bed. For example, two corners of the harness might be mounted to one strap extending across a bed, and another corner mounted to another strap extending across the bed.
It is to be understood that the foregoing is a detailed description of preferred and alternative embodiments. It would be apparent to those skilled in the art that many more modifications than mentioned above are possible without departing from the invention or while implementing it. The disclosure, therefore, is not to be restricted by the foregoing detailed descriptions, and the scope of the invention is to be determined by reference to the claims as issued. | Body orienting harnesses and associated structures are disclosed, along with methods of use. The body orienting harness can position a body, such an infant, with respect to the associated structure, such as a bed, bed frame or crib, a sheet, or a blanket for example. The harness may be integrated with a sheet or blanket in order to secure not only a body in position but also secure the sheet or blanket in position with respect to the body. The sheet, blanket, or other cover, can provide a slip cover for an underlying support surface, such as a mattress for example. Alternatively, the cover can be secured in other ways to form a pocket in association with other structure, such as a bed sheet for example. The harness can be mounted in association with the pocket to secure a body in position with the respect to the pocket and associated structure, such as a mattress, crib, etc. When used to secure an infant during sleep, certain embodiments of the harness and associated structure can help significantly reduce the chance of overheating, suffocating, or otherwise harming the infant. | 0 |
BACKGROUND
This invention refers to a device for dispensing baked goods that combines with an upstream continuous baking oven.
Such devices for dispensing baked goods with an automatic continuous baking oven mounted upstream used especially for installation in supermarkets is known from EP 1 688 042 A2, for example, in which a conveyor belt running parallel to the front of a dispensing unit transports fully baked rolls to a chute through which they fall into a dispensing compartment or directly into a bag. Wider baguettes, on the other hand, are dropped forward and can be taken from a dispensing compartment.
However, there is still demand for a device allowing fast and at the same time space-saving dispensing of baked goods. Making such a device available is a task of this invention.
SUMMARY
Additional objects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.
In accordance with aspects of the invention, a device is provided for dispensing baked goods for combination with a continuous baking oven mounted upstream having a plurality of peripheral carriers for storing the baked goods, and with transfer means for transferring the baked goods from the carriers to the dispensing means. The device includes a delivery device and a dispensing compartment for transferring the baked goods from the delivery device to the dispensing compartment. The dispensing means additionally have an intermediate conveyor device, wherein the delivery device can be loaded with baked goods, on the one hand, directly by the transfer means and, on the other hand, by the intermediate conveyor device mounted between the transfer means and the delivery device.
The advantages of the invention lie especially in the fact that the delivery device can be loaded on the one hand with at least one baked good by one of the transfer means and on the other hand additional baked goods make a detour through the intermediate conveyor device before they reach the delivery device. Accordingly, the delivery device can be loaded both directly by a transfer means and by the intermediate conveyor device with at least one baked good. First of all, a transfer means loads the delivery device and after a customer request for further transfer, at least one baked good is sent to the dispensing compartment. Afterwards, the intermediate conveyor devices transport at least one additional baked good to the delivery device. Such a division saves a lot of space, but at the same time also allows an extremely fast re-supply of baked goods to the delivery device.
According to the previous paragraph, it is useful for the baked goods to be transported, on the one hand, towards the delivery device directly from one of the transfer means and, on the other hand, from the intermediate conveyor device in largely perpendicular direction to one another. This allows the device to utilize available space optimally, something that is especially important in supermarkets, where rigorous space management is the norm.
It is especially advantageous for the delivery device to be executed as a tilting conveyor, in accordance with aspects of the invention. This design allows an especially gentle diversion of the baked goods. The undesired chipping off of the crust of the baked goods is effectively prevented. In addition, a tilting conveyor occupies little space because its length can be selected according to a baked good. In particular, the swiveling axis of the tilting conveyor can run parallel to the dispensing front or—preferably—perpendicularly to it. A slide can be attached to the tilting conveyor for guiding the baked goods to a dispensing compartment.
An additional advantageous and space-saving design feature foresees the delivery device and the intermediate conveyor device to be arranged side by side—and preferably aligned flush with respect to one another—so they can have together largely the width of one carrier. In this arrangement, the delivery device and the intermediate conveyor device run advantageously parallel to the front side of the system, in which case this front side generally faces the supermarket's sales area or something similar (i.e. the customer).
Generally, the baked goods are arranged side by side on each carrier, and the carriers are oriented parallel to the dispensing front of the dispensing unit. The double loading of the delivery unit allows the transfer means to transport at least one baked good from one of the carriers directly to the delivery device, while the other baked goods on this transfer means are transported for the time being to the intermediate conveyor device. In this case, the transportation directions of the baked goods to the delivery device and to the intermediate conveyor device are the same and preferably face the dispensing front or the device's front side that faces the customer. After the delivery device has been emptied, the baked good closest to the delivery device can then be transported—parallel to the system's front side—from the intermediate conveyor device to the delivery device.
A corresponding, advantageous further development foresees the intermediate conveyor device to have at least one linear conveyor, preferably executed as conveyor belt capable of transporting the baked goods in cycles to the delivery device.
The transfer means may preferably include dropping means for the baked goods—for dropping the baked goods off the carriers, for example. These dropping means can be executed as swiveling devices that swivel a carrier in such a way that the baked goods on it slide off.
The transfer means can also be preferably executed as electronically-controlled sliders, especially for transporting the baked goods to the intermediate conveyor device and the delivery device.
An advantageous embodiment foresees the transfer means to include a temporary storage compartment for the baked goods, in which case the baked goods from the carriers are stored for the time being in this temporary storage compartment and then transported to the delivery device and the intermediate conveyor device. Such a design reduces a customer's waiting time in case all the baked goods that used to be in the delivery device and the intermediate conveyor device are sold out. Without a temporary storage compartment, the re-supply of a correspondingly loaded carrier can sometimes be time consuming owing to its travel duration and the customer might be annoyed by the ensuing waiting time.
It is advantageous if the sliders of the transfer means can be controlled independently from one another. With this feature, and depending on full or partial loading of the carriers and/or loading of the delivery device and intermediate conveyor device, a corresponding individual transfer of the individual baked goods can take place. In other words, no single slider is responsible for all baked goods that must be transported to the delivery device and intermediate conveyor device. Rather, one single slider can be provided for each baked good. Alternatively, one slider is provided for several, but not all, baked goods.
In another design also deemed as a separate aspect of the invention, the temporary storage compartment mentioned above is also provided and designed for the constant simultaneous loading of numerous baked goods, whereas for the transportation of the baked goods from the temporary storage compartment, the previously mentioned individually controllable sliders are provided. The temporary storage compartment can be loaded, for example, by a wide slider that grasps all baked goods or by a common dropping off of the baked goods from a carrier. The conveyance devices for loading the temporary storage compartment and transporting the goods from it are preferably equal.
Especially preferred is an electronic control device for controlling the movements of the carriers, the transfer means, the intermediate conveyor device and the delivery device. With correspondingly arranged sensors, the loading status of the various elements in the different positions can be measured and adjusted according to customer demands or requests.
The invention likewise applies to an automatic baking machine equipped with a continuous baking oven and to a device mounted downstream from the oven as described above.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in more detail with the help of the figures, which show schematically:
FIG. 1 a side view of a storage unit and a dispensing unit (with lateral sheathing removed) and a baking oven mounted upstream;
FIG. 2 a top view of a part of the device's dispensing unit according to FIG. 1 ;
FIG. 3 a front view of the device according to FIGS. 1 & 2 (with front sheathing removed);
FIG. 4 a partial side view of a second embodiment of a device according to the invention;
FIG. 5 a top view of a part of the dispensing unit of the device according to FIG. 4 , and
FIG. 6 a partial front view of the device according to FIGS. 4 & 5 (with front sheathing removed).
DESCRIPTION
Reference will now be made to embodiments of the invention, one or more examples of which are shown in the drawings. Each embodiment is provided by way of explanation of the invention, and not as a limitation of the invention. For example features illustrated or described as part of one embodiment can be combined with another embodiment to yield still another embodiment. It is intended that the present invention include these and other modifications and variations to the embodiments described herein.
FIGS. 1-3 show a first embodiment of a device according to the invention, in which a continuous baking oven 1 is mounted upstream of a storage unit 5 and a dispensing unit 20 . The baking oven 1 is preferably a part of an automatic baking machine for set-up in a supermarket or similar facility in which a conveyor belt 2 transports several baked goods B (here, loaves of bread B) that have been thoroughly baked and run side-by-side through the baking oven 1 to the storage unit 5 (arrow f1), where they are placed in a relatively unchanged position. In the embodiments according to the figures, each carrier 6 takes three loaves of bread B and lays them side by side. The front side areas of many carriers 6 moving peripherally (arrow f2) are attached to continuous conveyor chains 7 , which are deflected by diverting rollers 8 .
The carriers 6 have been designed for swiveling and can therefore, by a swiveling motion, deposit the baked goods B placed on them on a guiding sheet metal 10 that leads downwards (arrow f3) and faces the dispensing unit 20 . The tilting of the carriers 6 slightly above the guiding sheet metal 10 is accomplished by laterally arranged and linearly moveable cogs 9 that are moved on top of one another from their resting position in the axial direction of the carriers 6 by an electronic control when baked goods B are requested. The outer underside of the corresponding carrier 6 slides along both cogs 9 and tilts the carrier 6 (see FIG. 1 ). The baked goods B on this carrier then slide downwards (arrow f3) on the guiding sheet metal 10 , while the carrier 6 swivels back to its normal position after passing the cogs 9 , and the cogs 9 are moved to their resting position.
According to the embodiment shown in FIGS. 1-3 , the baked goods B reach two different dispensing means of the dispensing unit 20 (arrow 3 in each case) from the guiding sheet metal 10 . These are, on the one hand, an intermediate conveyor device 22 and, on the other hand, a delivery device 21 arranged beside it, here executed as tilting conveyor 21 , wherein both devices 21 , 22 run flush parallel together to the front side of the device. In this case, the intermediate conveyor device 22 picks up two loaves of bread B, while one loaf of bread B reaches the tilting conveyor 21 . An electronic control command can swivel the tilting conveyor 21 downwards when a customer requests a loaf of bread B (see especially the short dashes of the tilting conveyor 21 in FIG. 3 and the associated double arrow). Here, the bread B deposited on the tilting conveyor slides along a dispensing slide 23 (arrow f6) to a dispensing compartment 24 accessible to the customer from the front side of the device.
After swiveling to an upper position, the tilting conveyor 21 can pick up another loaf of bread B, which is transferred from the intermediate conveyor device 22 that runs electronically in cycles and is in this case executed as a linear conveyor belt, to the tilting conveyor 21 (arrow f5). The tilting conveyor 21 is preferably loaded with a new customer request without previous waiting, as it just has to be merely swiveled when the next request arrives in order to guide a loaf of bread into the dispensing compartment 24 .
When both the tilting conveyor 21 and the intermediate conveyor device 22 are empty, a corresponding command of the electronic control device (not shown) moves a carrier 6 loaded with loaves of bread B to the guiding sheet metal 8 so three loaves of bread B are dropped off to the tilting conveyor 21 and the intermediate conveyor device 22 , wherefrom a customer request can be quickly taken care of.
A second embodiment of the device according to the invention is shown in FIGS. 4-6 . Here, only partial cutouts are reproduced. The features that are not shown can especially—and readily—correspond to the embodiment shown in FIGS. 1-3 . The important difference between the two embodiments is that in the one shown in FIGS. 4-6 , a temporary storage compartment 12 has been provided that the loaves of bread B led by the guiding sheet metal 10 (arrow f3) reach for temporary storage therein. If the tilting conveyor 21 and the intermediate conveyor device 22 are empty, they can be filled without delay by the temporary storage compartment 12 (arrow f4). To achieve this, sliders 11 controlled independently from one another have been provided (shown dashed in FIG. 4 ), in which case one slider 11 each pushes one individual loaf of bread B from the temporary storage compartment 12 to the tilting conveyor 21 and the intermediate conveyor device 22 . Here, the sliding direction (arrow f4) is perpendicular to the transporting direction of the intermediate conveyor device 22 to the tilting conveyor 21 (arrow f5).
Owing to the temporary storage compartment 12 , a provision of bread B is possible that ensures a fast re-supply of the delivery device 21 when there are several customer requests following in quick succession. If after dispensing the first three loaves of bread B more than three loaves of bread B are ordered in very short intervals—without taking the position and loading of the individual carriers 6 into account—three additional loaves of bread B can be very quickly transported from the temporary storage compartment 12 on the delivery device 21 (executed here as tilting conveyor) or conveyor device 22 . The arrows f3 in FIG. 5 indicate the loading of a temporary storage compartment 12 with three additional loaves of bread B that used to be on a common carrier 6 .
The delivery device 21 with its loading options—both directly from the transfer means and indirectly by interposing the intermediate conveyor device—offers the advantage of compact and quick dispensing of the loaves of bread B. A chipping off of the bread crust is also largely prevented by the gentle forwarding of the loaves of bread B if the delivery device is additionally executed as tilting conveyor 21 , as shown here, since in this case the loaves of bread B don't have to overcome a high falling distance. Furthermore, the tilting conveyor 21 does not protrude sideways from the carriers 6 —when seen from the device's front side—so that the width of the device can be kept very low (see especially FIGS. 2 , 3 & 5 , 6 ).
The following applies to both embodiments shown in the figures: The transportation direction from the transfer means 10 or 10 , 11 & 12 onto the tilting conveyor 21 and the intermediate conveyor device 22 (arrow f3 or arrows 3 & 4), respectively, is perpendicular to the direction in which the baked goods B are being transported from the intermediate conveyor device 22 onto the tilting conveyor 21 (arrow f5).
The embodiments used as examples should not be understood as being final. Variations within the claims are certainly possible. Thus, for example, sliders for emptying the carriers can be provided. The intermediate conveyor device can also be executed as one or several tilting conveyors. In addition, the delivery device does not necessarily have to be executed as a tilting conveyor, even if this design is currently preferred owing to the gentle forwarding of the baked goods. | The invention relates to a device for distributing baked goods, for combining with a continuous baking oven ( 1 ) arranged upstream of said device, said device comprising a plurality of peripheral carriers ( 6 ) for storing the baked goods (B), and transfer means ( 9, 10, 11, 12 ) for transferring the baked goods (B) from the carriers ( 6 ) to the dispensing means ( 21, 22, 23, 24 ) comprising a distribution device ( 21 ) and a dispensing compartment ( 24 ) for transferring the baked goods (B) from the distribution device ( 21 ) to the dispensing compartment ( 24 ). The device according to the invention is characterized in that the dispensing means ( 21, 22, 23, 24 ) also comprise an intermediate conveyor device ( 22 ), the distribution device ( 21 ) being loaded with baked goods (B) directly from the transfer means ( 9, 10, 11, 12 ) and also from the intermediate conveyor device ( 22 ) arranged between the transfer means ( 9, 10, 11, 12 ) and the distribution device ( 21 ). | 0 |
This application claims priority to U.S. Provisional application 60/150,488 filed Aug. 24, 1999 now abandoned.
TECHNICAL FIELD
The present invention relates generally to the biosynthesis of glycans found as free oligosaccharides or covalently bound to proteins and glycolipids. In particular, this invention relates to a family of nucleic acids encoding UDP-N-acetylglucosamine: N-acetylgalactosamine-β1,6-N-acetylglucosaminyltransferases (Core-β1,6-N-acetylglucosaminyltransferases), which add N-acetylglucosamine to the hydroxy group at C6 of 2-acetamido-2-deoxy-D-galactosamine (GalNAc) in O-glycans of the core 1 and the core 3 type thereby forming the core 2 and core 4 types. Previously two members of this family have been identified and designated C2GnT1 and C2GnT2.
This invention is more particularly related to a gene encoding a third member of this family of O-glycan β1,6-N-acetylglucosaminyltransferases, termed C2GnT3, probes to the DNA encoding C2GnT3, DNA constructs comprising DNA encoding C2GnT3, recombinant plasmids and recombinant methods for producing C2GnT3, recombinant methods for stably transforming or transfecting cells for expression of C2GnT3, methods for identification of agents with the ability to inhibit or stimulate C2GnT3 biological activity, and methods for identification of DNA polymorphism in patients. In the U.S. Provisional patent application No. 60/150,488 filed on Aug. 24, 1999, from which the present application claims priority, this novel Core 2 β6GlcNAc-transferase isoform was identified and designated C2GnTII. The designation C2GnTII has here been replaced by the designation C2GnT3 in accordance with its scientific publication (14).
BACKGROUND OF THE INVENTION
O-linked protein glycosylation involves an initiation stage in which a family of N-acetylgalactosaminyltransferases catalyzes the addition of N-acetylgalactosamine to Serine or Threonine residues (1). Further assembly of O-glycan chains involves several sucessive or alternative biosynthetic reactions: i) formation of simple mucin-type core 1 structures by UDP-Gal: GalNAcα-R β1,3Gal-transferase activity; ii) conversion of core 1 to complex-type core 2 structures by UDP-GlcNAc: Galβ1-3GalNAcα-R β1,6GlcNAc-transferase activities; iii) direct formation of complex mucin-type core 3 by UDP-GlcNAc: GalNAcα β1,3GlcNAc-transferase activities; and iv) conversion of core 3 to core 4 by UDP-GlcNAc: GlcNAcβ1-3GalNAcα-R β1,6GlcNAc-transferase activity. The formation of β1,6GlcNAc branches (reactions ii and iv) may be considered a key controlling event of O-linked protein glycosylation leading to structures produced upon differentiation and malignant transformation (2-6). For example, increased formation of GlcNAc□1-6GalNAc branching in O-glycans has been demonstrated during T-cell activation, during the development of leukemia, and for immunodeficiencies like Wiskott-Aldrich syndrome and AIDS (7; 8). Core 2 branching may play a role in tumor progression and metastasis (9). In contrast, many carcinomas show changes from complex O-glycans found in normal cell types to immaturely processed simple mucin-type O-glycans such as T (Thomsen-Friedenreich antigen; Galβ1-3GalNAcα1-R), Tn (GalNAcα1-R), and sialosyl-Tn (NeuAcα2-6GalNAcα1-R) (10). The molecular basis for this has been extensively studied in breast cancer, where it was shown that specific downregulation of a core 2 β6GlcNAc-transferase was responsible for the observed lack of complex type O-glycans on the mucin MUC1 (6). O-glycan core assembly may therefore be controlled by inverse changes in the expression level of Core-β1,6-N-acetylglucosaminyl-transferases and the sialyltransferases forming sialyl-T and sialyl-Tn.
Interestingly, the metastatic potential of tumors has been correlated with increased expression of core 2 β6GlcNAc-transferase activity (5). The increase in core 2 β6GlcNAc-transferase activity was associated with increased levels of poly N-acetyllactosamine chains carrying sialyl-Le x , which may contribute to tumor metastasis by altering selectin-mediated adhesion (4; 11). The control of O-glycan core assembly is regulated by the expression of key enzyme activities; however, epigenetic factors including posttranslational modification, topology, or competition for substrates may also play a role in this process (11).
Changes in surface carbohydrates of T-cells have been identified during development and activation. O-glycan branches of the core 2 type are restricted to immature thymocytes of the thymal cortex but are no longer exposed on the surface of mature medullary thymocytes (17). Core 2 structures on T-cell surface proteins are ligands for the S-type lectin galectin-1, which participates in thymocyte - thymic epithelia interaction (18). The elimination of Core 2 structures from the thymocyte cell surface was found to be essential for controlled apoptosis mediated by galectin-1 (19).
Core 2 β6GlcNAc-transferase activity is carried out by more than one enzyme isoform. The first Core 2 β6GlcNAc-transferase isoform was initially identified as a critical enzyme in blood cell development and differentiation and designated leukocyte form or L-Form (C2GnT-L)(12). The gene encoding C2GnT-L has been cloned by expression cloning from a cDNA library of the human promyelocytic leukemia cell line HL-60 (13). This gene has now been renamed as C2GnT1 (14). Using the C2GnT1 sequence as a probe for BLAST analysis of the human expressed sequence tag database, a homologous gene encoding a second Core 2 β6GlcNAc-transferase isoform has been identified and designated C2/4GnT (15) and C2GnT-M (I16). This gene has now been renamed as C2GnT2 (14).
C2GnT1 was predicted to control synthesis of core 2 selectin ligands in leukocytes and lymphoid tissues, however, mice deficient in C2GnT1 exhibited only partial reduction in selectin ligand production and no significant changes in lymphocyte homing properties (Ellies, L. G., et al. 1998, Immunity 9: 881-890). One possible explanation for these results would be the expression of additional Core 2 β6GlcNAc-transferases. C2GnT2 does not appear to be a candidate, as its expression pattern is restricted to mucous secreting organs (15, 16).
Consequently, there exists a need in the art for detecting as yet unidentified UDP-N-acetylglucosamine: Galactose-β1,3-N-acetylgalactosamine-α-R (GlcNAc to GalNAc) β1-6 N-acetylglucosaminyltransferases and identifying the primary structures of the genes encoding such enzymes. The present invention meets this need, and further presents other related advantages.
SUMMARY OF THE INVENTION
The present invention provides isolated nucleic acids encoding human UDP-N-acetylglucosamine: N-acetylgalactosamine β1,6 N-acetylglucosaminyltransferase 3 (C2GnT3), including cDNA and genomic DNA. C2GnT3 has acceptor substrate specificities comparable to C2GnT1 (14). The complete nucleotide sequence encoding C2GnT3 is set forth in SEQ ID NO: 1 and in FIG. 1 .
Variations in one or more nucleotides may exist among individuals within a population due to natural allelic variation. Any and all such nucleic acid variations are within the scope of the invention. DNA sequence polymorphisms may also occur which lead to changes in the amino acid sequence of a C2GnT3 polypeptide. These amino acid polymorphisms are also within the scope of the present invention. In addition, species variations i.e. variations in nucleotide sequence naturally occurring among different species, are within the scope of the invention.
Among Core 2 β6GlcNAc-transferases, C2GnT3 appears to be the dominant isoform in thymus (14). Thus, C2GnT3 is likely to have important functions during thymocyte development as well as T-cell maturation and homing (14). The identification of agents with the ability to inhibit or stimulate C2GnT3 enzymatic activity therefore has the potential for both diagnostic and therapeutic purposes of related diseases.
Access to the gene encoding C2GnT3 allows production of a glycosyltransferase for use in formation of core 2-based O-glycan modifications on oligosaccharides, glycoproteins and glycosphingolipids. This enzyme can be used, for example, in pharmaceutical or other commercial applications that require synthetic addition of core 2-based O-glycans to these or other substrates, in order to produce appropriately glycosylated glycoconjugates having particular enzymatic, immunogenic, or other biological and/or physical properties.
In one aspect, the invention encompasses isolated nucleic acids comprising the nucleotide sequence of nucleotides 1-1362 as set forth in FIG. 1 or sequence-conservative or function-conservative variants thereof. Also provided are isolated nucleic acids hybridizable with nucleic acids having the sequence as set forth in FIG. 1 or fragments thereof or sequence-conservative or function-conservative variants thereof, preferably, the nucleic acids are hybridizable with C2GnT3 sequences under conditions of intermediate stringency, and, most preferably, under conditions of high stringency. In one embodiment, the DNA se-quence encodes the amino acid sequence shown in FIG. 1, from methionine (amino acid no. 1) to serine (amino acid no. 453). In another embodiment, the DNA sequence encodes an amino acid sequence comprising a sequence from proline (no. 39) to serine (no.453) of the amino acid sequence set forth in FIG. 1 .
In a related aspect, the invention provides nucleic acid vectors comprising C2GnT3 DNA sequences, including but not limited to those vectors in which the C2GnT3 DNA sequence is operably linked to a transcriptional regulatory element, with or without a polyadenylation sequence. Cells comprising these vectors are also provided, including without limitation transiently and stably expressing cells. Viruses, including bacteriophages, comprising C2GnT3-derived DNA sequences are also provided. The invention also encompasses methods for producing C2GnT3 polypeptides. Cell-based methods include without limitation those comprising: introducing into a host cell an isolated DNA molecule encoding C2GnT3, or a DNA construct comprising a DNA sequence encoding C2GnT3; growing the host cell under conditions suitable for C2GnT3 expression; and isolating C2GnT3 produced by the host cell. A method for generating a host cell with de novo stable expression of C2GnT3 comprises: introducing into a host cell an isolated DNA molecule encoding C2GnT3 or an enzymatically active fragment thereof (such as, for example, a polypeptide comprising amino acids 39-453 of the sequence set forth FIG. 1 ), or a DNA construct comprising a DNA sequence encoding C2GnT3 or an enzymatically active fragment thereof; selecting and growing host cells in an appropriate medium; and identifying stably transfected cells expressing C2GnT3. The stably transfected cells may be used for the production of C2GnT3 enzyme for use as a catalyst and for recombinant production of peptides or proteins with appropriate glycosylation. For example, eukaryotic cells, whether normal or diseased cells, having their glycosylation pattern modified by stable transfection as above, or components of such cells, may be used to deliver specific glycoforms of glycopeptides and glycoproteins, such as, for example, as immunogens for vaccination.
In yet another aspect, the invention provides isolated C2GnT3 polypeptides, including without imitation polypeptides having the sequence set forth in FIG. 1, polypeptides having the sequence of amino acids 39-453 as set forth in FIG. 1, and a fusion polypeptide consisting of at least amino acids 39-453 as set forth in FIG. 1 used in frame to a second sequence, which may be any sequence that is compatible with retention of C2GnT3 enzymatic activity in the fusion polypeptide.
Suitable second sequences include without limitation those comprising an affinity ligand or a reactive group.
In a related aspect, methods are disclosed for the identification of agents with the ability to inhibit or stimulate the enzymatic activity of C2GnT3. Assays utilizing C2GnT3 to screen for potential inhibitors or stimulators thereof are encompassed by the invention. Furthermore, methods of using C2GnT3 in the structure-based design of inhibitors or stimulators thereof are also an aspect of the invention. Such a design would comprise the steps of determining the three-dimensional structure of the C2GnT3 polypeptide, analyzing the three-dimensional structure for the likely binding sites of donor and/or acceptor substrates, synthesis, of a molecule that incorporates a predictive reactive site, and determining the inhibiting or stimulating activity of the molecule.
In another aspect of the present invention, methods are disclosed for screening for mutations in the coding region of the C2GnT3 gene using genomic DNA isolated from, e.g., blood cells of patients. In one embodiment, the method comprises: isolation of DNA from a patient; PCR amplification of the coding exon; DNA sequencing of amplified exon DNA fragments and establishing therefrom potential structural defects of the C2GnT3 gene associated with disease.
In accordance with an aspect of the invention there is provided a method of, and products for (i.e. kits), diagnosing and monitoring conditions mediated by C2GnT3 by determining, in a biological sample, the presence of nucleic acid molecules and polypeptides of the invention.
Still further the invention provides a method for evaluating a test compound for its ability to modulate the biological activity of a C2GnT3 polypeptide of the invention. For example, a substance that inhibits or enhances the catalytic activity of a C2GnT3 polypeptide may be evaluated. “Modulate” refers to a change or an alteration in the biological activity of a polypeptide of the invention. Modulation may be an increase or a decrease in activity, a change in characteristics, or any other change in the biological, functional, or immunological properties of the polypeptide.
Compounds which modulate the biological activity of a polypeptide of the invention may also be identified using the methods of the invention by comparing the pattern and level of expression of a nucleic acid molecule or polypeptide of the invention in biological samples, tissues and cells, in the presence, and in the absence of the compounds.
In an embodiment of the invention a method is provided for screening a compound for effectiveness as an antagonist of a polypeptide of the invention, comprising the steps of a) contacting a sample containing said polypeptide with a compound, under conditions wherein antagonist activity of said polypeptide can be detected, and b) detecting antagonist activity in the sample.
Methods are also contemplated that identify compounds or substances (e.g. polypeptides), which interact with C2GnT3 nucleic acid regulatory sequences (e.g. promoter sequences, enhancer sequences, negative modulator sequences).
The nucleic acids, polypeptides, and substances and compounds identified using the methods of the invention, may be used to modulate the biological activity of a C2GnT3 polypeptide of the invention, and they may be used in the treatment of conditions mediated by C2GnT3 such as proliferative diseases including cancer, and thymus-related disorders. Accordingly, the nucleic acids, polypeptides, substances and compounds may be formulated into compositions for administration to individuals suffering from one or more of these conditions. Therefore, the present invention also relates to a composition comprising one or more of a polypeptide, nucleic acid molecule, or substance or compound identified using the methods of the invention, and a pharmaceutically acceptable carrier, excipient or diluent. A method for treating or preventing these conditions is also provided comprising administering to a patient in need thereof, a composition of the invention.
The present invention in another aspect provides means necessary for production of gene-based therapies directed at the thymus. These therapeutic agents may take the form of polynucleotides comprising all or a portion of a nucleic acid of the invention comprising a regulatory sequence of a C2GnT3 nucleic acid placed in appropriate vectors or delivered to target cells in more direct ways.
Having provided a novel C2GnT3, and nucleic acids encoding same, the invention accordingly further provides methods for preparing oligosaccharides. In specific embodiments, the invention relates to a method for preparing an oligosaccharide comprising contacting a reaction mixture comprising a donor substrate, and an acceptor substrate in the presence of a C2GnT3 polypeptide of the invention.
In accordance with a further aspect of the invention, there are provided processes for utilizing polypeptides or nucleic acid molecules, for in vitro purposes related to scientific research, synthesis of DNA, and manufacture of vectors.
These and other aspects of the present invention will become evident upon reference to the following detailed description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts the DNA sequence of the C2GnT3 gene (accession # AF132035; SEQ ID NO: 1) and the predicted amino acid sequence of C2GnT3 (SEQ ID NO: 2). The amino acid sequence is shown in single letter code. The hydrophobic segment representing the putative transmembrane domain is double underlined. Four consensus motifs for N-glycosylation are indicated by asterisks. The location of the primers used for preparation of the expression constructs are indicated by single underlining.
FIG. 2 is an illustration of a sequence comparison between human C2GnT3 (accession # AF132035; SEQ ID NO: 2), human C2GnT2 (formerly designated C2/4GnT; accession # AF038650; SEQ ID NO: 15), human C2GnT1 (formerly designated C2GnT-L; accession # M97347; SEQ ID NO: 13), and human IGnT (accession # Z19550; SEQ ID NO: 17). Introduced gaps are shown as hyphens, and aligned identical residues are boxshaded (black for all sequences, dark grey for three sequences, and light grey for two sequences). The putative transmembrane domains are boxed. The positions of conserved cysteines are indicated by asterisks. One conserved N-glycosylation site is indicated by an open circle. The corresponding nucleotide sequences are SEQ ID NO: 1 (C2GnT3); SEQ ID NO: 14 (C2GnT2), SEQ ID NO: 12 (C2GnT1), and SEQ ID NO: 16 (IGnT).
FIGS. 3A-3C depicts Northern blot analyses of healthy human adult and fetal tissues. Panel A: loading pattern for the human mRNA master blot (CLONTECH). Dots in row H contain 100 ng (H1-H7) or 500 ng (H8) of control DNA or RNA. Panel B: autoradiogram of master blot expression analysis using a 32 P-labeled C2GnT3 probe corresponding to the soluble expression fragment of C2GnT3 (base pairs 115-1359). Panel C: A multiple human tissue northern blot (MTN II from Clontech) was probed as described for panel B.
FIG. 4 shows a PCR analysis of C2GnT3 expression in human blood cell fractions. PCR amplifications with primers specific for human C2GnT3 (C2GnT3) or GAPDH (G3PDH) were performed on a normalized human blood cell cDNA panel (MTC from Clontech) for 3 1 cycles.
FIG. 5 is a schematic representation of forward and reverse PCR primers that can be used to amplify the coding exon of the C2GnT3 gene. The sequences of the primers TSHC119 and TSHC123 are also shown.
DETAILED DESCRIPTION OF THE INVENTION
All patent applications, patents, and literature references cited in this specification are hereby incorporated by reference in their entirety. In the case of conflict, the present description, including definitions, is intended to control.
Definitions
1. “Nucleic acid” or “polynucleotide” as used herein refers to purine- and pyrimidine-containing polymers of any length, either polyribonucleotides or polydeoxyribonucleotides or mixed polyribo-polydeoxyribo nucleotides. This includes single- and double-stranded molecules, i.e., DNA—DNA, DNA-RNA and RNA—RNA hybrids, as well as “protein nucleic acids” (PNA) formed by conjugating bases to an amino acid backbone. This also includes nucleic acids containing modified bases (see below).
2. “Complementary DNA or cDNA” as used herein refers to a DNA molecule or sequence that has been enzymatically synthesized from the sequences present in a mRNA template, or a clone of such a DNA molecule. A “DNA Construct” is a DNA molecule or a clone of such a molecule, either single- or double-stranded, which has been modified to contain segments of DNA that are combined and juxtaposed in a manner that would not otherwise exist in nature. By way of non-limiting example, a cDNA or DNA which has no introns, i.e., is free from non-coding sequences, is inserted adjacent to, or within, exogenous (e.g., heterologous) DNA sequences.
3. A plasmid or, more generally, a vector or “expression vector”, is a DNA construct containing genetic information that may provide for its replication when inserted into a host cell. A plasmid generally contains at least one gene sequence to be expressed in the host cell, as well as sequences that facilitate such gene expression, including promoters and transcription initiation sites. It may be a linear or closed circular molecule. Inserted coding sequences do not occur naturally in the organism from which the vector is derived.
4. Nucleic acids are “hybridizable” to each other when at least one strand of one nucleic acid can anneal to another nucleic acid under defined stringency conditions. Stringency of hybridization is determined, e.g., by a) the temperature at which hybridization and/or washing is performed, and b) the ionic strength and polarity (e.g., formamide) of the hybridization and washing solutions, as well as other parameters. Hybridization requires that the two nucleic acids contain substantially complementary sequences; depending on the stringency of hybridization, however, mismatches may be tolerated. Typically, hybridization of two sequences at high stringency (such as, for example, in an aqueous solution of 0.5X SSC, at 65° C.) requires that the sequences exhibit some high degree of complementarity over their entire sequence. Conditions of intermediate stringency (such as, for example, an aqueous solution of 2X: SSC at 65° C.) and low stringency (such as, for example, an aqueous solution of 2X SSC at 55° C.), require correspondingly less overall complementarily between the hybridizing sequences. (1X SSC is 0.15 M NaCl, 0.015 M Na citrate).
5. An “isolated” nucleic acid or polypeptide as used herein refers to a component that is removed from its original environment (for example, its natural environment if it is naturally occurring). An isolated nucleic acid or polypeptide contains less than about 50%, preferably less than about 75%, and most preferably less than about 90%, of the cellular components with which it was originally associated.
6. A “probe” refers to a nucleic acid that forms a hybrid structure with a sequence in a target region due to complementarily of at least one sequence in the probe with a sequence in the target region.
7. A nucleic acid that is “derived from” a designated sequence refers to a nucleic acid sequence that corresponds to a region of the designated sequence. This encompasses sequences that are homologous, or complementary to the sequence, as well as “sequence-conservative variants” and “function-conservative variants”. Sequence-conservative variants are those in which a change of one or more nucleotides in a given codon position results in no alteration in the amino acid encoded at that position. Function-conservative variants of C2GnT3 are those in which a given amino acid residue in the polypeptide has been changed without altering the overall conformation and enzymatic activity (including substrate specificity) of the native polypeptide; these changes include, but are not limited to, replacement of an amino acid with one having similar physico-chemical properties (such as, for example, acidic, basic, hydrophobic, and the like).
8. A “donor substrate” is a molecule recognized by, e.g., a Core-β1,6-N-acetylglucosaminyltransferase and that contributes an N-acetylglucosaminyl moiety for the transferase reaction. For C2GnT3, a donor substrate is UDP-N-acetylglucosamine. An “acceptor substrate” is a molecule, preferably a saccharide or oligosaccharide, that is recognized by, e.g., an N-acetylglucosaminyltransferase and that is the target for the modification catalyzed by the transferase, i.e., receives the N-acetylglucosaminyl moiety. For C2GnT3, acceptor substrates include without limitation oligosaccharides, glycoproteins, O-linked core 1-glycopeptides, and glycosphingolipids comprising the sequences Galβ1-3GalNAc, or GlcNAcβ1-3GalNAc.
9. In accordance with the present invention there may be employed conventional molecular biology, microbiology, and recombinant DNA techniques within the skill of the art. Such techniques are explained fully in the literature. See for example, Sambrook, Fritsch, Maniatis, Molecular Cloning: A Laboratory Manual, Second Edition (1989) Cold Spring Harbor Laboratory Press, Cold Spring Harbor, N.Y.), DNA Cloning: A Practical Approach, Volumes I and II (D. N. Glover ed. 1985); Oligonucleotide Synthesis (M. J. Gait ed. 1984); Nucleic Acid Hybridization B. D. Hames & S. J. Higgins eds. (1985); Transcription and Translation B. D. Haimes & S. J. Higgins eds (1984); Animal Cell Culture R. I. Freshney, ed. (1986); Immobilized Cells and enzymes IRL Press, (1986); and B. Perbal, A Practical Guide to Molecular Cloning (1984).
10. The terms “sequence similarity” or “sequence identity” refer to the relationship between two or more amino acid or nucleic acid sequences, determined by comparing the sequences, which relationship is generally known as “homology”. Identity in the art also means the degree of sequence relatedness between amino acid or nucleic acid sequences, as the case may be, as determined by the match between strings of such sequences. Both identity and similarity can be readily calculated (Computational Molecular Biology, Lesk, A. M., ed., Oxford University Press New York, 1988; Biocomputing: Informatics and Genome Projects, Smith, D. W. ed., Academic Press, New York, 1993;Computer Analysis of Sequence Data, Part I, Griffin, A. M., and Griffin, H. G. eds. Humana Press, New Jersey, 1994; Sequence Analysis in Molecular Biology, von Heinje, G., Academic Press, New York, 1987; and Sequence Analysis Primer, Gribskov, M. and Devereux, S., eds. M. Stockton Press, New York, 1991). While there are a number of existing methods to measure identity and similarity between two amino acid sequences or two nucleic acid sequences, both terms are well known to the skilled artisan (Sequence Analysis in Molecular Biology, von Hinge, G., Academic Press, New York, 1987; Sequence Analysis Primer, Gribskov, M. and Devereux, J., eds. M. Stockton Press, New York, 1991; and Carillo, H., and Lipman, D. SIAM J. Applied Math., 48 1073, 1988). Preferred methods for determining identity are designed to give the largest match between the sequences tested. Methods to determine identity are codified in computer programs. Preferred computer program methods for determining identity and similarity between two sequences include but are not limited to the GCG program package (20), BLASTP, BLASTN, and FASTA (21). Identity or similarity may also be determined using the alignment algorithm of Dayhoff et al. (Methods in Enzymology 91: 524-545 (1983)].
Preferably the nucleic acids of the present invention have substantial sequence identity using the preferred computer programs cited herein, for example greater than 40%, 45%, 50%, 60%, 70%, 75%, 80%, 85%, or 90% identity; more preferably at least 95%, 96%, 97%, 98%, or 99% sequence identity to the sequence shown in SEQ ID NO: 1 and FIG. 1 .
11. The polypeptides of the invention also include homologs of a C2GnT3 polypeptide and/or truncations thereof as described herein. Such homologs include polypeptides whose amino acid sequences are comprised of the amino acid sequences of C2GnT3 polypeptide regions from other species that hybridize under selected hybridization conditions (see discussion of hybridization conditions in particular stringent hybridization conditions herein) with a probe used to obtain a C2GnT3 polypeptide. These homologs will generally have the same regions which are characteristic of a C2GnT3 polypeptide. It is anticipated that a polypeptide comprising an amino acid sequence which has at least 40% identity or at least 60% similarity, preferably at least 60-65% identity or at least 80-85% similarity, more preferably at least 70-80% identity or at least 90-95% similarity, most preferably at least 95% identity or at least 99% similarity with the amino acid sequence shown in SEQ ID NO: 2 and FIGS. 1 and 2, will be a homolog of a C2GnT3 polypeptide. A percent amino acid sequence similarity or identity is calculated using the methods described herein, preferably the computer programs described herein.
Identification and Cloning of C2GnT3
The present invention provides the isolated DNA molecules, including genomic DNA and cDNA, encoding the UDP-N-acetylglucosamine: N-acetylgalactosamine β1,6 N-acetylglucosaminyl-transferase 3 (C2GnT3).
C2GnT3 was identified by analysis of genomic survey sequences (GSS), and cloned based on a genomic clone obtained from a human foreskin fibroblast library. The cloning strategy may be briefly summarized as follows. 1) isolation and sequencing of GSS clone CIT-HSP-2288B17.TF (GSS GenBank accession number AQ005888); 2) synthesis of oligonucleotides derived from GSS sequence information, designated TSHC96 and TSHC101; 3) identification, cloning and sequencing of genomic P1 clone GS22597 #844/B1; 4) identification of a novel cDNA sequence corresponding to C2GnT3; 5) confirmatory sequencing of a cDNA clone obtained by reverse-transcription-polymerase chain reaction (RT-PCR) using human thymus poly A-mRNA; 6) construction of expression constructs; 7) expression of the cDNA encoding C2GnT3 in Sf9 (Spodoptera frugiperda) cells. More specifically, the isolation of a representative DNA molecule encoding a novel third member of the mammalian UDP-N-acetylglucosamine: β-N-actylgalactosamine β1,6-N-acetylglucosaminyltransferase family involved the following procedures described below.
Identification of DNA Homologous to C2/4GnT (C2GnT2)
Database searches were performed with the coding sequence of the human C2/4GnT (C2GnT2) sequence (13) using the BLASTn and the tBLASTn algorithm with the GSS database at The National Center for Biotechnology Information, USA. The BLASTn algorithm was used to identify clones representing the query gene (identities of ≧95%), whereas tBLASTn was used to identify non-identical, but similar GSS sequences. GSSs with 50-90% nucleotide sequence identity were regarded as different from the query sequence. Two GSS clones with several apparent short sequence motifs and cysteine residues arranged with similar spacing were selected for further sequence analysis.
Cloning of Human C2GnT3
GSS clone CIT-HSP-2288B17.TF (GSS GenBank accession number AQ005888), derived from a putative homologue to C2/4GnT (C2GnT2), was obtained from Research Genetics Inc., USA. Sequencing of this clone revealed a partial open reading frame with significant sequence similarity to C2/4GnT (C2GnT2). The coding region of human C2GnT-L (C2GnT1), C2/4GnT (C2GnT2) and a bovine homologue was previously found to be organized in one exon ((22),(15)). Since the 3′ sequence available from the C2GnT3 GSS was incomplete but likely to be located in a single exon, the missing 3′ portion of the open reading frame was obtained by sequencing a genomic P1 clone. The P1 clone was obtained from a human foreskin genomic P1 library (DuPont Merck Pharmaceutical Co. Human Foreskin Fibroblast P1 Library) by screening with the primer pair:
TSHC96 (5′-GGTTTCACCGTCTCCAACATA-3′, SEQ ID NO: 3) and
TSHC101 (5′-TCGTAAGGCACCTGATACTT-3′, SEQ ID NO: 6).
One genomic clone for C2GnT3, GS22597 #844/B1 was obtained from Genome Systems Inc. DNA from P1 phage was prepared as recommended by Genome Systems Inc. The entire coding sequence of the C2GnT3 gene was represented in the clone and sequenced in full using automated sequencing (ABI377, Perkin-Elmer). Confirmatory sequencing was performed on a cDNA clone obtained by PCR (30 cycles at 95° C. for 10 sec; 55 ° C. for 15 sec and 68 ° C. for 2 min 30 sec) on cDNA from human thymus poly A-mRNA with the sense primer:
TSHC99 (5′- CGAGGATCCAGAATGAAGATATTCAAATGTTA-3′, SEQ ID NO: 4), and the anti-sense primer
TSHC121 (5′-AGCGAATTCTTACTATCATGATGTGGTAGTG-3′, SEQ ID NO: 9).
The composite sequence contained an open reading frame of 1359 base pairs encoding a putative protein of 453 amino acids with type II domain structure predicted by the TMpred-algorithm at the Swiss Institute for Experimental Cancer Research (ISREC).
(http://www.ch.embnet.org/software/TNPRED_form. html).
Expression of C2GnT3
An expression construct designed to encode amino acid residues 39-453 of C2GnT3 was prepared by PCR using P1 DNA, and the primer pair:
TSHC100 (5′-CGAGGATCCGCAAAAAGACATTTACTTGGTT -3′, SEQ ID NO: 5) and
TSHC121 (5′-AGCGAATTCTTACTATCATGATGTGGTAGTG-3′, SEQ ID NO: 9) with BamH1 and EcoRI restriction sites, respectively (FIG. 2 ). The PCR product was cloned between the BamHI and EcoRI sites of pAcGP67A (PharMingen), and the insert was fully sequenced. pAcGP67-C2GnT3-sol was co-transfected with Baculo-Gold™ DNA (PharMingen) as described previously (23). Recombinant Baculovirus was obtained after two successive amplifications in Sf9 cells grown in serum-containing medium, and titers of virus were estimated by titration in 24-well plates with monitoring of enzyme activities. Transfection of Sf9-cells with pAcGP67-C2GnT3-sol resulted in marked increase in GlcNAc-transferase activity compared to uninfected cells or cells infected with a control construct. C2GnT3 showed significant activity with disaccharide derivatives of O-linked core 1 (Galβ2-3GalNAcα1-R). In contrast, no activity was found with core 3 structures (GlcNAcβ1-3GalNAcα1-R), lacto-N-neotetraose as well as GlcNAcβ1-3Gal-Me as acceptor substrates indicating that C2GnT3 has no Core4GnT and IGnT-activity. Additionally, no activity could be detected wih α-D-GalNAc-1- para-nitrophenyl indicating that C2GnT3 does not form core 6 (GlcNAcβ1-6GalNAcα1-R) (Table I). No substrate inhibition of enzyme activity was found at high acceptor concentrations up to 20 mM core 1-para-nitrophenyl. C2GnT3 shows strict donor substrate specificity for UDP-GlcNAc, no activity could be detected with UDP-Gal or UDP-GalNAc (data not shown).
TABLE I
Substrate specificities of C2GnT3 and C2GnT1
C2GnT3 a
C2GnT1
Substrate
2 mM
10 mM
2 mM
10 mM
nmol/h/mg
nmol/h/mg
β-D-Gal-(1-3)-α-D-GalNAc
6.6
14.3
9.6
19.0
β-D-Gal-(1-3)-α-D-GalNAc-1-
18.1
26.1
16.2
23.6
p-Nph
β-D-GlcNAc-(1-3)-α-D-GalNAc-
<0.1
<0.1
<0.1
<0.1
1-p-Nph
α-D-GalNAc-1-p-Nph
<0.1
<0.1
<0.1
<0.1
D-GalNAc
<0.1
<0.1
<0.1
<0.1
lacto-N-neo-tetraose
<0.1
<0.1
<0.1
<0.1
β-D-GlcNAc-(1-3)-β-D-Gal-1-Me
<0.1
<0.1
<0.1
<0.1
a Enzyme sources were partially purified media of infected High Five ™ cells (see “Experimental Procedures”). Background values obtained with uninfected cells or cells infected with an irrelevant construct were subtracted.
b Me, methyl; Nph, nitrophenyl.
Controls included the pAcGP67-GalNAc-T3-sol (24). The kinetic properties were determined with partially purified enzymes expressed in High Five™ cells. Partial purification was performed by consecutive chromatography on Amberlite IRA-95, DEAE-Sephacryl and SP-Sepharose essentially as described (25; 25).
Northern Blot Analysis of Human Organs
A human RNA master blot containing mRNA from fifty healthy human adult and fetal organs (CLONTECH) and a human multiple tissue northern blot (MTNII from CLONTECH) were probed with a 32 P-labeled probe corresponding to the soluble fragment of C2GnT3 (base pairs 115-1359). The autoradiographic analyses showed expression of C2GnT3 predominantly in lymphoid organs and in organs of the gastrointestinal tract with high transcription levels observed in thymus, and lower levels in PBLs, lymph node, stomach, pancreas and small intestine (FIG. 3 A and 3 B). The size of the single transcript was approximately 5.5 kilobases, which correlates to the transcript size of 5.4 kilobases of the biggest of three transcripts of human C2GnT1 (FIG. 3 C). Multiple transcripts of C2GnT1 have been suggested to be caused by differential usage of polyadenylation signals, which affects the length of the 3′ UTR (13).
The C2GnT3 enzyme of the present invention was shown to exhibit O-glycosylation capacity implying that the C2GnT3 gene is vital for correct/full O-glycosylation in vivo as well. A structural defect in the C2GnT3 gene leading to a deficient enzyme or completely defective enzyme would therefore expose a cell or an organism to protein/peptide sequences which were not covered by O-glycosylation as seen in cells or organisms with intact C2GnT3 gene. Described in Example 5 below is a method for scanning the coding exon for potential structural defects. Similar methods could be used for the characterization of defects in the non-coding region of the C2GnT3 gene including the promoter region.,
DNA, Vectors, and Host Cells
In practicing the present invention, many conventional techniques in molecular biology, microbiology, recombinant DNA, and immunology, are used. Such techniques are well known and are explained fully in, for example, Sambrook et al., 1989, Molecular Cloning A Laboratory Manual, Second Edition, Cold Spring Harbor Laboratory Press, Cold Spring Harbor, N.Y.; DNA Cloning: A Practical Approach, Volumes I and II, 1985 (D. N. Glover ed.); Oligonucleotide Synthesis, 1984, (M. L. Gait ed.); Nucleic Acid Hybridization, 1985, (Hames and Higgins); Transcription and Translation, 1984 (Harmes and Higgins eds.); Animal Cell Culture, 1986 (.I. Freshney ed.); Immobilized Cells and Enzymes, 1986 (IRL Press); Perbal, 1984, A Practical Guide to Molecular Cloning, the series, Methods in Enzymology (Academic Press, Inc.); Gene Transfer Vectors for Mammalian Cells, 1987 (J. H. Miller and M. P. Calos eds., Cold Spring Harbor Laboratory); Methods in Enzymology Vol. 154 and Vol. 155 (Wu and Grossman, and Wu, eds., respectively); Immunochemical Methods in Cell and Molecular Biology, 1987 (Mayer and Waler, eds; Academic Press,. London); Scopes, 1987, Protein Purification: Principles and Practice, Second Edition (Springer-Verlag, N.Y.) and Handbook of Experimental Immunology, 1986, Volumes I-IV (Weir and Blackwell eds.).
The invention encompasses isolated nucleic acid fragments comprising all or part of the nucleic acid sequence disclosed herein as set forth in FIG. 1 . The fragments are at least about 8 nucleotides in length, preferably at least about 12 nucleotides in length, and most preferably at least about 15-20 nucleotides in length. The invention further encompasses isolated nucleic acids comprising sequences that are hybridizable under stringency conditions of 2X SSC, 55° C., to the sequence set forth in FIG. 1; preferably, the nucleic acids are hybridizable at 2X SSC, 65 ° C.; and most preferably, are hybridizable at 0.5X SSC, 65° C.
The nucleic acids may be isolated directly from cells. Alternatively, the polymerase chain reaction (PCR) method can be used to produce the nucleic acids of the invention, using either chemically synthesized strands or genomic material as templates. Primers used for PCR can be synthesized using the sequence information provided herein and can further be designed to introduce appropriate new restriction sites, if desirable, to facilitate incorporation into a given vector for recombinant expression.
The nucleic acids of the present invention may be flanked by natural human regulatory sequences, or may be associated with heterologous sequences, including transcriptional control elements such as promoters, enhancers, and response elements, or other sequences such as signal sequences, polyadenylation sequences, introns, 5′- and 3′- noncoding regions, and the like. Preferably, although not necessarily, any two nucleotide sequences to be expressed as a fusion polypeptide are inserted in-frame. The nucleic acids may also be modified by many means known in the art. Non-limiting examples of such modifications include methylation, “caps”, substitution of one or more of the naturally occurring nucleotides with an analog, internucleotide modifications such as, for example, those with uncharged linkages (e.g., methyl phosphonates, phosphotriesters, phosphoroamidates, carbamates, etc.) and with charged linkages (e.g., phosphorothioates, phosphorodithioates, etc.). Nucleic acids may contain one or more additional covalently linked moieties, such as, for example, proteins (e.g., nucleases, toxins, antibodies, signal peptides, poly-L-lysine, etc.), intercalators (e.g., acridine, psoralen, etc.), chelators (e.g., metals, radioactive metals, iron, oxidative metals, etc.), and alkylators. The nucleic acid may be derivatized by formation of a methyl or ethyl phosphotriester or an alkyl phosphoramidate linkage. Furthermore, the nucleic acid sequences of the present invention may also be modified with a label capable of providing a detectable signal, either directly or indirectly. Exemplary labels include radioisotopes, fluorescent molecules, biotin, and the like.
According to the present invention, useful probes comprise a probe sequence at least eight nucleotides in length that consists of all or part of the sequence from among the sequences as set forth in FIG. 1 or sequence-conservative or function-conservative variants thereof, or a complement thereof, and that has been labelled as described above.
The invention also provides nucleic acid vectors comprising the disclosed sequence or derivatives or fragments thereof A large number of vectors, including plasmid and fungal vectors, have been described for replication and/or expression in a variety of eukaryotic and prokaryotic hosts, and may be used for gene therapy as well as for simple cloning or protein expression.
Recombinant cloning vectors will often include one or more replication systems for cloning or expression, one or more markers for selection in the host, e.g. antibiotic resistance, and one or more expression cassettes. The inserted coding sequences may be synthesized by standard methods, isolated from natural sources, or prepared as hybrids, etc. Ligation of the coding sequences to transcriptional regulatory elements and/or to other amino acid coding sequences may be achieved by known methods. Suitable host cells may be transformed/transfected/infected as appropriate by any suitable method including electroporation, CaCl 2 mediated DNA uptake, fungal infection, microinjection, microprojectile, or other established methods.
Appropriate host cells included bacteria, archaebacteria, fungi, especially yeast, and plant and animal cells, especially mammalian cells. Also included are avian and insect cells. Of particular interest are Saccharomyces cerevisiae, Schizosaccharomyces pombe, Pichia pastoris, Hansenula polymorpha; Neurospora spec., SF9 cells, C129 cells, 293 cells, and CHO cells, COS cells, HeLa cells, and immortalized mammalian myeloid and lymphoid cell lines. Preferred replication systems include M13, ColE1, 2μ, ARS, SV40, baculovirus, lambda, adenovirus, and the like. A large number of transcription initiation and termination regulatory regions have been isolated and shown to be effective in the transcription and translation of heterologous proteins in the various hosts. Examples of these regions, methods of isolation, manner of manipulation, etc. are known in the art. Under appropriate expression conditions, host cells can be used as a source of recombinantly produced C2GnT3 derived peptides and polypeptides.
Advantageously, vectors may also include a transcription regulatory element (i.e., a promoter) operably linked to the C2GnT3 coding portion. The promoter may optionally contain operator portions and/or ribosome binding sites. Non-limiting examples of bacterial promoters compatible with E. coli include: β-lactamase (penicillinase) promoter; lactose promoter; tryptophan (trp) promoter; arabinose BAD operon promoter; lambda-derived P1 promoter and N gene ribosome binding site; and the hybrid tac promoter derived from sequences of the trp and lac UV5 promoters. Non-limiting examples of yeast promoters include 3-phosphoglycerate kinase promoter, glyceraldehyde-3 phosphate dehydrogenase (GAPDH) promoter, galactokinase (GAL1) promoter, galactoepimerase (GAL10) promoter, metallothioneine (CUP) promoter and alcohol dehydrogenase (ADH) promoter. Suitable promoters for mammalian cells include without limitation viral promoters such as that from Simian Virus 40 (SV40), Rous sarcoma virus (RSV), adenovirus (ADV), and bovine papilloma virus (BPV). Mammalian cells may also require terminator sequences and poly A addition sequences and enhancer sequences which increase expression may also be included; sequences which cause amplification of the gene may also be desirable. Furthermore, sequences that facilitate secretion of the recombinant product from cells, including, but not limited to, bacteria, yeast, and animal cells, such as secretory signal sequences and/or prohormone pro region sequences, may also be included. These sequences are known in the art.
Nucleic acids encoding wild type or variant polypeptides may also be introduced into cells by recombination events. For example, such a sequence can be introduced into a cell, and thereby effect homologous recombination at the site of an endogenous gene or a sequence with substantial identity to the gene. Other recombination-based methods such as nonhomologous recombinations or deletion of endogenous genes by homologous recombination may also be used.
The nucleic acids of the present invention find use, for example, as probes for the detection of C2GnT3 in other species or related organisms and as templates for the recombinant production of peptides or polypeptides. These and other embodiments of the present invention are described in more detail below.
Polypeptides and Antibodies
The present invention encompasses isolated peptides and polypeptides encoded by the disclosed cDNA sequence. Peptides are preferably at least five residues in length.
Nucleic acids comprising protein-coding sequences can be used to direct the recombinant expression of polypeptides in intact cells or in cell-free translation systems. The known genetic code, tailored if desired for more efficient expression in a given host organism, can be used to synthesize oligonucleotides encoding the desired amino acid sequences. The phosphoramidite solid support method of (26), the method of (27), or other well known methods can be used for such synthesis. The resulting oligonucleotides can be inserted into an appropriate vector and expressed in a compatible host organism.
The polypeptides of the present invention, including function-conservative variants of the disclosed sequence, may be isolated from native or from heterologous organisms or cells (including, but not limited to, bacteria, fungi, insect, plant, and mammalian cells) into which a protein-coding sequence has been introduced and expressed. Furthermore, the polypeptides may be part of recombinant fusion proteins.
Methods for polypeptide purification are well known in the art, including, without limitation, preparative discontiuous gel elctrophoresis, isoelectric focusing, HPLC, reversed-phase HPLC, gel filtration, ion exchange and partition chromatography, and countercurrent distribution. For some purposes, it is preferable to produce the polypeptide in a recombinant system in which the protein contains an additional sequence tag that facilitates purification, such as, but not limited to, an affinity ligand, reactive group, and/or a polyhistidine sequence. The polypeptide can then be purified from a crude lysate of the host cell by chromatography on an appropriate solid-phase matrix. Alternatively, antibodies produced against a protein or against peptides derived therefrom can be used as purification reagents. Other purification methods are possible.
The present invention also encompasses derivatives and homologues of polypeptides. For some purposes, nucleic acid sequences encoding the peptides may be altered by substitutions, additions, or deletions that provide for functionally equivalent molecules, i.e., function-conservative variants. For example, one or more amino acid residues within the sequence can be substituted by another amino acid of similar properties, such as, for example, positively charged amino acids (arginine, lysine, and histidine); negatively charged amino acids (aspartate and glutamate); polar neutral amino acids; and non-polar amino acids.
The isolated polypeptides may be modified by, for example, phosphorylation, sulfation, acylation, or other protein modifications. They may also be modified with a label capable of providing a detectable signal, either directly or indirectly, including, but not limited to, radioisotopes and fluorescent compounds.
The present invention encompasses antibodies that specifically recognize immunogenic components derived from C2GnT3. Such antibodies can be used as reagents for detection and purification of C2GnT3.
C2GnT3 specific antibodies according to the present invention include polyclonal and monoclonal antibodies. The antibodies may be elicited in an animal host by immunization with C2GnT3 components or may be formed by in vitro immunization of immune cells. The immunogenic components used to elicit the antibodies may be isolated from human cells or produced in recombinant systems. The antibodies may also be produced in recombinant systems programmed with appropriate antibody-encoding DNA. Alternatively, the antibodies may be constructed by biochemical reconstitution of purified heavy and light chains. The antibodies include hybrid antibodies (i.e., containing two sets of heavy chain/light chain combinations, each of which recognizes a different antigen), chimeric antibodies (i.e., in which either the heavy chains, light chains, or both, are fusion proteins), and univalent antibodies (i.e., comprised of a heavy chain/light chain complex bound to the constant region of a second heavy chain). Also included are Fab fragments, including Fab′ and F(ab) 2 fragments of antibodies. Methods for the production of all of the above types of antibodies and derivatives are well known in the art. For example, techniques for producing and processing polyclonal antisera are disclosed in Mayer and Walker, 1987, Immunochemical Methods in Cell and Molecular Biology, (Academic Press, London).
The antibodies of this invention can be purified by standard methods, including but not limited to preparative disc-gel elctrophoresis, isoelectric focusing, HPLC, reversed-phase HPLC, gel filtration, ion exchange and partition chromatography, and countercurrent distribution. Purification methods for antibodies are disclosed, e.g., in The Art of Antibody Purification, 1989, Amicon Division, W. R. Grace & Co. General protein purification methods are described in Protein Purification: Principles and Practice, R. K. Scopes, Ed., 1987, Springer-Verlag, New York, N.Y.
Anti C2GnT3 antibodies, whether unlabeled or labeled by standard methods, can be used as the basis for immunoassays. The particular label used will depend upon the type of immunoassay used. Examples of labels that can be used include, but are not limited to, radiolabels such as 32 P, 125 I, 3 H and 14 C; fluorescent labels such as fluorescein and its derivatives, rhodamine and its derivatives, dansyl and umbelliferone; chemiluminescers such as luciferia and 2,3-dihydrophthalazinediones; and enzymes such as horseradish peroxidase, alkaline phosphatase, lysozyme and glucose-6-phosphate dehydrogenase.
The antibodies can be tagged with such labels by known methods. For example, coupling agents such as aldehydes, carbodiimides, dimaleimide, imidates, succinimides, bisdiazotized benzadine and the like may be used to tag the antibodies with fluorescent, chemiluminescent or enzyme labels. The general methods involved are well known in the art and are described in, e.g., Chan (Ed.), 1987, Immunoassay: A Practical Guide, Academic Press, Inc., Orlando, Fla.
Applications of the Nucleic Acid Molecules, Polypeptides, and Antibodies of the Invention
The nucleic acid molecules, C2GnT3 polypeptide, and antibodies of the invention may be used in the prognostic and diagnostic evaluation of conditions associated with altered expression or activity of a polypeptide of the invention or conditions requiring modulation of a nucleic acid or polypeptide of the invention including thymus-related disorders and proliferative disorders (e.g. cancer), and the identification of subjects with a predisposition to such conditions (See below). Methods for detecting nucleic acid molecules and polypeptides of the invention can be used to monitor such conditions by detecting and localizing the polypeptides and nucleic acids. It would also be apparent to one skilled in the art that the methods described herein may be used to study the developmental expression of the polypeptides of the invention and, accordingly, will provide further insight into the role of the polypeptides. The applications of the present invention also include methods for the identification of substances or compounds that modulate the biological activity of a polypeptide of the invention (See below). The substances, compounds, antibodies etc., may be used for the treatment of conditions requiring modulation of polypeptides of the invention (See below).
Diagnostic Methods
A variety of methods can be employed for the diagnostic and prognostic evaluation of conditions requiring modulation of a nucleic acid or polypeptide of the invention (e.g. thymus-related disorders, and cancer), and the identification of subjects with a predisposition to such conditions. Such methods may, for example, utilize nucleic acids of the invention, and fragments thereof, and antibodies directed against polypeptides of the invention, including peptide fragments. In particular, the nucleic acids and antibodies may be used, for example, for: (1) the detection of the presence of C2GnT3 mutations, or the detection of either over- or under-expression of C2GnT3 mRNA relative to a non-disorder state or the qualitative or quantitative detection of alternatively spliced forms of C2GnT3 transcripts which may correlate with certain conditions or susceptibility toward such conditions; or (2) the detection of either an over- or an under-abundance of a polypeptide of the invention relative to a non-disorder state or the presence Of a modified (e.g., less than full length) polypeptide of the invention which correlates with a disorder state, or a progression toward a disorder state.
The methods described herein may be performed by utilizing pre-packaged diagnostic kits comprising at least one specific nucleic acid or antibody described herein, which may be conveniently used, e.g., in clinical settings, to screen and diagnose patients and to screen and identify those individuals exhibiting a predisposition to developing a disorder.
Nucleic acid-based detection techniques and peptide detection techniques are described below. The samples that may be analyzed using the methods of the invention include those that are known or suspected to express C2GnT3 nucleic acids or contain a polypeptide of the invention. The methods may be performed on biological samples including but not limited to cells, lysates of cells which have been incubated in cell culture, chromosomes isolated from a cell (e.g. a spread of metaphase chromosomes), genomic DNA (in solutions or bound to a solid support such as for Southern analysis), RNA (in solution or bound to a solid support such as for northern analysis), cDNA (in solution or bound to a solid support), an extract from cells or a tissue, and biological fluids such as serum, urine, blood, and CSF. The samples may be derived from a patient or a culture.
Methods for Detection of Nucleic Acid Molecules of the Invention
The nucleic acid molecules of the invention allow those skilled in the art to construct nucleotide probes for use in the detection of nucleic acid sequences of the invention in biological materials. Suitable probes include nucleic acid molecules based on nucleic acid sequences encoding at least sequential amino acids from regions of the C2GnT3 polypeptide (see SEQ ID NO: 1), preferably they comprise 15 to 50 nucleotides, more preferably 15 to 40 nucleotides, most preferably 15-30 nucleotides. A nucleotide probe may be labelled with a detectable substance such as a radioactive label that provides for an adequate signal and has sufficient half-life such as 32 P, 3 H, 14 C or the like. Other detectable substances that may be used include antigens that are recognized by a specific labelled antibody, fluorescent compounds, enzymes, antibodies specific for a labelled antigen, and luminescent compounds. An appropriate label may be selected having regard to the rate of hybridization and binding of the probe to the nucleotide to be detected and the amount of nucleotide available for hybridization. Labelled probes may be hybridized to nucleic acids on solid supports such as nitrocellulose filters or nylon membranes as generally described in Sambrook et al, 1989, Molecular Cloning, A Laboratory Manual (2nd ed.). The nucleic acid probes may be used to detect C2GnT3 genes, preferably in human cells. The nucleotide probes may also be used for example in the diagnosis or prognosis of conditions such as thymus-related disorders and cancer, and in monitoring the progression of these conditions, or monitoring a therapeutic treatment.
The probe may be used in hybridisation techniques to detect a C2GnT3 gene. The technique generally involves contacting and incubating nucleic acids (e.g. recombinant DNA molecules, cloned genes) obtained from a sample from a patient or other cellular source with a probe of the present invention under conditions favourable for the specific annealing of the probes to complementary sequences in the nucleic acids. Alter incubation, the non-annealed nucleic acids are removed, and the presence of nucleic acids that have hybridized to the probe if any are detected.
The detection of nucleic acid molecules of the invention may involve the amplification of specific gene sequences using an amplification method (e.g. PCR), followed by the analysis of the amplified molecules using techniques known to those skilled in the art. Suitable primers can be routinely designed by one of skill in the art. For example, primers may be designed using commercially available software, such as OLIGO 4.06. Primer Analysis software (National Biosciences, Plymouth, Minn.) or another appropriate program, to be about 22 to 30 nucleotides in length, to have a GC content of about 50% or more, and to anneal to the template at temperatures of about 60° C. to 72° C.
Genomic DNA may be used in hybridization or amplification assays of biological samples to detect abnormalities involving C2GnT3 nucleic acid structure, including point mutations, insertions, deletions, and chromosomal rearrangements. For example, direct sequencing, single stranded conformational polymorphism analyses, heteroduplex analysis, denaturing gradient gel electrophoresis, chemical mismatch cleavage, and oligonucleotide hybridization may be utilized.
Genotyping techniques known to one skilled in the art can be used to type polymorphisms that are in close proximity to the mutations in a C2GnT3 gene. The polymorphisms may be used to identify individuals in families that are likely to carry mutations. If a polymorphism exhibits linkage disequalibrium with mutations in the G2GnT3 gene, it can also be used to screen for individuals in the general population likely to carry mutations. Polymorphisms which may be used include restriction fragment length polymorphisms (RFLPs), single-nucleotide polymorphisms (SNP); and simple sequence repeat polymorphisms (SSLPs).
A probe or primer of the invention may be used to directly identify RFLPs. A probe or primer of the invention can additionally be used to isolate genomic clones such as YACs, BACs, PACs, cosmids, phage or: plasmids. The DNA in the clones can be screened for SSLPs using hybridization or sequencing procedures.
Hybridization and amplification techniques described herein may be used to assay qualitative and quantitative aspects of C2GnT3 expression. For example RNA may be isolated from a cell type or tissue known to express C2GnT3 and tested utilizing the hybridization (e.g. standard Northern analyses) or PCR techniques referred to herein. The techniques may be used to detect differences in transcript size that may be doe to normal or abnormal alternative splicing. The techniques may be used to detect quantitative differences between levels of full length and/or alternatively splice transcripts detected in normal individuals relative to those individuals exhibiting symptoms of a disease.
The primers and probes may be used in the above described methods in situ i.e directly on tissue sections (fixed and/or frozen) of patient tissue obtained from biopsies or resections.
Oligonucleotides or longer fragments derived from any of the nucleic acid molecules of the invention may be used as targets in a microarray. The microarray can be used to simultaneously monitor the expression levels of large numbers of genes and to identify genetic variants, mutations, and polymorphisms. The information from the microarray may be used to determine gene function, to understand the genetic basis of a disorder, to identify predisposition to a disorder, to treat a disorder, to diagnose a disorder, and to develop and monitor the activities of therapeutic agents.
The preparation, use, and analysis of micro arrays are well known to a person skilled in the art. (see, for example, Brennan, T. M., et al. (1995), U.S. Pat. No. 5,474,796; Schena et al. (1996), Proc. Nati. Acad. Sci. 93:10614-10619; Baldeschweiler et al. (1995), PCT Application WO95/251116; Shalon, D., et al. (1995), PCT application W095/35505; Heller, R. A., et al. (1997), Proc. Natl. Acad. Sci. 94:2150-2155; and Heller, M. J., et al. (1997), U.S. Pat. No. 5,605,662.)
Methods for Detecting Polypeptides
Antibodies specifically reactive with a C2GnT3 Polypeptide, or derivatives, such as enzyme conjugates or labeled derivatives, may be used to detect C2GnT3 polypeptides in various biological materials. They may be used as diagnostic or prognostic reagents and they may be used to detect abnormalities in the level of C2GnT3 polypeptides, expression, or abnormalities in the structure, and/or temporal, tissue, cellular, or subcellular location of the polypeptides. Antibodies may also be used to screen potentially therapeutic compounds in vitro to determine their effects on a condition such as a thymus-related disorder or cancer. In vitro immunoassays may also be used to assess or monitor the efficacy of particular therapies. Preferably, antibodies for use in a detection assay have a dissociation constant lower than 1μM, even more preferably lower than or about 10 nM.
The antibodies of the invention may also be used in vitro to determine the level of C2GnT3 polypeptide expression in cells genetically engineered to produce a C2GnT3 polypeptide. The antibodies may be used to detect and quantify polypeptides of the invention in a sample in order to determine their role in particular cellular events or pathological states, and to diagnose and treat such pathological states.
In particular, the antibodies of the invention may be used in immuno-histochemical analyses, for example, at the cellular and sub-subcellular level, to detect a polypeptide of the invention, to localize it to particular cells and tissues, and to specific subcellular locations, and to quantitate the level of expression.
The antibodies may be used in any known immunoassays that rely on the binding interaction>> between an antigenic determinant of a polypeptide of the invention, and the antibodies. Examples of such assays are radio immunoassays, enzyme immunoassays (e.g. ELISA), immunofluorescence, immunoprecipitation, latex agglutination, hemagglutination, and histochemical tests,
Cytochemical techniques known in the art for localizing antigens using light and electron microscopy may be used to detect a polypeptide of the invention. Generally, an antibody of the invention may be labelled with a detectable substance and a polypeptide may be localised in tissues and cells based upon the presence of the detectable substance. Various methods of labelling polypeptides are known in the art and may be used. Examples of detectable substances include, but are not limited to, the following: radioisotopes (e.g., 3 H, 14 C, 35 S, 125 I, 131 I), fluorescent labels (e.g., FITC, Rhodamine, lanthanide phosphors), luminescent labels such as luminol, enzymatic labels (e.g., horseradish peroxidase, β-galactosidase, luciferase, alkaline phosphatase, acetylcholinesterase), biotinyl groups (which can be detected by marked avidin e.g., streptavidin containing a fluorescent marker or enzymatic activity that can be detected by optical or calorimetric methods), predetermined polypeptide epitopes recognized by a secondary reporter (e.g., leucine zipper pair sequences, binding sites for secondary antibodies, metal binding domains, epitope tags). In some embodiments, labels are attached via spacer arms of various lengths to reduce potential steric hindrance. Antibodies may also be coupled to electron dense substances, such as ferritin or colloidal gold, which are readily visualised by electron microscopy.
The antibody or sample may be immobilized on a carrier or solid support which is capable of immobilizing cells, antibodies, etc. For example, the carrier or support may be nitrocellulose, or glass, polyacrylamides, gabbros, and magnetite. The support material may have any possible configuration including spherical (e.g. bead), cylindrical (e.g. inside surface of a test tube or well, or the external surface of a rod), or flat (e.g. sheet, test strip). Indirect methods may also be employed in which the primary antigen-antibody reaction is amplified by the introduction of a second antibody, having specificity for the antibody reactive against a polypeptide of the invention. By way of example, if the antibody having specificity against a polypeptide of the invention is a rabbit IgG antibody, the second antibody may be goat anti-rabbit gamma-globulin labelled with a detectable substance as described herein.
Where a radioactive label is used as a detectable substance, a polypeptide of the invention may be localized by radioautography. The results of radioautography may be quantitated by determining the density of particles in the radioautographs by various optical methods, or by counting the grains.
A polypeptide of the invention may also be detected by assaying for C2GnT3 activity as described herein. For example, a sample may be reacted with an acceptor substrate and a donor substrate under conditions where a C2GnT3 polypeptide is capable of transferring the donor substrate to the acceptor substrate to produce a donor substrate-acceptor substrate complex.
Methods for Identifying or Evaluating Substances/Compounds
The methods described herein are designed to identify substances and compounds that modulate the expression or biological activity of a C2GnT3 polypeptide including substances that interfere with or enhance the expression or activity of a C2GnT3 polypeptide.
Substances and compounds identified using the methods of the invention include but are not limited to peptides such as soluble peptides including Ig-tailed fusion peptides, members of random peptide libraries and combinatorial chemistry-derived molecular libraries made of D-and/or L-configuration amino acids, phosphopeptides (including members of random or partially degenerate, directed phosphopeptide libraries), antibodies [e.g. polyclonal, monoclonal, humanized, anti-idiotypic, chimeric, single chain antibodies, fragments, (e.g. Fab, F(ab) 2 , and Fab expression library fragments, and epitope-binding fragments thereof)], polypeptides, nucleic acids, carbohydrates, and small organic or inorganic molecules. A substance or compound may be an endogenous physiological compound or it may be a natural or synthetic compound.
Modulation of a C2GnT3 polypeptide can be evaluated, for instance, by evaluating the inhibitory/stimulatory effect of an agent on C2GnT3 biological activity in comparison to a control or reference. The control or reference may be, e.g., a predetermined reference value, or may be evaluated experimentally. For example, in a cell-based assay where a host cell expressing recombinant C2GnT3 is incubated in a medium containing a potential modulating agent, a control or reference may be, e.g., a host cell incubated with an agent having a known effect on C2GnT3 expression/activity, a host cell incubated in the same medium without any agent, a host cell transfected with a “mock” vector not expressing any C2GnT3 polypeptide, or any other suitable control or reference. In a cell-free assay where C2GnT3 polypeptide is incubated in a medium containing a potential modulating agent, a control or reference may be, for example, medium not containing C2GnT3 polypeptide, medium not containing any agent, medium containing a reference polypeptide or agent, or any other suitable control or reference.
Substances which modulate a C2GnT3 polypeptide can be identified based on their ability to associate with a C2GnT3 polypeptide. Therefore, the invention also provides methods for identifying substances that associate with a C2GnT3 polypeptide. Substances identified using the methods of the invention may be isolated, cloned and sequenced using conventional techniques. A substance that associates with a polypeptide of the invention may be an agonist or antagonist of the biological or immunological activity of a polypeptide of the invention.
The term “agonist” refers to a molecule that increases the amount of, or prolongs the duration of, the activity of the polypeptide. The term “antagonist” refers to a molecule which decreases the biological or immunological activity of the polypeptide. Agonists and antagonists may include proteins, nucleic acids, carbohydrates, or any other molecules that associate with a polypeptide of the invention.
Substances which can associate with a C2GnT3 polypeptide may be identified by reacting a C2GnT3 polypeptide with a test substance which potentially associates with a C2GnT3 polypeptide, under conditions which permit the association, and removing and/or detecting the associated C2GnT3 polypeptide and substance. The Substance-polypeptide complexes, free substance, or non-complexed polypeptides may be assayed. Conditions which permit the formation of substance-polypeptide complexes may be selected having regard to factors such as the nature and amounts of the substance and the polypeptide.
The substance-polypeptide complex, free substance or non-complexes polypeptides may be isolated by conventional isolation techniques, for example, salting out, chromatography, electrophoresis, gel filtration, fractionation, absorption, polyacrylamide gel electrophoresis, agglutination, or combinations thereof. To facilitate the assay of the components, antibody against a polypeptide of the invention or the substance, or labelled polypeptide, or a labelled substance may be utilized. The antibodies, polypeptides, or substances may be labelled with a detectable substance as described above.
A C2GnT3 polypeptide, or the substance used in the method of the invention may be insolubilized. For example, a polypeptide, or substance may be bound to a suitable carrier such as agarose, cellulose, dextran, Sephadex, Sepharose, carboxymethyl cellulose polystyrene, filter paper, ion-exchange resin, plastic film, plastic tube, glass beads, polyamine-methyl vinyl-ether-maleic acid copolymer, amino acid copolymer, ethylene-maleic acid copolymer, nylon, silk, etc. The carrier may be in the shape of, for example, a tube, test plate, beads, disc, sphere etc. The insolubilized polypeptide or substance may be prepared by reacting the material with a suitable insoluble carrier using known chemical or physical methods, for example, cyanogen bromide coupling.
The invention also contemplates a method for evaluating a compound for its ability to modulate the biological activity of a polypeptide of the invention, by assaying for an agonist or antagonist (i.e. enhancer or inhibitor) of the association of the polypeptide with a substance which interacts with the polypeptide (e.g. donor or acceptor substrates or parts thereof). The basic method for evaluating if a compound is an agonist or antagonist of the association of a polypeptide of the invention and a substance that associates with the polypeptide is to prepare a reaction mixture containing the polypeptide and the substance under conditions which permit the formation of substance-polypeptide complexes, in the presence of a test compound. The test compound may be initially added to the mixture, or may be added subsequent to the addition of the polypeptide and substance. Control reaction mixtures without the test compound or with a placebo are also prepared. The formation of complexes is detected and the formation of complexes in the control reaction but not in the reaction mixture indicates that the test compound interferes with the interaction of the polypeptide and substance. The reactions may be carried out in the liquid phase or the polypeptide, substance, or test compound may be immobilized as described herein.
It will be understood that the agonists and antagonists i.e. inhibitors and enhancers, that can be assayed using the methods of the invention may act on one or more of the interaction sites an the polypeptide or substance including agonist binding sites, competitive antagonist binding cites, non-competitive antagonist binding sites or allosteric sites.
The invention also makes it possible to screen for antagonists that inhibit the effects of an agonist of the interaction of a polypeptide of the invention with a substance which is capable of associating with the polypeptide. Thus, the invention may be used to assay for a compound that competes for the same interacting site of a polypeptide of the invention.
Substances that modulate a C2GnT3 polypeptide of the invention can be identified based on their ability to interfere with or enhance the activity of a C2GnT3 polypeptide. Therefore, the invention provides a method for evaluating a compound for its ability to modulate the activity of a C2GnT3 polypeptide comprising (a) reacting an acceptor substrate and a donor substrate for a C2GnT3 polypeptide in the presence of a test substance; (b) measuring the amount of donor substrate transferred to acceptor substrate, and (c) carrying out steps (a) and (b) in the absence of the test substance to determine if the substance interferes with or enhances transfer of the sugar donor to the acceptor by the C2GnT3 polypeptide.
Suitable acceptor substrate for use in the methods of the invention are a saccharide, oligosaccharides, polysaccharides, polypeptides, glycopolypeptides, or glycolipids which are either synthetic with linkers at the reducing end or naturally occuring structures, for example, asialo-agalacto-fetuin glycopeptide. Acceptors will generally comprise β-D-galactosyl-1,3-N-acetyl-D-galactosaminyl.
The donor substrate may be a nucleotide sugar, dolichol-phosphate-sugar or dolichol-pyrophosphate-oligosaccharide, for example, uridine diphospho-N-acetylglucosamine (UDP-GlcNAc), or derivatives or analogs thereof The C2GnT3 polypeptide may be obtained from natural sources or produced used recombinant methods as described herein.
The acceptor or donor substrates may be labeled with a detectable substance as described herein, and the interaction of the polypeptide of the invention with the acceptor and donor will give rise to a detectable change. The detectable change may be colorimetric, photometric, radiometric, potentiometric, etc. The activity of C2GnT3 polypeptide of the invention may also be determined using methods based on HPLC (Koenderman et al., FEBS Lett. 222: 42, 1987) or methods employed synthetic oligosaccharide acceptors attached to hydrophobic aglycones (Palcic et al Glycoconjugate 5:49, 1988; and Pierce et al, Biochem. Biophys. Res. Comm. 146: 679, 1987). The C2GnT3 polypeptide is reacted with the acceptor and donor substrates at a pH and temperature effective for the polypeptide to transfer the donor to the acceptor, and where one of the components is labeled, to produce a detectable change. It is preferred to use a buffer with the acceptor and donor to maintain the pH within the pH range effective for the polypeptides. The buffer, acceptor and donor may be used as an assay composition. Other compounds such as EDTA and detergents may be added to the assay composition.
The reagents suitable for applying the methods of the invention to evaluate compounds that modulate a C2GnT3 polypeptide may be packaged into convenient kits providing the necessary materials packaged into suitable containers. The kits may also include suitable supports useful in performing the methods of the invention.
Substances that modulate a C2GnT3 polypeptide can also be identified by treating immortalized cells which express the polypeptide with a test substance, and comparing the morphology of the cells with the morphology of the cells in the absence of the substance and/or with immortalized cells which do not express the polypeptide. Examples of immortalized cells that can be used include lung epithelial cell lines such as MvlLu or HEK293 (human embryonal kidney) transfected with a vector containing a nucleic acid of the invention. In the absence of an inhibitor the cells show signs of morphologic transformation (e.g. fibroblastic morphology, spindle shape and pile up; the cells are less adhesive to substratum; there is less cell to cell contact in monolayer culture; there is reduced growth-factor requirements for survival and proliferation; the cells grow in soft-agar of other semi-solid medium; there is a lack of contact inhibition and increased apoptosis in low-serum high density cultures; there is enhanced cell motility, and there is invasion into extracellular matrix and secretion of proteases). Substances that inhibit one or more phenotypes may be considered an inhibitor.
A substance that inhibits a C2GnT3 polypeptide may be identified by treating a cell which expresses the polypeptide with a test substance, and assaying for complex core 2-based O-linked structures (e.g. repeating Gal[β]1-4GlcNAc[β]) associated with the cell. The complex core 2-based O-linked structures can be assayed using a substance that binds to the structures (e.g. antibodies). Cells that have not been treated with the substance or which do not express the polypeptide may be employed as controls.
Substances which inhibit transcription or translation of a C2GnT3 gene may be identified by transfecting a cell with an expression vector comprising a recombinant molecule of the invention, including a reporter gene, in the presence of a test substance and comparing the level of expression of the C2GnT3 polypeptide, or the expression of the polypeptide encoded by the reporter gene with a control cell transfected with the nucleic acid molecule in the absence of the substance. The method can be used to identify transcription and translation inhibitors of a C2GnT3 gene.
Compositions and Treatments
The substances or compounds identified by the methods described herein, polypeptides, nucleic acid molecules, and antibodies of the invention may be used for modulating the biological activity of a C2GnT3 polypeptide, and they may be used in the treatment of conditions mediated by a C2GnT3 polypeptide. In particular, they may be used to T-cell development and lymphocyte homing and they may be used in the prevention and treatment of thymus-related disorders.
Therefore, the present invention may be useful for diagnosis or treatment of various thymus-related disorders in mammals, preferably humans. Such disorders include the following: tumors and cancers, hypoactivity, hyperactivity, atrophy, enlargement of the thymus, and the like. Other disorders include disregulation of T-lymphocyte selection or activity and would include but not be limited to disorders involving autoimmunity, arthritis, leukemias, lymphomas, immunosuppression, sepsis, wound healing, acute and chronic in action, cell mediated immunity, humor immunity, TH1/TH2 imbalance, and the like.
The substances or compounds identified by the methods described herein, antibodies, and polypeptides, and nucleic acid molecules of the invention may be useful in the prevention and treatment of tumors. Tumor metastasis may be inhibited or prevented by inhibiting the adhesion of circulating cancer cells. The substances, compounds, etc. of the invention may be especially useful in the treatment of various forms of neoplasia such as leukemias, lymphomas, melanomas, adenomas, sarcomas, and carcinomas of solid tissues in patients. In particular the composition may be used for treating malignant melanoma, pancreatic cancer, cervico-uterine cancer, cancer of the liver, kidney, stomach, lung, rectum, breast, bowel, gastric, thyroid, neck, cervix, salivary gland, bile duct, pelvis, mediastinum, urethra, bronchogenic, bladder, esophagus and colon, and Kaposi's Sarcoma which is a form of cancer associated with HIV-infected patients with Acquired Immune Deficiency Syndrome (AIDS). The substances etc. are particularly useful in the prevention and treatment of tumors of the immune system and thymus and the metastases derived from these tumors.
A substance or compound identified in accordance with the methods described herein, antibodies, polypeptides, or nucleic acid molecules of the invention may be used to modulate T-cell activation and immunodeficiency due to the Wiskott-Aldrich syndrome or AIDS, or to stimulate hematopoietic progenitor cell growth, and/or confer protection against chemotherapy and radiation therapy in a subject.
Accordingly, the substances, antibodies, and compounds may be formulated into pharmaceutical compositions for administration to subjects in a biologically compatible form suitable for administration in vivo. By biologically compatible form suitable for administration in vivo is meant a form of the substance to be administered in which any toxic effects are outweighed by the therapeutic effects. The substances may be administered to living organisms including humans, and animals. Administration of a therapeutically active amount of the pharmaceutical compositions of the present invention is defined as an amount effective, at dosages and for periods of time necessary to achieve the desired result. For example, a therapeutically active amount of a substance may vary according to factors such as the disease state, age, sex, and weight of the individual, and the ability of antibody to elicit a desired response in the individual. Dosage regima may be adjusted to provide the optimum therapeutic response. For example, several divided doses may be administered daily or the dose may be proportionally reduced as indicated by the exigencies of the therapeutic situation.
The active substance may be administered in a convenient manner such as by injection (subcutaneous, intravenous, etc.), oral administration, inhalation, transdermal application, or rectal administration. Depending on the route of administration, the active substance may be coated in a material to protect the compound from the action of enzymes, acids and other natural conditions that may inactivate the compound.
The compositions described herein can be prepared by methods known per se for the preparation of pharmaceutically acceptable compositions which can be administered to subjects, such that an effective quantity of the active substance is combined in a mixture with a pharmaceutically acceptable vehicle. Suitable vehicles are described, for example, in Remington's Pharmaceutical Sciences (Remington's Pharmaceutical Sciences, Mack Publishing Company, Easton, Pa., USA 1985). On this basis, the compositions include, albeit not exclusively, solutions of the substances or compounds in association with one or more pharmaceutically acceptable vehicles or diluents, and contained in buffered solutions with a suitable pH and iso-osmotic with the physiological fluids.
After pharmaceutical compositions have been prepared, they can be placed in an appropriate container and labeled for treatment of an indicated condition. For administration of an inhibitor of a polypeptide of the invention, such labeling would include amount, frequency, and method of administration.
The nucleic acids encoding C2GnT3 polypeptides or any fragment thereof, or antisense, sequences may be used for therapeutic purposes. Antisense to a nucleic acid molecule encoding a polypeptide of the invention may be med in situations to block the synthesis of the polypeptide. In particular, cells may be transformed with sequences complementary to nucleic acid molecules encoding C2GnT3 polypeptide. Thus, antisense sequences may be used to modulate C2GnT3 activity or to achieve regulation of gene function. Sense or antisense oligomers or larger fragments, can be designed from various locations along the coding or regulatory regions of sequences encoding a polypeptide of the invention.
Expression vectors may be derived from retroviruses, adenoviruses, herpes or vaccinia viruses or from various bacterial plasmids for delivery of nucleic acid sequences to the target organ, tissue, or cells. Vectors that express antisense nucleic acid sequences of C2GnT3 polypeptide can be constructed using techniques well known to those skilled in the art (see for example, Sambrook, Fritsch, Maniatis, Molecular Cloning, A. Laboratory Manual, Second Edition (1989) Cold Spring Harbor Laboratory Press, Cold Spring Harbor, N.Y.).
Genes encoding C2CnT3 polypeptide can be turned off by transforming a cell or tissue with expression vectors that express high levels of a nucleic acid molecule or fragment thereof which encodes a polypeptide of the invention. Such constructs may be used to introduce untranslatable sense or antisense sequences into a cell. Even if they do not integrate into the DNA, the vectors may continue to transcribe RNA molecules until all copies are disabled by endogenous nucleases. Transient expression may last for extended periods of time (e.g. a month or more) with a non-replicating vector or if appropriate replication elements are part of the vector system.
Modification of gene .expression may be achieved by designing antisense molecules, DNA, RNA, or PNA, to the control regions of a C2GnT3 polypeptide gene i.e. the promoters, enhancers, and introns. Preferably the antisense molecules are oligonucleotides derived from the transcription initiation site (e.g. between positions −10 and +10 from the start site). Inhibition can also be achieved by using triple-helix base-pairing techniques. Triple helix pairing causes inhibition of the ability of the double helix to open sufficiently for the binding of polymerases, transcription factors, or regulatory molecules (see Gee J. E. et al (1994)In: Huber, B. E. and B. I. Carr, Molecular and Immunologic Approaches, Futura Publishing Co., Mt. Kisco, N.Y.).
Ribozymes, enzymatic RNA molecules, may be used to catalyze the specific cleavage of RNA. Ribozyme action involves sequence-specific hybridization of the ribozyme molecule to complementary target RNA, followed by endonucleolytic cleavage. For example, hammerhead motif ribozyme molecules may be engineered that can specifically and efficiently catalyze endonucleolytic cleavage of sequences encoding a polypeptide of the invention:
Specific ribosome cleavage sites within any RNA target may be initially identified by scanning the target molecule for ribozyme cleavage sites which include the following sequences: GUA, GUU, and GUC. Short RNA sequences of between 15 and 20 ribonucleotides corresponding to the region of the cleavage site of the target gene may be evaluated for secondary structural features which may render the oligonucleotide inoperable. The suitability of candidate targets may be evaluated by testing accessibility to hybridization with complementary oligonucleotides using ribonuclease protection assays.
Therapeutic efficacy and toxicity may be determined by standard pharmaceutical procedures in cell cultures or with experimental animals, such as by calculating the ED 50 (the dose therapeutically effective in 50% of the population) or LD 50 (the dose lethal to 50% of the population) statistics. The therapeutic index is the dose ratio of therapeutic to toxic effects and it can be expressed as the ED 50 /LD 50 ratio. Pharmaceutical compositions which exhibit large therapeutic indices are preferred.
The invention also provides methods for studying the function of a C2GnT3 polypeptide. Cells, tissues, and non-human animals lacking in C2GnT3 expression or partially lacking in C2GnT3 expression may be developed using recombinant expression vectors of the invention having specific deletion or insertion mutations in a C2GnT3 gene. A recombinant expression vector may be used to inactivate or alter the endogenous gene by homologous recombination, and thereby create a C2GnT3 deficient cell, tissue or animal.
Null alleles may be generated in cells, such as embryonic stem cells by deletion mutation. A recombinant C2GnT3 gene may also be engineered to contain an insertion mutation which inactivates C2GnT3. Such a construct may then be introduced into a cell, such as an embryonic stem cell, by a technique such as transfection, elcctroporation, injection etc. Cells lacking an intact C2GnT3 gene may then be identified, for example by Southern blotting, Northern Blotting or by assaying for expression of a polypeptide of the invention using the methods described herein. Such cells may then be used to generate transgenic non-human animals deficient in C2GnT3. Germline transmission of the mutation may be achieved, for example, by aggregating the embryonic stem cells with early stage embryos, such as 8 cell embryos, in vitro; transferring the resulting blastocysts into recipient females and; generating germline transmission of the resulting aggregation chimeras. Such a mutant animal may be used to define specific cell populations, developmental patterns and in vivo processes, normally dependent on C2GnT3 expression.
The invention thus provides a transgenic non-human mammal all of whose germ cells and somatic cells contain a recombinant expression vector that inactivates or alters a gene encoding a C2GnT3 polypeptide. Further the invention provides a transgenic non-human mammal, which does not express a C2GnT3 polypeptide of the invention.
A transgenic non-human animal includes but is not limited to mouse, rat, rabbit, sheep, hamster, guinea pig, micro-pig, pig, dog, cat, goat, and non-human primate, preferably mouse.
The invention also provides a transgenic non-human animal assay system which provides a model system for testing for an agent that reduces or inhibits a pathology associated with a C2GnT3 polypeptide comprising: (a) administering the agent to a transgenic non-human animal of the invention; and (b) determining whether said agent reduces or inhibits the pathology in the transgenic non-human animal relative to a transgenic non-human animal of step (a) to which the agent has not been administered.
The agent may be useful to treat the disorders and conditions discussed herein. The agents may also be incorporated in a pharmaceutical composition as described herein.
A polypeptide of the invention may be used to support the survival, growth, migration, and/or differentiation of cells expressing the polypeptide. Thus, a polypeptide of the invention may be used as a supplement to support, for example cells in culture.
Methods to Prepare Oligosaccharides
The invention relates to a method for preparing an oligosaccharide comprising contacting a reaction mixture comprising an activated donor substrate e.g. GlcNAc, and an acceptor substrate in the presence of a polypeptide of the invention.
Examples of acceptor substrates for use in the method for preparing an oligosaccharide are a saccharide, oligosaccharides, polysaccharides, glycopeptides, glycopolypeptides, or glycolipids which are either synthetic with linkers at the reducing end or naturally occurring structures, for example, asialo-agalacto-fetuin glycopeptide. The activated donor substrate is preferably GlcNAc which may be part of a nucleotide-sugar, a dolichol-phosphate-sugar, or dolichol-pyrophosphate-oligosaccharide.
In an embodiment of the invention, the oligosaccharides are prepared on a carrier that is non-toxic to a mammal, in particular a human such as a lipid isoprenoid or polyisoprenoid alcohol. An example of a suitable carrier is dolichol phosphate. The oligosaccharide may be attached to a carrier via a labile bond allowing for chemical removal of the oligosaccharide from the lipid carrier. In the alternative, the oligosaccharide transferase may be used to transfer the oligosaccharide from a lipid carrier to a polypeptide.
The following examples are intended to further illustrate the invention without limiting its scope.
EXAMPLE 1
A: Identification of cDNA Homologous to C2GnT3 by Analysis of GSS Database Sequence Information.
Database searches were performed with the coding sequence of the human C2/4GnT (C2GnT2) sequence using the BLASTn and tBLASTn algorithms against the GSS database at The National Center for Biotechnology Information, USA. The BLASTn algorithm was used to identify GSSs representing the query gene (identities of ≧95%), whereas tBLASTn was used to identify non-identical, but similar GSS sequences. GSSs with 50-90% nucleotide sequence identity were regarded as different from the query sequence. Composites of the sequence information for two GSSs were compiled and analysed for sequence similarity to human C2/4GnT (C2GnT2).
B: Cloning and Sequencing of C2GnT3
A GSS clone CIT-HSP-2288B17.TF (GSS GenBank accession number AQ005888), derived from a putative homologue to C2/4GnT (C2GnT2), was obtained from Research Genetics Inc., USA. Sequencing of this clone revealed a partial open reading frame with significant sequence similarity to C2/4GnT (C2GnT2). The coding region of human C2GnT-L (C2GnT1), C2/4GnT (C2GnT2) and a bovine homologue was previously found to be organized in one exon ((22),(15)). Since the 3′ sequence available from the C2GnT3 GSS was incomplete but likely to be located in the single exon, the missing 3′ portion of the open reading frame was obtained by sequencing a genomic P1 clone. The P1 clone was obtained from a human foreskin genomic P1 library (DuPont Merck Pharmaceutical Co. Human Foreskin Fibroblast P1 Library) by screening with the primer pair:
TSHC96 (5′-GGTTTCACCGTCTCCAACATA-3′, SEQ ID NO: 3) and
TSHC101 (5′-TCGTAAGGCACCTGATACTT -3′, SEQ ID NO: 6).
One genomic clone for C2GnT3, GS22597 #844/B1 was obtained from Genome Systems Inc., USA. DNA from P1 phage was prepared as recommended by Genome Systems Inc. The entire coding sequence of the C2GnT3 gene was represented in the clone and sequenced in full using automated sequencing (ABI377, Perkin-Elmer). Confirmatory sequencing was performed on a DNA clone obtained by PCR (30 cycles at 95° C. for 10 sec; 55° C. for 15 sec and 68° C. for 2 min 30 sec) on cDNA from human thymus poly A-mRNA with the sense primer:.
TSHC99 (5′- CGAGGATCCAGAATGAAGATATTCAAATGTTA-3′, SEQ ID NO: 4), and the anti-sense primer:
TSHC121 (5′-AGCGAATTCTTACTATCATGATGTGGTAGTG-3′, SEQ ID NO: 9).
The composite sequence contained an open reading frame of 1359 base pairs encoding a putative protein of 453 amino acids with type II domain structure predicted by the TMpred-algorithm at the Swiss Institute for Experimental Cancer Research (ISREC).(http://www.ch.embnet.org/ software/TMPRED_form.html).
EXAMPLE 2
A: Expresson of C2GnT3 in Sf9 cells
An expression vector construct designed to encode amino acid residues 39-453 of C2GnT3 was prepared by PCR using P1 DNA, and the primer pair:
TSHC100 (5′-CGAGGATCCGCAAAAAGACATTTACTTGGTT -3′, SEQ ID NO: 5) and
TSHC121 (5′-AGCGAATTCTTACTATCATGATGTGGTAGTG-3′, SEQ ID NO: 9) with BamH1 and EcoRI restriction sites, respectively (FIG. 2 ). The PCR product was cloned between the BamHI and EcoRI sites of pAcGP67A (PharMingen), and the insert was fully sequenced. pAcGP67-C2GnT3-sol was co-transfected with Baculo-Gold1υ DNA (PharMingen) as described previously (23). Recombinant Baculo-viruses were obtained after two successive amplifications in Sf9 cells grown in serum-containing medium, and titers of virus were estimated by titration in 24-well plates with monitoring of enzyme activities. Transfection of Sf9-cells with pAcGP67-C2GnT3-sol resulted in marked increase in GlcNAc-transferase activity compared to uninfected cells or cells infected with a control construct.
B: Analysis of C2GnT3 Activity
Standard assays were performed using culture supernatant from infected cells in 50 μl reaction mixtures containing 100 mM MES (pH 6.5), 0.1% Nonidet P-40, 150 μM UDP-[ 14 C]-GlcNAc (2,000 cpm/nmol) (Amersham Pharmacia Biotech), and the indicated concentrations of acceptor substrates (Sigma and Toronto Research Laboratories Ltd., see Table I for structures). Reaction products were quantified by chromatography on Dowex AG1-X8.
EXAMPLE 3
Restricted Organ Expression Pattern of C2GnT3
A human RNA master blot (CLONTECH) was used for expression analysis. The cDNA-fragment of soluble C2GnT3 was used as a probe for hybridization. The probe was random primer-labeled using [α 32 P]dATP and and the Strip-EZ DNA labeling kit (Ambion). The membrane was probed for 6 h at 65° C. following the protocol of the manufacturer (CLONTECH) and washed five times for 20 min each at 65° C. with 2×x SSC, 1% SDS and twice for 20 min each at 55° C. with 0.1 ×SSC, 0.5 % SDS. A human multiple tissue Northern blot MTN II (CLONTECH), was probed as described (24), and washed twice for 10 min each at room temperature with 2 ×SSC, 0.1% SDS; twice for 10 min each at 55° C. with 1 ×SSC, 0.1% SDS; and once for 10 min with 0.1 ×SSC, 0.1% SDS at 55° C.
EXAMPLE 4
Analysis of C2GnT3 Gene Expression in Peripheral Blood Mononuclear Cells
PCR analysis of C2GnT3 expression in resting and activated human blood cell fractions was performed using the primer pair:
TSHC118 (5′-GAGTCAGTGTGGAATTGAATAC-3′, SEQ ID NO: 7) and
TSHC126 (5′-CAACAGTCTCCTCAACCCTG-3′, SEQ ID NO: 11).
PCR amplifications with primers specific for human C2GnT3 (C2GnT3) or GAPDH (G3PDH, supplied by the manufacturer) were performed on a normalized human blood cell cDNA panel (MTC from CLONTECH) for 31 cycles. Expression of C2GnT3 transcript was detected in all peripheral blood mononuclear cell (PBMC) fractions with particularly high levels of expression in CD4 and CD8 positive T-lymphocytes (FIG. 4 ).
EXAMPLE 5
Analysis of DNA Polymorphism of the C2GnT3 Gene
Primer pairs such as:
TSHC123 (5′-GGGCAGCATTTGCCTAGTATG-3′, SEQ ID NO: 10) and
TSHC119 (5′-GATCTCTGATTTGGCTCAGTG-3′, SEQ ID NO: 8) as described in FIG. 5 have been used for PCR amplification of individual sequences of the coding exon. Each PCR product was subcloned and the sequence of 10 clones containing the appropriate insert was determined assuring that both alleles of each individual are characterized. Polymorphism of the amplified DNA can be analyzed using, e.g., DNA sequencing, single-strand conformational polymorphism (SSCP) or mismatch mutation.
From the foregoing it will be evident that, although specific embodiments of the invention have been described herein for purposes of illustration, various modifications may be made without deviating from the spirit and scope of the invention.
REFERENCES
1. Clausen, H. and Bennett, E. P. A family of UDP-GalNAc: polypeptide N-acetylgalactosaminyltransferases control the initiation of mucin-type O-linked glycosylation. Glycobiology 6: 635-646, 1996.
2. Piller, F., Piller, V., Fox, R. I., and Fukuda, M. Human T-lymphocyte activation is associated with changes in O-glycan biosynthesis. J. Biol. Chem. 263: 15146-15150, 1988.
3. Yang, J. M., Byrd, J. C., Siddiki, B. B., Chung, Y. S., Okuno, M., Sowa, M., Kim, Y. S., Matta, K. L., and Brockhausen, I. Alterations of O-glycan biosynthesis in human colon cancer tissues. Glycobiology 4: 873-884, 1994.
4. Yousefi, S., Higgins, E., Daoling, Z., Pollex-Kruger, A., Hindsgaul, O., and Dennis, J. W. Increased UDP-GlcNAc:Gal beta 1-3GalNAc-R (GlcNAc to GalNAc) beta-1, 6-N-acetylglucosaminyltransferase activity in metastatic murine tumor cell lines. Control of polylactosamine synthesis. J. Biol. Chem. 266: 1772-1782, 1991.
5. Fukuda, M. Possible roles of tumor-associated carbohydrate antigens. Cancer Res. 56: 2237-2244, 1996.
6. Brockhausen, I., Yang, J. M., Burchell, J., Whitehouse, C., and Taylor-Papadimitriou, J. Mechanisms underlying aberrant glycosylation of MUC1 mucin in breast cancer cells. Eur. J. Biochem. 233: 607-617, 1995.
7. Brockhausen, I., Kuhns, W., Schachter, H., Matta, K. L., Sutherland, D. R., and Baker, M. A. Biosynthesis of O-glycans in leukocytes from normal donors and from patients with leukemia: increase in O-glycan core 2 UDP-GlcNAc:Gal beta 3 GalNAc alpha-R (GlcNAc to GalNAc) beta(1-6)-N-acetylglucosaminyltransferase in leukemic cells. Cancer Res. 51: 1257-1263, 1991.
8. Higgins, E. A., Siminovitch, K. A., Zhuang, D. L., Brockhausen, I., and Dennis, J. W. Aberrant O-linked oligosaccharide biosynthesis in lymphocytes and platelets from patients with the Wiskott-Aldrich syndrome. J. Biol. Chem. 266: 6280-6290, 1991.
9. Saitoh, O., Piller, F., Fox, R. I., and Fukuda, M. T-lymphocytic leukemia expresses complex, branched O-linked oligosaccharides on a major sialoglycoprotein, leukosialin. Blood 77: 1491-1499, 1991.
10. Springer, G. F. T and Tn, general carcinoma autoantigens. Science 224: 1198-1206, 1984.
11. Kumar, R., Camphausen, R. T., Sullivan, F. X., and Cumming, D. A. Core2 beta-1,6-N-acetylglucosaminyltransferase enzyme activity is critical for P-selectin glycoprotein ligand-1 binding to P-selectin. Blood 88: 387214 3879, 1996.
12. Williams, D. and Schachter, H. Mucin synthesis. I. Detection in canine submaxillary glands of an N-acetylglucosaminyltransferase which acts on mucin substrates. J. Biol. Chem. 255: 11247-11252, 1980.
b 13 . Bierhuizen, M. F. and Fukuda, M. Expression cloning of a cDNA encoding UDP-GlcNAc:Gal beta 1-3-GalNAc-R (GlcNAc to GalNAc) beta 1-6GlcNAc transferase by gene transfer into CHO cells expressing polyoma large tumor antigen. Proc. Natl. Acad. Sci. U.S.A. 89: 9326-9330, 1992.
14. Schwientek, T., Yeh, J. C., Levery, S. B., Keck, B., Merkx, G., van Kessel, A. G., Fukuda, M., and Clausen, H. Control of O-glycan branch formation. Molecular cloning and characterization of a novel thymus-associated core 2 betal, 6-n-acetylglucosaminyltransferase. J. Biol. Chem. 275: 11106-111-13, 2000.
15. Schwientek, T., Nomoto, M., Levery, S. B., Merkx, G., van Kessel, A. G., Bennett, E. P., Hollingsworth, M. A., and Clausen, H. Control of O-glycan branch formation. Molecular cloning of human cDNA encoding a novel betal,6-N-acetylglucosaminyl-transferase forming core 2 and core 4. J. Biol. Chem. 274: 4504-4512, 1999.
16. Yeh, J. C., Ong, E., and Fukuda, M. Molecular cloning and expression of a novel beta-1,6-N-acetylglucosaminyltransferase that forms core 2, core 4, and I branches. J. Biol. Chem. 274: 3215-3221, 1999.
17. Baum, L. G., Pang, M., Perillo, N. L., Wu, T., Delegeane, A., Uittenbogaart, C. H., Fukuda, M., and Seilhamer, J. J. Human thymic epithelial cells express an endogenous lectin, galectin-1, which binds to core 2 O-glycans on thymocytes and T lymphoblastoid cells. J. Exp. Med. 181: 877-887, 1995.
18. Perillo, N. L., Marcus, M. E., and Baum, L. G. Galectins: versatile modulators of cell adhesion, cell proliferation, and cell death. J. Mol. Med. 76: 402-412, 1998.
19. Perillo, N. L., Pace, K. E., Seilhamer, J. J., and Baum, L. G. Apoptosis of T cells mediated by galectin-1. Nature 378: 736-739, 1995.
20. Devereux, J., Haeberli, P., and Smithies, O. A comprehensive set of sequence analysis programs for the VAX. Nucleic Acids Res. 12: 387-395, 1984.
21. Altschul, S. F., Gish, W., Miller, W., Myers, E. W., and Lipman, D. J. Basic local alignment search tool. J. Mol. Biol. 1990, Oct. 5., 215: 403-410,
22. Bierhuizen; M. F., Maemura, K., Kudo, S., and Fukuda, M. Genomic organization of core 2 and I branching beta-1,6-N- acetylglucosaminyltransferases. Implication for evolution of the beta- 1,6-N-acetylglucosaminyltransferase gene family. Glycobiology 5: 417-425, 1995.
23. Almeida, R., Amado, M., David, L., Levery, S. B., Holmes, E. H., Merkx, G., van Kessel, A. G., Rygaard, E., Hassan, H., Bennett, E., and Clausen, H. A family of human beta4-galactosyltransferases. Cloning and expression of two novel UDP-galactose: beta-N-acetylglucosamine beta1,4-galactosyltransferases, beta4Gal-T2 and beta4Gal-T3. J. Biol. Chem. 272: 31979-31991, 1997.
24. Bennett, E. P., Hassan, H., and Clausen, H. cDNA cloning and expression of a novel human UDP-N-acetyl-alpha-D-galactosamine. Polypeptide N-acetylgalactosaminyltransferase, GalNAc-T3. J. Biol. Chem. 271: 17006-17012, 1996.
25. Wandall, H. H., Hassan, H., Mirgorodskaya, E., Kristensen, A. K., Roepstorff, P., Bennett, E. P., Nielsen, P. A., Hollingsworth, M. A., Burchell, J., Taylor-Papadimitriou, J., and Clausen, H. Substrate specificities of three members of the human UDP-N-acetyl-alpha-D-galactosamine: Polypeptide N-acetylgalactosaminyltransferase family, GalNAc-T1, -T2, and -T3. J. Biol. Chem. 272: 23503-23514, 1997.
26. Matteucci, M. D. and Caruthers, M. H. J. Am. Chem. Soc. 103: 3185-3191. 1981.
27. Yoo, Y., Rote, K., and Rechsteiner, M. Synthesis of peptides as cloned ubiquitin extensions. J. Biol. Chem. 264: 17078-17083, 1989.
17
1
1362
DNA
Human
1
atgaagatat tcaaatgtta ttttaaacat accctacagc agaaagtttt catcctgttt 60
ttaaccctat ggctgctctc tttgttaaag cttctaaatg tgagacgact ctttccgcaa 120
aaagacattt acttggttga gtactcccta agtacctcgc cttttgtaag aaacagatac 180
actcatgtta aggatgaagt caggtatgaa gttaactgtt cgggtatcta tgaacaggag 240
cctttggaaa ttggaaagag tctggaaata agaagaaggg acatcattga cttggaggat 300
gatgatgttg tggcaatgac cagtgattgt gacatttatc agactctaag aggttatgct 360
caaaagcttg tctcaaagga ggagaaaagc ttcccaatag cctattcttt ggttgtccac 420
aaagatgcaa ttatggttga aaggcttatc catgctatat acaaccagca caatatttac 480
tgcatccatt atgatcgtaa ggcacctgat accttcaaag ttgccatgaa caatttagct 540
aagtgcttct ccaatatttt cattgcttcc aaattagagg ctgtggaata tgcccacatt 600
tccagactcc aggctgattt aaattgcttg tcggaccttc tgaagtcttc aatccagtgg 660
aaatatgtta tcaacttgtg tgggcaagat tttcccctga agtcaaattt tgaattggtg 720
tcagagttga aaaaactcaa tggagcaaat atgttggaga cggtgaaacc cccaaacagt 780
aaattggaaa gattcactta ccatcatgaa cttagacggg tgccttatga atatgtgaag 840
ctaccaataa ggacaaacat ctccaaggaa gcaccccccc ataacattca gatatttgtt 900
ggcagtgctt attttgtttt aagtcaagca tttgttaaat atattttcaa caactccatc 960
gttcaagact tttttgcctg gtctaaagac acatactctc ctgatgagca cttttgggct 1020
accttgattc gggttccagg aatacctggg gagatttcca gatcagccca ggatgtgtct 1080
gatctgcaga gtaagactcg ccttgtcaag tggaattact atgaaggctt tttctatccc 1140
agttgtactg gatctcacct tcgaagcgtg tgtatttatg gagctgcaga attaaggtgg 1200
cttatcaaag atggacattg gtttgctaat aaatttgatt ctaaggtgga ccctatcttg 1260
attaaatgct tggcagaaaa gcttgaagaa cagcagagag actggatcac tttgccctca 1320
gaaaagttat ttatggatag aaatctcact accacatcat ga 1362
2
453
PRT
Human
2
Met Lys Ile Phe Lys Cys Tyr Phe Lys His Thr Leu Gln Gln Lys Val
1 5 10 15
Phe Ile Leu Phe Leu Thr Leu Trp Leu Leu Ser Leu Leu Lys Leu Leu
20 25 30
Asn Val Arg Arg Leu Phe Pro Gln Lys Asp Ile Tyr Leu Val Glu Tyr
35 40 45
Ser Leu Ser Thr Ser Pro Phe Val Arg Asn Arg Tyr Thr His Val Lys
50 55 60
Asp Glu Val Arg Tyr Glu Val Asn Cys Ser Gly Ile Tyr Glu Gln Glu
65 70 75 80
Pro Leu Glu Ile Gly Lys Ser Leu Glu Ile Arg Arg Arg Asp Ile Ile
85 90 95
Asp Leu Glu Asp Asp Asp Val Val Ala Met Thr Ser Asp Cys Asp Ile
100 105 110
Tyr Gln Thr Leu Arg Gly Tyr Ala Gln Lys Leu Val Ser Lys Glu Glu
115 120 125
Lys Ser Phe Pro Ile Ala Tyr Ser Leu Val Val His Lys Asp Ala Ile
130 135 140
Met Val Glu Arg Leu Ile His Ala Ile Tyr Asn Gln His Asn Ile Tyr
145 150 155 160
Cys Ile His Tyr Asp Arg Lys Ala Pro Asp Thr Phe Lys Val Ala Met
165 170 175
Asn Asn Leu Ala Lys Cys Phe Ser Asn Ile Phe Ile Ala Ser Lys Leu
180 185 190
Glu Ala Val Glu Tyr Ala His Ile Ser Arg Leu Gln Ala Asp Leu Asn
195 200 205
Cys Leu Ser Asp Leu Leu Lys Ser Ser Ile Gln Trp Lys Tyr Val Ile
210 215 220
Asn Leu Cys Gly Gln Asp Phe Pro Leu Lys Ser Asn Phe Glu Leu Val
225 230 235 240
Ser Glu Leu Lys Lys Leu Asn Gly Ala Asn Met Leu Glu Thr Val Lys
245 250 255
Pro Pro Asn Ser Lys Leu Glu Arg Phe Thr Tyr His His Glu Leu Arg
260 265 270
Arg Val Pro Tyr Glu Tyr Val Lys Leu Pro Ile Arg Thr Asn Ile Ser
275 280 285
Lys Glu Ala Pro Pro His Asn Ile Gln Ile Phe Val Gly Ser Ala Tyr
290 295 300
Phe Val Leu Ser Gln Ala Phe Val Lys Tyr Ile Phe Asn Asn Ser Ile
305 310 315 320
Val Gln Asp Phe Phe Ala Trp Ser Lys Asp Thr Tyr Ser Pro Asp Glu
325 330 335
His Phe Trp Ala Thr Leu Ile Arg Val Pro Gly Ile Pro Gly Glu Ile
340 345 350
Ser Arg Ser Ala Gln Asp Val Ser Asp Leu Gln Ser Lys Thr Arg Leu
355 360 365
Val Lys Trp Asn Tyr Tyr Glu Gly Phe Phe Tyr Pro Ser Cys Thr Gly
370 375 380
Ser His Leu Arg Ser Val Cys Ile Tyr Gly Ala Ala Glu Leu Arg Trp
385 390 395 400
Leu Ile Lys Asp Gly His Trp Phe Ala Asn Lys Phe Asp Ser Lys Val
405 410 415
Asp Pro Ile Leu Ile Lys Cys Leu Ala Glu Lys Leu Glu Glu Gln Gln
420 425 430
Arg Asp Trp Ile Thr Leu Pro Ser Glu Lys Leu Phe Met Asp Arg Asn
435 440 445
Leu Thr Thr Thr Ser
450
3
21
DNA
Artificial Sequence
Primer
3
ggtttcaccg tctccaacat a 21
4
32
DNA
Artificial Sequence
Primer
4
cgaggatcca gaatgaagat attcaaatgt ta 32
5
31
DNA
Artificial Sequence
Primer
5
cgaggatccg caaaaagaca tttacttggt t 31
6
20
DNA
Artificial Sequence
Primer
6
tcgtaaggca cctgatactt 20
7
22
DNA
Artificial Sequence
Primer
7
gagtcagtgt ggaattgaat ac 22
8
21
DNA
Artificial Sequence
Primer
8
gatctctgat ttggctcagt g 21
9
31
DNA
Artificial Sequence
Primer
9
agcgaattct tactatcatg atgtggtagt g 31
10
21
DNA
Artificial Sequence
Primer
10
gggcagcatt tgcctagtat g 21
11
20
DNA
Artificial Sequence
Primer
11
caacagtctc ctcaaccctg 20
12
1287
DNA
Human
12
atgctgagga cgttgctgcg aaggagactt ttttcttatc ccaccaaata ctactttatg 60
gttcttgttt tatccctaat caccttctcc gttttaagga ttcatcaaaa gcctgaattt 120
gtaagtgtca gacacttgga gcttgctggg gagaatccta gtagtgatat taattgcacc 180
aaagttttac agggtgatgt aaatgaaatc caaaaggtaa agcttgagat cctaacagtg 240
aaatttaaaa agcgccctcg gtggacacct gacgactata taaacatgac cagtgactgt 300
tcttctttca tcaagagacg caaatatatt gtagaacccc ttagtaaaga agaggcggag 360
tttccaatag catattctat agtggttcat cacaagattg aaatgcttga caggctgctg 420
agggccatct atatgcctca gaatttctat tgcgttcatg tggacacaaa atccgaggat 480
tcctatttag ctgcagtgat gggcatcgct tcctgtttta gtaatgtctt tgtggccagc 540
cgattggaga gtgtggttta tgcatcgtgg agccgggttc aggctgacct caactgcatg 600
aaggatctct atgcaatgag tgcaaactgg aagtacttga taaatctttg tggtatggat 660
tttcccatta aaaccaacct agaaattgtc aggaagctca agttgttaat gggagaaaac 720
aacctggaaa cggagaggat gccatcccat aaagaagaaa ggtggaagaa gcggtatgag 780
gtcgttaatg gaaagctgac aaacacaggg actgtcaaaa tgcttcctcc actcgaaaca 840
cctctctttt ctggcagtgc ctacttcgtg gtcagtaggg agtatgtggg gtatgtacta 900
cagaatgaaa aaatccaaaa gttgatggag tgggcacaag acacatacag ccctgatgag 960
tatctctggg ccaccatcca aaggattcct gaagtcccgg gctcactccc tgccagccat 1020
aagtatgatc tatctgacat gcaagcagtt gccaggtttg tcaagtggca gtactttgag 1080
ggtgatgttt ccaagggtgc tccctacccg ccctgcgatg gagtccatgt gcgctcagtg 1140
tgcattttcg gagctggtga cttgaactgg atgctgcgca aacaccactt gtttgccaat 1200
aagtttgacg tggatgttga cctctttgcc atccagtgtt tggatgagca tttgagacac 1260
aaagctttgg agacattaaa acactga 1287
13
428
PRT
Human
13
Met Leu Arg Thr Leu Leu Arg Arg Arg Leu Phe Ser Tyr Pro Thr Lys
1 5 10 15
Tyr Tyr Phe Met Val Leu Val Leu Ser Leu Ile Thr Phe Ser Val Leu
20 25 30
Arg Ile His Gln Lys Pro Glu Phe Val Ser Val Arg His Leu Glu Leu
35 40 45
Ala Gly Glu Asn Pro Ser Ser Asp Ile Asn Cys Thr Lys Val Leu Gln
50 55 60
Gly Asp Val Asn Glu Ile Gln Lys Val Lys Leu Glu Ile Leu Thr Val
65 70 75 80
Lys Phe Lys Lys Arg Pro Arg Trp Thr Pro Asp Asp Tyr Ile Asn Met
85 90 95
Thr Ser Asp Cys Ser Ser Phe Ile Lys Arg Arg Lys Tyr Ile Val Glu
100 105 110
Pro Leu Ser Lys Glu Glu Ala Glu Phe Pro Ile Ala Tyr Ser Ile Val
115 120 125
Val His His Lys Ile Glu Met Leu Asp Arg Leu Leu Arg Ala Ile Tyr
130 135 140
Met Pro Gln Asn Phe Tyr Cys Val His Val Asp Thr Lys Ser Glu Asp
145 150 155 160
Ser Tyr Leu Ala Ala Val Met Gly Ile Ala Ser Cys Phe Ser Asn Val
165 170 175
Phe Val Ala Ser Arg Leu Glu Ser Val Val Tyr Ala Ser Trp Ser Arg
180 185 190
Val Gln Ala Asp Leu Asn Cys Met Lys Asp Leu Tyr Ala Met Ser Ala
195 200 205
Asn Trp Lys Tyr Leu Ile Asn Leu Cys Gly Met Asp Phe Pro Ile Lys
210 215 220
Thr Asn Leu Glu Ile Val Arg Lys Leu Lys Leu Leu Met Gly Glu Asn
225 230 235 240
Asn Leu Glu Thr Glu Arg Met Pro Ser His Lys Glu Glu Arg Trp Lys
245 250 255
Lys Arg Tyr Glu Val Val Asn Gly Lys Leu Thr Asn Thr Gly Thr Val
260 265 270
Lys Met Leu Pro Pro Leu Glu Thr Pro Leu Phe Ser Gly Ser Ala Tyr
275 280 285
Phe Val Val Ser Arg Glu Tyr Val Gly Tyr Val Leu Gln Asn Glu Lys
290 295 300
Ile Gln Lys Leu Met Glu Trp Ala Gln Asp Thr Tyr Ser Pro Asp Glu
305 310 315 320
Tyr Leu Trp Ala Thr Ile Gln Arg Ile Pro Glu Val Pro Gly Ser Leu
325 330 335
Pro Ala Ser His Lys Tyr Asp Leu Ser Asp Met Gln Ala Val Ala Arg
340 345 350
Phe Val Lys Trp Gln Tyr Phe Glu Gly Asp Val Ser Lys Gly Ala Pro
355 360 365
Tyr Pro Pro Cys Asp Gly Val His Val Arg Ser Val Cys Ile Phe Gly
370 375 380
Ala Gly Asp Leu Asn Trp Met Leu Arg Lys His His Leu Phe Ala Asn
385 390 395 400
Lys Phe Asp Val Asp Val Asp Leu Phe Ala Ile Gln Cys Leu Asp Glu
405 410 415
His Leu Arg His Lys Ala Leu Glu Thr Leu Lys His
420 425
14
1317
DNA
Human
14
atggttcaat ggaagagact ctgccagctg cattacttgt gggctctggg ctgctatatg 60
ctgctggcca ctgtggctct gaaactttct ttcaggttga agtgtgactc tgaccacttg 120
ggtctggagt ccagggaatc tcaaagccag tactgtagga atatcttgta taatttcctg 180
aaacttccag caaagaggtc tatcaactgt tcaggggtca cccgagggga ccaagaggca 240
gtgcttcagg ctattctgaa taacctggag gtcaagaaga agcgagagcc tttcacagac 300
acccactacc tctccctcac cagagactgt gagcacttca aggctgaaag gaagttcata 360
cagttcccac tgagcaaaga agaggtggag ttccctattg catactctat ggtgattcat 420
gagaagattg aaaactttga aaggctactg cgagctgtgt atgcccctca gaacatatac 480
tgtgtccatg tggatgagaa gtccccagaa actttcaaag aggcggtcaa agcaattatt 540
tcttgcttcc caaatgtctt catagccagt aagctggttc gggtggttta tgcctcctgg 600
tccagggtgc aagctgacct caactgcatg gaagacttgc tccagagctc agtgccgtgg 660
aaatacttcc tgaatacatg tgggacggac tttcctataa agagcaatgc agagatggtc 720
caggctctca agatgttgaa tgggaggaat agcatggagt cagaggtacc tcctaagcac 780
aaagaaaccc gctggaaata tcactttgag gtagtgagag acacattaca cctaaccaac 840
aagaagaagg atcctccccc ttataattta actatgttta cagggaatgc gtacattgtg 900
gcttcccgag atttcgtcca acatgttttg aagaacccta aatcccaaca actgattgaa 960
tgggtaaaag acacttatag cccagatgaa cacctctggg ccacccttca gcgtgcacgg 1020
tggatgcctg gctctgttcc caaccacccc aagtacgaca tctcagacat gacttctatt 1080
gccaggctgg tcaagtggca gggtcatgag ggagacatcg ataagggtgc tccttatgct 1140
ccctgctctg gaatccacca gcgggctatc tgcgtttatg gggctgggga cttgaattgg 1200
atgcttcaaa accatcacct gttggccaac aagtttgacc caaaggtaga tgataatgct 1260
cttcagtgct tagaagaata cctacgttat aaggccatct atgggactga actttga 1317
15
438
PRT
Human
15
Met Val Gln Trp Lys Arg Leu Cys Gln Leu His Tyr Leu Trp Ala Leu
1 5 10 15
Gly Cys Tyr Met Leu Leu Ala Thr Val Ala Leu Lys Leu Ser Phe Arg
20 25 30
Leu Lys Cys Asp Ser Asp His Leu Gly Leu Glu Ser Arg Glu Ser Gln
35 40 45
Ser Gln Tyr Cys Arg Asn Ile Leu Tyr Asn Phe Leu Lys Leu Pro Ala
50 55 60
Lys Arg Ser Ile Asn Cys Ser Gly Val Thr Arg Gly Asp Gln Glu Ala
65 70 75 80
Val Leu Gln Ala Ile Leu Asn Asn Leu Glu Val Lys Lys Lys Arg Glu
85 90 95
Pro Phe Thr Asp Thr His Tyr Leu Ser Leu Thr Arg Asp Cys Glu His
100 105 110
Phe Lys Ala Glu Arg Lys Phe Ile Gln Phe Pro Leu Ser Lys Glu Glu
115 120 125
Val Glu Phe Pro Ile Ala Tyr Ser Met Val Ile His Glu Lys Ile Glu
130 135 140
Asn Phe Glu Arg Leu Leu Arg Ala Val Tyr Ala Pro Gln Asn Ile Tyr
145 150 155 160
Cys Val His Val Asp Glu Lys Ser Pro Glu Thr Phe Lys Glu Ala Val
165 170 175
Lys Ala Ile Ile Ser Cys Phe Pro Asn Val Phe Ile Ala Ser Lys Leu
180 185 190
Val Arg Val Val Tyr Ala Ser Trp Ser Arg Val Gln Ala Asp Leu Asn
195 200 205
Cys Met Glu Asp Leu Leu Gln Ser Ser Val Pro Trp Lys Tyr Phe Leu
210 215 220
Asn Thr Cys Gly Thr Asp Phe Pro Ile Lys Ser Asn Ala Glu Met Val
225 230 235 240
Gln Ala Leu Lys Met Leu Asn Gly Arg Asn Ser Met Glu Ser Glu Val
245 250 255
Pro Pro Lys His Lys Glu Thr Arg Trp Lys Tyr His Phe Glu Val Val
260 265 270
Arg Asp Thr Leu His Leu Thr Asn Lys Lys Lys Asp Pro Pro Pro Tyr
275 280 285
Asn Leu Thr Met Phe Thr Gly Asn Ala Tyr Ile Val Ala Ser Arg Asp
290 295 300
Phe Val Gln His Val Leu Lys Asn Pro Lys Ser Gln Gln Leu Ile Glu
305 310 315 320
Trp Val Lys Asp Thr Tyr Ser Pro Asp Glu His Leu Trp Ala Thr Leu
325 330 335
Gln Arg Ala Arg Trp Met Pro Gly Ser Val Pro Asn His Pro Lys Tyr
340 345 350
Asp Ile Ser Asp Met Thr Ser Ile Ala Arg Leu Val Lys Trp Gln Gly
355 360 365
His Glu Gly Asp Ile Asp Lys Gly Ala Pro Tyr Ala Pro Cys Ser Gly
370 375 380
Ile His Gln Arg Ala Ile Cys Val Tyr Gly Ala Gly Asp Leu Asn Trp
385 390 395 400
Met Leu Gln Asn His His Leu Leu Ala Asn Lys Phe Asp Pro Lys Val
405 410 415
Asp Asp Asn Ala Leu Gln Cys Leu Glu Glu Tyr Leu Arg Tyr Lys Ala
420 425 430
Ile Tyr Gly Thr Glu Leu
435
16
1203
DNA
Human
16
atgcctttat caatgcgtta cctcttcata atttctgtct ctagtgtaat tatttttatc 60
gtcttctctg tgttcaattt tgggggagat ccaagcttcc aaaggctaaa tatctcagac 120
cctttgaggc tgactcaagt ttgcacatct tttatcaatg gaaaaacacg tttcctgtgg 180
aaaaacaaac taatgatcca tgagaagtct tcttgcaagg aatacttgac ccagagccac 240
tacatcacag cccctttatc taaggaagaa gctgactttc ccttggcata tataatggtc 300
atccatcatc actttgacac ctttgcaagg ctcttcaggg ctatttacat gccccaaaat 360
atctactgtg ttcatgtgga tgaaaaagca acaactgaat ttaaagatgc ggtagagcaa 420
ctattaagct gcttcccaaa cgcttttctg gcttccaaga tggaacccgt tgtctatgga 480
gggatctcca ggctccaggc tgacctgaac tgcatcagag atctttctgc cttcgaggtc 540
tcatggaagt acgttatcaa cacctgtggg caagacttcc ccctgaaaac caacaaggaa 600
atagttcagt atctgaaagg atttaaaggt aaaaatatca ccccaggggt gctgccccca 660
gctcatgcaa ttggacggac taaatatgtc caccaagagc acctgggcaa agagctttcc 720
tatgtgataa gaacaacagc gttgaaaccg cctccccccc ataatctcac aatttacttt 780
ggctctgcct atgtggctct atcaagagag tttgccaact ttgttctgca tgacccacgg 840
gctgttgatt tgctccagtg gtccaaggac actttcagtc ctgatgagca tttctgggtg 900
acactcaata ggattccagg tgttcctggc tctatgccaa atgcatcctg gactggaaac 960
ctcagagcta taaagtggag tgacatggaa gacagacacg gaggctgcca cggccactat 1020
gtacatggta tttgtatcta tggaaacgga gacttaaagt ggctggttaa ttcaccaagc 1080
ctgtttgcta acaagtttga gcttaatacc taccccctta ctgtggaatg cctagaactg 1140
aggcatcgcg aaagaaccct caatcagagt gaaactgcga tacaacccag ctggtatttt 1200
tga 1203
17
400
PRT
Human
17
Met Pro Leu Ser Met Arg Tyr Leu Phe Ile Ile Ser Val Ser Ser Val
1 5 10 15
Ile Ile Phe Ile Val Phe Ser Val Phe Asn Phe Gly Gly Asp Pro Ser
20 25 30
Phe Gln Arg Leu Asn Ile Ser Asp Pro Leu Arg Leu Thr Gln Val Cys
35 40 45
Thr Ser Phe Ile Asn Gly Lys Thr Arg Phe Leu Trp Lys Asn Lys Leu
50 55 60
Met Ile His Glu Lys Ser Ser Cys Lys Glu Tyr Leu Thr Gln Ser His
65 70 75 80
Tyr Ile Thr Ala Pro Leu Ser Lys Glu Glu Ala Asp Phe Pro Leu Ala
85 90 95
Tyr Ile Met Val Ile His His His Phe Asp Thr Phe Ala Arg Leu Phe
100 105 110
Arg Ala Ile Tyr Met Pro Gln Asn Ile Tyr Cys Val His Val Asp Glu
115 120 125
Lys Ala Thr Thr Glu Phe Lys Asp Ala Val Glu Gln Leu Leu Ser Cys
130 135 140
Phe Pro Asn Ala Phe Leu Ala Ser Lys Met Glu Pro Val Val Tyr Gly
145 150 155 160
Gly Ile Ser Arg Leu Gln Ala Asp Leu Asn Cys Ile Arg Asp Leu Ser
165 170 175
Ala Phe Glu Val Ser Trp Lys Tyr Val Ile Asn Thr Cys Gly Gln Asp
180 185 190
Phe Pro Leu Lys Thr Asn Lys Glu Ile Val Gln Tyr Leu Lys Gly Phe
195 200 205
Lys Gly Lys Asn Ile Thr Pro Gly Val Leu Pro Pro Ala His Ala Ile
210 215 220
Gly Arg Thr Lys Tyr Val His Gln Glu His Leu Gly Lys Glu Leu Ser
225 230 235 240
Tyr Val Ile Arg Thr Thr Ala Leu Lys Pro Pro Pro Pro His Asn Leu
245 250 255
Thr Ile Tyr Phe Gly Ser Ala Tyr Val Ala Leu Ser Arg Glu Phe Ala
260 265 270
Asn Phe Val Leu His Asp Pro Arg Ala Val Asp Leu Leu Gln Trp Ser
275 280 285
Lys Asp Thr Phe Ser Pro Asp Glu His Phe Trp Val Thr Leu Asn Arg
290 295 300
Ile Pro Gly Val Pro Gly Ser Met Pro Asn Ala Ser Trp Thr Gly Asn
305 310 315 320
Leu Arg Ala Ile Lys Trp Ser Asp Met Glu Asp Arg His Gly Gly Cys
325 330 335
His Gly His Tyr Val His Gly Ile Cys Ile Tyr Gly Asn Gly Asp Leu
340 345 350
Lys Trp Leu Val Asn Ser Pro Ser Leu Phe Ala Asn Lys Phe Glu Leu
355 360 365
Asn Thr Tyr Pro Leu Thr Val Glu Cys Leu Glu Leu Arg His Arg Glu
370 375 380
Arg Thr Leu Asn Gln Ser Glu Thr Ala Ile Gln Pro Ser Trp Tyr Phe
385 390 395 400 | A novel gene defining a novel human UDP-GlcNAc: Galβ1-3 GalNAcα β1,6GlcNAc-transferase, termed C2GnT3, with unique enzymatic properties is disclosed. The enzymatic activity of C2GnT3 is shown to be distinct from that of previously identified enzymes of this gene family. The invention discloses isolated DNA molecules and DNA constructs encoding C2GnT3 and derivatives thereof by way of amino acid deletion, substitution or insertion exhibiting C2GnT3 activity, as well as cloning and expression vectors including such DNA, cells transfected with the vectors, and recombinant methods for providing C2GnT3. The enzyme C2GnT3 and C2GnT3-active derivatives thereof are disclosed, in particular soluble derivatives comprising the catalytically active domain of C2GnT3. Further, the invention discloses methods of obtaining 1,6-N-acetylglucosaminyl glycosylated saccharides, glycopeptides or glycoproteins by use of an enzymically active C2GnT3 protein or fusion protein thereof or by using cells stably transfected with a vector including DNA encoding an enzymatically active C2GnT3 protein as an expression system for recombinant production of such glycopeptides or glycoproteins. Methods are disclosed for the identification of agents with the ability to inhibit or stimulate the biological activity of C2GnT3. Furthermore, methods of using C2GnT3 in the structure-based design of inhibitors or stimulators thereof are also disclosed in the invention. Also a method for the identification of DNA sequence variations in the C2GnT3 gene by isolating DNA from a patient, amplifying C2GnT3-coding exons by PCR, and detecting the presence of DNA sequence variation, are disclosed. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. Ser. No. 13/035,387, filed Feb. 25, 2011, which is based upon and claims the benefit of priority of the prior Japanese Patent Application No. 2010-79051 filed on Mar. 30, 2010, the entire contents of which are incorporated herein by reference.
FIELD
The present application relates to a storage device, a data processing device, a registration method, and a recording medium that prevent data leakage.
BACKGROUND
As one of technologies for preventing leakage of information stored in a personal computer (PC), for example, there is known a technology for preventing, when a PC is stolen, information leakage from the stolen PC by erasing an encryption key of an encrypted hard disk drive (HDD) provided in the PC by an instruction from remote. That is, by erasing the encryption key, it becomes impossible to decrypt encrypted information in the HDD so that the information leakage may be prevented.
However, in the above-described technology, since the encryption key may not be erased when the HDD is detached from the PC before the instruction from remote is received, there is a possibility that the encrypted information in the HDD is decrypted by using other PCs.
As a technology capable of solving such problem, for example, as described in Japanese Laid-open Patent Publication No. 2009-258979, there is a HDD including a self-erasing function in which a disk erasing program and a circuit for executing the erasing program are mounted and, when configuration between a BIOS and the HDD fails, the erasing program is executed to erase information in the HDD.
With this technology, for example, after the HDD is detached from the PC, when trying to connect the HDD to another PC to view the information in the HDD, the information in the HDD is erased at the point when the HDD is connected to another PC to be activated.
However, since the above-described HDD including the self-erasing function may be required modification of hardware, the HDD includes a problem that it is difficult for companies that develop anti-theft technologies for PCs to incorporate the anti-theft technologies in existing HDDs.
SUMMARY
A storage device disclosed in the present application includes a switching unit which switches an access destination in a storage area between a first storage area and a second storage area in response to an access request from a host device; and a nonvolatile storage medium which stores a first host device information used to identify the host device in the second storage area, and a software module executed by a CPU provided in the host device, the software module comprising: causing the host device to function as a first host device information acquisition unit which acquires the first host device information stored in the second storage area, causing the host device to function as a second host device information acquisition unit which acquires a second host device information used to identify the host device from a nonvolatile storage medium stored by the host device that is different from the storage device, and causing an authority grant unit which transmits a control signal for switching the access destination to the first storage area to the switching unit of the storage device, when the acquired first and second host device information are compared to find that the first and second host device information match with each other.
The object and advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the claims.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are not restrictive of the invention, as claimed.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic view illustrating a schematic structure of a storage device according to the present embodiment;
FIG. 2 is a schematic view explaining a functional structure of the storage device;
FIG. 3 is a flowchart illustrating a processing procedure on boot-up;
FIG. 4 is a schematic view illustrating a structure at the time of an initial setting;
FIG. 5 is a flowchart illustrating a procedure for the initial setting;
FIG. 6 is a schematic view illustrating a structure at the time of maintenance processing;
FIG. 7 is a flowchart explaining a procedure for the maintenance processing; and
FIG. 8 is a schematic view illustrating a device structure of a second embodiment.
DESCRIPTION OF EMBODIMENTS
The present invention will be specifically described hereinbelow on the basis of the drawings illustrating embodiments thereof.
First Embodiment
FIG. 1 is a schematic view illustrating a schematic structure of a storage device according to the present embodiment. A storage device 1 according to the present embodiment is a storage device in conformity with TCG Opal SSC specifications (Trusted Computing Group Opal Security Subsystem Class) standardized by TCG (Trusted Computing Group). Specifically, the storage device 1 according to the present embodiment is a storage device such as a HDD (Hard Disk Drive), a SSD (Solid State Drive), or the like.
A conventional HDD (a HDD that is not in conformity with TCG Opal SSC specifications) is capable of including only one image that may be activated in a storage area, but a storage device in conformity with TCG Opal SSC specifications (hereinafter referred to as a TCG-HDD) is capable of including two images. One is in a data storage area 11 where user's data is stored, and the other one is in a PBA area 12 (PBA: PreBoot Authentication) that includes an authentication function, and is generated for the purpose of carrying out authentication before boot-up of a PC.
The storage device 1 according to the present embodiment includes the above-mentioned data storage area 11 and PBA area 12 , and includes an image switching unit 10 for switching the storage area to be used on boot-up.
The image switching unit 10 performs image load control and access control of the data storage area 11 and the PBA area 12 . In the data storage area 11 , there are stored an OS (Operating System) booted by a PC 2 as a connection destination (see FIG. 2 ), data created by a user of the PC 2 , and the like. In the PBA area 12 , the OS image may also be stored similarly to the storage area, and the capacity of 128 Mbytes is secured.
As operational modes of the TCG-HDD, there are two types of an ATA mode and a TCG mode. In the ATA mode, the HDD may be controlled from the outside (BIOS and OS) by using the same ATA command as that for the conventional HDD, and the same usage as that for the conventional HDD may be adopted. However, the image switching or the preboot authentication (PBA) that characterize the TCG-HDD do not function.
On the other hand, in the TCG mode, the HDD is controlled by using a TCG command that is different from the conventional command. In addition, in the TCG mode as well, it is possible to set use/non-use of the PBA area 12 and, when the PBA area 12 is not used, the OS image in the data storage area 11 is activated similarly to the conventional HDD.
The storage device 1 according to the present embodiment is constituted such that the image switching unit 10 and the PBA area 12 function by adopting a setting in which the TCG mode and the PBA area 12 are used. In the conventional HDD, a MBR (Master Boot Record) is provided at the head portion of the storage area and, when the control is shifted from the BIOS to the HDD, the MBR is firstly read. In the TCG-HDD as well, a Shadow-MBR is provided in the PBA area 12 .
In a case where the control is shifted to the image switching unit 10 from the BIOS, when the preboot authentication (PBA) is used, the image switching unit 10 loads the image in the PBA area 12 in order to read the Shadow-MBR. When the image is switched from the image in the PBA area 12 to the image in the data storage area 11 , a program stored in the PBA area 12 performs the control. A CPU (not illustrated) in the PC 2 executes a “MBR-DONE” command as the TCG command, and the image switching unit 10 thereby loads the image in the data storage area 11 to switch the OS image.
As will be described later, when a PC as a connection destination is not authenticated, the storage device 1 erases data stored in the data storage area 11 . The erasing of data may be implemented by directly overwriting the data by 0.
In addition, since the TCG-HDD includes an encryption function using hardware, the erasing of the data may also be implemented by re-generating an encryption key instead of the erasing by directly overwriting the data. Specifically, a “GenKey” command as the TCG command is used. The “GenKey” command is an erasing command corresponding to “Security Erase Unit” as the ATA command.
FIG. 2 is a schematic view explaining the functional structure of the storage device 1 . FIG. 2 also illustrates the schematic structure of the PC 2 as the connection destination for the explanation. The PC 2 is, e.g., a personal computer, and includes a CPU, a ROM, a RAM and the like. A device information storing unit 21 of the PC 2 stores information that uniquely identifies the PC 2 (device information). For example, it is possible to use a unique information of 18 digits (FMVAB1Z300R1234567 or the like) obtained by combining the model name and the production number of the PC 2 .
In the present embodiment, although the device information is stored in the device information storing unit 21 , the device information may also be stored in a NVRAM of a BIOS 20 .
The storage device 1 is capable of acquiring the device information via the BIOS 20 of the PC 2 . It may be considered that the method for acquiring the device information differs according to a model or a manufacturer. In this case, the storage device 1 is not capable of registering another model or a PC manufactured by another manufacturer as a registered PC. However, the storage device 1 may recognize that the PC is different from the registered PC by not being able to acquire the device information, it is possible to execute the erasing of data in the data storage area 11 .
The PBA area 12 of the storage device 1 includes a device authentication unit 121 , an erasing unit 122 , and a registered device information storing unit 123 that function by being run by the CPU of the PC 2 when the authentication of the HDD or the data erasing is performed, and a maintenance processing unit 124 and a maintenance device information storing unit 125 that function by being run by the CPU of the PC 2 at the time of the maintenance of the HDD.
The device authentication unit 121 compares the device information of the PC 2 to which the device (storage device 1 ) is connected with a device information retained in the registered device information storing unit 123 to perform authentication. When the device authentication unit 121 authenticates the connected PC 2 , the device authentication unit 121 grants access authority to the data storage area 11 to the image switching unit 10 , and causes the image switching unit 10 to load the OS image in the data storage area 11 . When the device authentication unit 121 does not authenticate the connected PC 2 , the device authentication unit 121 instructs the erasing unit 122 to erase data stored in the data storage area 11 .
In addition, when there is no device information registered in the registered device information storing unit 123 , the registered device information storing unit 123 acquires the device information of the PC 2 to which the device (storage device 1 ) is connected, and registers the acquired device information.
The erasing unit 122 receives the instruction of the device authentication unit 121 to erase data in the data storage area 11 . In the present embodiment, the data erasing is performed by resetting an encryption key with which data is encrypted.
In the registered device information storing unit 123 , the device information acquired from the PC 2 to which the device (storage device 1 ) is connected is registered at the time of initial registration. In addition, it is also possible to register the device information by providing an application for registering the device information (registration application) in the PBA area 12 or on the OS. For example, there may be considered a method in which a registration application that displays a menu screen in the PC 2 when a specific operation is performed at a certain timing is provided in the PBA area 12 in advance, and the device information is registered from the menu screen.
In the present embodiment, the registered device information storing unit 123 is assumed to be capable of registration of a plurality of devices. It is assumed that the first device to be registered is automatically registered by an initial setting, and the second and subsequent devices are additionally registered by a user using the registration application in the PBA area 12 or on the OS.
The maintenance processing unit 124 compares the device information of the PC 2 to which the device (storage device 1 ) is connected with a device information retained in the maintenance device information storing unit 125 , and executes maintenance processing when the device information match with each other. In the maintenance processing, the device information stored in the registered device information storing unit 123 and the maintenance device information storing unit 125 are cleared. By clearing the registered device information storing unit 123 , it becomes possible to re-register the device. When the device information do not match with each other, the device information stored in the maintenance device information storing unit 125 is cleared, and the processing is shifted to the device authentication unit 121 . When the device information is not retained in the maintenance device information storing unit 125 , the processing is shifted to the device authentication unit 121 without carrying out any operation.
In the maintenance device information storing unit 125 , the device information of a PC for maintenance (PC 2 ) is registered. The reason why the device information retained therein is cleared every time the maintenance processing is performed is to prevent the avoidance of execution of the HDD erasing on boot-up by registering the PC for maintenance.
FIG. 3 is a flowchart illustrating a processing procedure on boot-up. When the PC 2 is booted (at S 11 ), the PC 2 executes processing of the BIOS 20 (at S 12 ). When the storage device 1 in conformity with the TCG Opal SSC specifications is connected to the PC 2 , the PC 2 loads the image in the PBA area 12 into a storage of the PC 2 such as the RAM or the like, and runs the image by the CPU of the PC 2 (at S 13 ). The image in the PBA area 12 is loaded and run by the CPU of the PC 2 , whereby the device authentication unit 121 , the erasing unit 122 , and the maintenance processing unit 124 function in the PC 2 .
The device authentication unit 121 acquires the device information from the PC 2 to which the device (storage device 1 ) is connected, and compares the device information with the device information retained in the registered device information storing unit 123 to determine whether or not the device information match with each other, whereby the device authentication unit 121 performs device authentication (at S 14 ).
When the device information match with each other (S 14 : YES), an authority grant signal for granting the access authority to the data storage area 11 to the image switching unit 10 is transmitted from the PC 2 to the device (storage device 1 ), and the image in the data storage area 11 is activated (at S 15 ). That is, the image in the data storage area 11 is loaded into the storage of the PC 2 such as the RAM or the like, and the image is run by the CPU of the PC 2 .
When the device information do not match with each other (S 14 : NO), the device authentication unit 121 instructs the erasing unit 122 to erase data in the data storage area 11 , and the erasing unit 122 resets the encryption key to erase data stored in the data storage area 11 (at S 16 ).
With these operations, even when trying to detach the storage device 1 connected to the authorized PC 2 and obtain data therein by connecting the storage device 1 to another PC, the data in the data storage area 11 is erased at the point when the PC is booted so that the leakage of secret information may be prevented.
Next, a description will be given of a procedure when the authentication function and the erasing function according to the present embodiment are set in the TCG-HDD. FIG. 4 is a schematic view illustrating the structure at the time of an initial setting. In order to set the authentication function and the erasing function in the TCG-HDD, it is preferable to set execution programs for implementing the above-described device authentication unit 121 , erasing unit 122 , and maintenance processing unit 124 , and storage areas for the registered device information storing unit 123 and the maintenance device information storing unit 125 in the PBA area 12 .
Since there is a possibility that such initial setting is made by a manufacturing plant or a user, as a method that allows the manufacturing plant and the user to easily make the initial setting, a structure is adopted in which an external medium 3 such as a CD-ROM, a USB memory or the like includes an initial setting unit 31 and execution programs to be installed.
The above-mentioned execution programs stored in the external medium 3 are captured into the PBA area 12 of the storage device 1 via an IF unit 22 of the PC 2 .
Since the registered device information is set in the initial setting processing, when the setting is completed, it is preferable to avoid the execution of an unnecessary initial setting. For example, there may be considered a method in which it is determined whether or not the programs are already installed in the PBA area 12 at the beginning of the processing by the initial setting unit 31 , and the initial setting processing is stopped when the programs are already set, or the like.
Further, in the method utilizing the PBA area 12 , a structure may also be adopted in which an initial setting program is stored in the PBA area 12 , the initial setting program downloads the execution programs from the external medium 3 at the first boot-up, and the initial setting program is erased at a stage where various settings are completed.
FIG. 5 is a flowchart illustrating a procedure for the initial setting. The flowchart illustrated in FIG. 5 illustrates a procedure when the initial setting is performed by a user. This initial setting is performed during boot-up of the OS. First, during boot-up of the OS, the external medium 3 such as the CD-ROM, the USB memory or the like is connected to the IF unit 22 of the PC 2 , and the initial setting processing by the initial setting unit 31 is executed (at S 21 ). The initial setting unit 31 may be automatically run when the external medium 3 is inserted into a drive.
The initial setting unit 31 firstly performs authentication (at S 22 ). In the authentication, it is possible to use user authentication, and device authentication. For example, by requiring password input, it is possible to allow only an authorized user to execute the initial setting. In addition, it is also possible to perform authentication in which manufacturer information of a device is acquired from the BIOS 20 in advance, and the initial setting is terminated when the device is a PC manufactured by the other manufacturers, or the manufacturer information is not obtained. The manufacturer information is retained in the NVRAM of the BIOS 20 similarly to a model number and the like.
When the authentication is successful (S 22 : YES), the initial setting unit 31 determines whether or not the execution programs are already installed in the PBA area 12 (at S 23 ). When the authentication is unsuccessful in the at S 22 (S 22 : NO), or when the execution programs are installed in the PBA area 12 (S 23 : YES), the processing according to the present flowchart is terminated.
When the authentication is successful (S 22 : YES) and it is determined that the execution programs are not installed in the PBA area 12 (S 23 : NO), the initial setting unit 31 starts the initial setting.
The initial setting unit 31 firstly installs the respective execution programs of the device authentication unit 121 , the erasing unit 122 , and the maintenance processing unit 124 in the PBA area 12 (at S 24 ). After the installation of the execution programs, the initial setting unit 31 secures areas for the registered device information storing unit 123 and the maintenance device information storing unit 125 , and sets the device information of the PC 2 to which the device (storage device 1 ) is currently connected in the registered device information storing unit 123 (at S 25 ).
The above-described operations complete the initial setting. On the next or subsequent boot-up, when the storage device 1 is connected to a PC other than the registered PC 2 , and the PC is booted, data stored in the data storage area 11 of the storage device 1 is erased.
Next, the maintenance processing will be described. FIG. 6 is a schematic view illustrating the structure at the time of the maintenance processing. Similarly to the initial setting, a structure is adopted in which the maintenance processing is executed by using an external medium 4 . A maintenance device registration unit 41 is contained in the external medium 4 that may be activated from the BIOS 20 of the PC 2 , and the PC 2 is registered as a device for maintenance in the storage device 1 only when the BIOS 20 activates the external medium 4 .
In the present embodiment, although a structure is adopted in which the maintenance device registration unit 41 is contained in the external medium 4 , a structure may also be adopted in which the maintenance device registration unit 41 is contained in the PC 2 , the PBA area 12 of the storage device 1 , a server on a network, or the like.
In addition, in the storage device 1 including the self-erasing function as described in the present embodiment, since data in the data storage area 11 is erased when a maintenance operation fails, it is desirable that the maintenance processing without any operational mistake may be executed. When the maintenance device registration unit 41 is contained in the PC 2 or the storage device 1 , it is preferable for a person in charge of the maintenance to perform an operation for reporting a timing for the maintenance at a specific timing. Accordingly, there is a possibility that mistakes are made due to the intervention of manual work by the person.
When the maintenance device registration unit 41 is contained in the server on the network, the maintenance processing is possible only in an environment that allows connection to the network.
When the external medium 4 is utilized, the maintenance processing is executed at a timing at which the external medium 4 is connected to the PC 2 . In particular, in a setting of a device startup sequence in the BIOS 20 , the external medium 4 such as the CD-ROM, the USB memory or the like is prioritized over the HDD, whereby the maintenance processing may be reliably started only by connecting the external medium 4 and booting the PC 2 .
However, when the external medium 4 is prioritized to be activated without limitation, there is a possibility that the operation becomes a method for avoiding the erasing of the HDD. Consequently, it is preferable to include some limitation that prevents the activation of the external medium 4 for the maintenance. For example, similarly to the initial setting, it is preferable to screen a device capable of using the external medium 4 by acquiring the manufacturer information from the PC 2 to allow the maintenance only with a device manufactured by a specific manufacturer, acquiring the model number of the device to allow the maintenance only when the model numbers match with each other, or the like. In addition, there may be considered a method in which a different password is set for each external medium 4 and the password may be required before the maintenance processing is executed. With this method, it becomes possible to screen a user capable of using the external medium 4 .
FIG. 7 is a flowchart explaining the procedure for the maintenance processing. First, the PC 2 is booted from the external medium 4 (at S 31 ), and the device information of the PC 2 is acquired (at S 32 ). Next, the maintenance device registration unit 41 of the external medium 4 sets the acquired device information of the PC 2 in the maintenance device information storing unit 125 provided in the PBA area 12 of the storage device 1 (at S 33 ). With the above-described steps, the device information of the device for maintenance is registered in the storage device 1 . When the device information is registered, the PC 2 is temporarily shut down (at S 34 ). The shutdown may be automatically performed by the maintenance device registration unit 41 , or may be manually performed by a user.
When the PC 2 is rebooted (at S 35 ), the maintenance processing unit 124 determines whether or not the device information is set in the maintenance device information storing unit 125 (at S 36 ). When the device information is not set in the maintenance device information storing unit 125 (S 36 : NO), the processing in and after the at S 14 is executed according to the same procedure as that in the flowchart illustrated in FIG. 3 .
When the device information is set in the maintenance device information storing unit 125 (S 36 : YES), the device information set in the maintenance device information storing unit 125 is compared with the device information acquired from the currently connected device, and it is thereby determined whether or not the currently connected device is the device for maintenance (at S 37 ).
When it is determined that the currently connected device is not the device for maintenance (S 37 : NO), the maintenance device information storing unit 125 is cleared (at S 38 ), and the processing in and after the at S 14 is then executed.
On the other hand, when it is determined that the currently connected device is the device for maintenance (S 37 : YES), both of the registered device information storing unit 123 and the maintenance device information storing unit 125 are cleared (at S 39 ).
In the maintenance processing, when home-visit repair service by a serviceman is assumed, e.g., in a case where a motherboard of the PC 2 is replaced with new one, a device information of the new motherboard is not registered in the registered device information storing unit 123 in the storage device 1 so that data in the data storage area 11 is erased. That is, when the registered PC 2 breaks down, it is not possible to use the storage device 1 in other PCs. Consequently, by executing the maintenance processing of which the procedure is illustrated in FIG. 7 , it is possible to continuously use the storage device 1 in other PCs.
Second Embodiment
In the first embodiment, although the structure is adopted in which the execution programs for implementing the device authentication unit, the erasing unit, and the maintenance processing unit are installed in the PBA area 12 of the storage device 1 by utilizing the external storage medium 3 , a structure may also be adopted in which these execution programs are downloaded from a server connected to a network.
In the second embodiment, a description will be given of a structure in which the execution programs are downloaded from the server to perform the initial setting.
FIG. 8 is a schematic view illustrating a device structure of the second embodiment. The structures of the storage device 1 and the PC 2 are exactly the same as those described in the first embodiment. The IF unit 22 of the PC 2 is connected to a server 50 via a communication network N.
As described in the first embodiment, it is preferable to set the execution programs for implementing the device authentication unit 121 , the erasing unit 122 , and the maintenance processing unit 124 , and storage areas for the registered device information storing unit 123 and the maintenance device information storing unit 125 in the PBA area 12 of the storage device 1 .
In the second embodiment, the execution programs for implementing the device authentication unit 121 , the erasing unit 122 , and the maintenance processing unit 124 are stored in the server 50 .
The PC 2 acquires the above-described execution programs stored in the server 50 via the communication network N at a timing at which the initial setting is performed, and installs the execution programs in the PBA area 12 of the storage device 1 . The procedure for the installation is exactly the same as the procedure described in FIG. 5 of the first embodiment.
In the present embodiment, although the connection to the communication network N may be required at the time of the initial setting, the present embodiment includes an advantage that, even when the TCG-HDDs are collectively introduced in units of several hundreds, or several thousands, the introduction thereof is facilitated.
All examples and conditional language recited herein are intended for pedagogical purposes to aid the reader in understanding the invention and the concepts contributed by the inventor to furthering the art, and are to be construed as being without limitation to such specifically recited examples and conditions, nor does the organization of such examples in the specification related to a showing of the superiority and inferiority of the invention. Although the embodiments of the present inventions have been described in detail, it should be understood that the various changes, substitutions, and alternations could be made hereto without departing from the spirit and scope of the invention. | A storage device includes a switching unit which switches an access destination in a storage area between a first storage area and a second storage area in response to an access request from a host device; and a nonvolatile storage medium which stores a first host device information used to identify the host device in the second storage area, and a software module executed by a CPU provided in the host device, the software module comprising causing an authority grant unit which transmits a control signal for switching the access destination to the first storage area to the switching unit of the storage device, when the acquired first and second host device information are compared to find that the first and second host device information match with each other. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This is an invention directed to blade type fuse blocks found in motor vehicles and is specifically an electrical adapter to provide an electrical connection to a fuse block terminal with the intent of facilitating the connection of a remote device which could be used to interrupt, monitor or draw electrical power from a particular circuit in a fuse block. This is accomplished by removing the protecting blade type fuse from its terminal socket in the fuse block and placing the blade type fuse block terminal adapter in its place and connecting a desired device to the adapter. The device could then be used to accomplish one or more of the above mentioned applications. A protective fuse or fuse-like system would have to be housed in the connected device or somewhere else in the circuit to protect against electrical irregularities.
In one form of this invention both of the blade terminals on the adapter extend past the housing so that an electrical connection can be made with a pair of female connectors mounted onto or connected by an electrical wire or cable associated with the monitoring device or auxiliary equipment being installed. In this form of the invention the blade terminals that would be exposed for connection with an auxiliary device, could be protected against arcing or accidental grounding by selectively covering with a protective insulated cap when not being used.
In a second form of this invention the secondary ends of both blade terminals would be mounted within a recessed cavity in the housing of the adapter having a recess of a size to permit two female connectors to be inserted therein to make electrical contact with the secondary ends of the blade terminals.
2. Description of the Prior Art
The automotive as well as other industries have uniformly begun to utilize blade type fuses and fuse blocks that reduce the complexity and problems associated with replacing, as well as monitoring glass cylindrical type fuses, traditionally used in protecting against electrical overloads and overheating in low amperage electrical wiring. The now widely used blade type fuse blocks have economized space due to the compact design of the blade fuses. This fuse housing design enables ease of manipulation and verification of failed fuses in conditions of overloaded or overheated wiring. Examples of blade type fuses and fuse blocks are disclosed in U.S. Pat. No. 3,909,767 and U.S. Pat. No. D,321,683.
In related inventions U.S. Pat. Nos. 4,884,050 and 4,986,767 to Emmett L. Kozel the issues of fuse element monitoring as well as ease of installation of auxiliary devices were addressed with the blade terminal tap fuse invention and the blade type fuse power tap. The first invention U.S. Pat. No. 4,884,050 of 1989 used one or both blade elements that protruded through the housing (identical in performance as well as appearance) allowing an electrical connection to an auxiliary device. This connection permitted a remote device to monitor the fuse element for a failed condition due to an overload in the circuit. It also enabled the quick tapping of electrical power through the same protruding blade elements mentioned above. The later invention U.S. Pat. No. 4,986,767 also made it possible to tap electrical power as well as monitor a blade type fuse element, only this time reproducing a fuse-like housing and replacing a fuse in the fuse block with it was no longer necessary. Instead a smaller and less involved tapping apparatus which could connect directly to the top of an existing fuse was used.
The inventions did simplify both tapping electrical power from a motor vehicle electrical system, as well as enabling remote monitoring of the condition of a fuse element. Unfortunately both of the above-mentioned inventions are limited by the use of a fuse they incorporate during operation. The use of fuse housing which contains an amperage-sensitive element linking the blade terminals, makes it impossible or unnecessary in applications where the working of a fuse interferes with the intent to interrupt a particular electrical circuit by placing a device between such circuit and it's fuse. In addition, if a special terminal was to be provided for the purposes of monitoring one or more of the electrical systems for such occurrences as voltage irregularities or strictly tapping electrical power, a fuse-like housing would not be needed but instead an adapter with no fuse element would suffice.
SUMMARY OF THE INVENTION
The blade type fuse block terminal adapter according to the invention has a fuse-like housing for adaptation in place of a fuse in the fuse block terminal but has no amperage-sensitive link between the blade terminals. This enables the above-mentioned adapter to perform this inventions preferred application of the invention, which is to permit the connection of a circuit-interrupting device such as a motor vehicle security system, between the circuit and it's fuse. In a preferred embodiment, the adapter features a 90 degree angle design that enables the upper portion of the housing to be inserted into a blade terminal with great ease as well as permitting the closing of the fuse box lid.
This invention employs a blade type fuse block having terminals with female electrical sockets to engage a pair of parallel and generally coplanar blade terminal elements that are mounted within an insulated solid voidless housing and which are not connected in such housing. Each of the blade elements includes a first end that extends outwardly from the housing to provide for electrical contact with the female terminal sockets of the fuse block.
In the first embodiment of the invention, the secondary ends that extend away from the primary ends intended to connect with the terminals of the fuse block, are spaced from the surrounding housing to provide two tappable male connectors that can then assist in intruding in an electrical circuit between the system and its protecting fuse, or as a way to draw electrical power from the motor vehicle's fuse block. When said secondary ends are not in use, an insulated cover may be placed over the blade terminals to insure that no accidental grounding occurs.
In the second embodiment of the invention both secondary ends of the blade terminals are recessed within the adapter's housing with a bore being provided around the secondary blade terminal ends so that female electrical connectors may be inserted within the space in a surrounding relationship with the blade terminals. Again, to prevent any accidental grounding of the secondary blade terminals, a plug may be inserted within the recess created in the housing when the secondary blade terminals are not in use.
In a third form of the original invention both the first and second embodiment mentioned above would be selectively employed in the manufacturing of a blade type fuse block terminal adapter where the housing and blade terminals are of the style and size of the MINI fuse type fuse (U.S. Pat. Nos. 4,661,793, and 4,604,602). Such fuses are gaining in popularity due to their smaller design enabling the placement of more fuses in the same space as previous fuses. All of the functions and intents of the original invention remain the same.
In a fourth form of the original invention both the first and second embodiments mentioned above would be selectively employed in the manufacturing of a blade type fuse block terminal adapter where the housing and blade terminals are of the style and size of the MAXI fuse type fuse (U.S. Pat. Nos. 4,635,023, and 4,604,602). Such fuses are gaining in popularity due to their larger design enabling the protection of more systems generating higher current loads on one fuse as well as large systems which were once unable to be protected by blade type fuses.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of the first embodiment of the present invention showing an electrically insulated cap for covering the secondary terminals of the adapter when not in use.
FIG. 2 is a cross sectional view taken through lines 2--2 of FIG. 1 and showing in dotted lines two electrical connectors being brought in overlapping relationship with respect to the secondary terminals of the adapter.
FIG. 3 is a cross sectional view similar to that of FIG. 1 taken through an alternative embodiment of the present invention where the secondary terminals are oriented within the adapter housing and shown in dotted lines are two auxiliary connectors being brought into aligned relationship to make the electrical connection.
FIG. 4 is a perspective view of an insulated cap which fits into the opening of the adapter of FIG. 3 to electrically insulate the secondary terminals when not in use.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With continued reference to the drawing FIGS. 1 and 2 show a first embodiment of the present invention. In this embodiment, the fuse block adapter is designed to provide a quick connection for an auxiliary electrical line or wire W such as shown in dotted lines in FIG. 2. The wire may extend to an electrical component or unit which is to be connected to the electrical system.
As previously discussed it is the primary intent of the present invention to provide a means to interrupt electrical power to a particular system by coming between the blade type fuse block terminal and the fuse used to protect that automotive system. The actual interrupting of the electrical circuit is accomplished with a remote device, and the adapter only assists such a device in the electrical connection procedure that would otherwise be complicated and time consuming utilizing splicing wiring and using harnesses. When it is desired to install an auxiliary electrical component such as a telephone or radio in a car, it is necessary to connect such components directly to the vehicle's electrical system. By utilizing the fuse block adapter shown in FIGS. 1 and 2, it is possible to accomplish the connection directly through the fuse block terminals in the cars. In this embodiment the adapter 10 includes an insulated plastic body portion 11, having an upper end 12, a lower end 13, side walls 14, front and rear walls 15. The housing 11 is formed of a suitable electrically insulated plastic material which may be molded about the remaining electrical components of the adapter. Such plastic materials are fire resistant and may include nylon, polystryenes and the like.
The blade type fuse block terminal adapter includes a pair of electrically conductive blade elements 16 and 17 that are designed to be engaged within a female terminal in a fuse block or panel (not shown). Each of the blade elements 16 and 17 includes an opening generally indicated at 20. When the adapter is formed the plastic material forming the housing 24 is forced through the openings 20 during molding, thereby securing the blade elements 16 and 17 to the housing 24. The blade element 16 is shown as extending through a channel 21 having openings along the upper and lower surfaces of the housing. The blade elements 16 and 17 include upper extending secondary end portions 22 and 23 which are designed to provide an electrical tap for the electrical wire W.
The secondary ends 22 and 23 of the blade terminals 16 and 17 extend over and beyond the upper half of the housing 24 that forms a 90 degree angle 32 at the center as part of the adapter design.
The two blade elements 16 and 17 are separated by an electrically insulated wall 24 which is provided to prevent any arcing between the blade elements.
When the adapter 10 of the present invention is not in use, a separate electrically insulated cover or cap 26 is provided which fits over and closely engages the secondary portions 22 and 23 of the blade elements 16 and 17. The cover or cap 26 includes a main body portion 38 having an opening which is of a size to cooperatively receive the secondary ends 22 and 23 of blade elements 16 and 17. The body portion 38 also engages the upper end 12 of the fuse block adapter when placed over the secondary blade elements 22 and 23. The cover further includes an outwardly extending flange 28 which may be engaged by a screw driver or a finger nail to lift the cover from the blade elements 22 and 23.
With the cover removed the blade type fuse block terminal adapter the present invention is ready to be utilized to provide a source into the electrical circuit between the fuse block terminal and the fuse it replaces. Once connected the fuse block adapter allows a circuit interruption device to be electrically connected to it through the secondary blade terminal ends. The device connected to the fuse block adapter may also act as an electrical voltage monitor or simply be tapping or sharing electrical power from such circuit.
As shown in FIG. 2 the crimpable connector elements 30 and 34 are attached to the free ends of the electrical wires W. By placing the crimpable connectors on the secondary ends 22 and 23 of the blade elements 16 and 17, an electrical contact is established through the electrical wires W to a remote electrical device (not shown).
With specific reference to FIG. 3 a second embodiment of the invention is disclosed. In this form the blade type fuse block terminal adapter 10 includes a housing 11 which is substantially identical to the housing shown and discussed above with respect to the embodiment of FIGS. 1 and 2. The only difference between the two housings is that the channel 48 (not illustrated) in which the secondary ends 22 and 23 of the blade elements 16 and 17 are located, includes bores 36 and 46 (not illustrated) along the uppermost end of the housing 11 after it angles 90 degrees. The bores 36 and 46 (not illustrated) are of a size to permit a female electrical connector 30 to be inserted therein to contact the secondary ends of the blade terminals 35 and 45.
The blade contact elements 16 and 17 of the present embodiment also include two upper secondary ends 35 and 45 that are spaced inwardly of the housing to be positioned totally within the bores 36 and 46 (not illustrated). In this manner secondary contact elements 35 and 45 are positioned entirely within the electrically insulated housing.
When electrical contact is desired the female electrical connectors are inserted within the bores in the housing as opposed to being inserted over the contact element outside of the housing, as was the case with the prior embodiment.
When the electrical contact elements 35 and 45 are not in use an electrically insulated cover or cap 38 is provided which includes two rectilinear sleeves 39 of a size to fit over the electrical contact elements 35 and 45 and cooperatively seated within the bores 36 and 46 (not illustrated). The cover 38 includes an outwardly extending flange portion 40 that provides a gripping surface for removing the cover from the contact elements 35 and 45.
The blade type fuse block terminal adaptor of the present invention is utilized in place of a blade fuse. The adapter is installed in the same manner as a blade fuse. However when connected it does not perform the function of a fuse, but is only a way to quickly enable tapping into an electrical circuit with the goals of interrupting such circuit, tapping electrical power from such circuit or monitoring electricity in such circuit by then allowing connection by the appropriate device. The installed device must then protect the circuit with a fuse or fuse-like system. In the event that a manufacturer provides an additional dedicated terminal socket in its fuse block, the above mentioned invention can then be that terminal's link to an electrical device or monitoring devices which no longer need to be professionally wired in. | An electrical adapter that includes an electrically insulated housing from which the first ends of a pair of parallel blade terminals extend to engage the contact element in a fuse block or panel in a motor vehicle where both of the parallel blade terminals are unrelated and don't come in contact with each other and were in both of the blade terminals includes a second end that is freely accessible either within, or which extend from, the housing remote from the first end thereof to permit an electrical connector of an auxiliary device to be selectively engagable therewith. | 7 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a casing for a pistol or revolver, which has been specifically designed to facilitate a safety handling of the pistol and its withdrawal from the casing.
[0002] In particular, the pistol casing according to the invention allows a user to bring a pistol without revealing the presence of such a pistol to third parties.
[0003] As is known, a great problem related to the use and bearing of fire weapons and, in particular, pistols or semiautomatic loader revolvers, is that of concealing said weapons, together with a very easy withdrawal thereof, which is very important in particular defence circumstances, in which the pistol gripping speed and the possibility of immediately firing would involve vital problems.
[0004] Further known is the fact that conventional pistol holsters or casing are born outside of the user body, and can be concealed under a jacket, with straps for allowing the pistol to be properly supported.
[0005] On the other hand, the provision of straps, belts, snap buttons, Velcro closures, hinder a quick withdrawal of the pistol.
[0006] In fact, if a pistol is held in a conventional holster it is usually necessary to deflect a closing flap or opening a Velcro closure, to grip the pistol and then withdraw it.
[0007] Thus, a precious time is lost.
SUMMARY OF THE INVENTION
[0008] Accordingly, the aim of the present invention is to provide a pistol casing specifically designed for obviating the above mentioned drawbacks, which pistol casing can be arranged at any desired part of a user body, by using suitable connecting straps, for example fixed at the user waist or on a user shoulder.
[0009] Within the scope of the above mentioned aim, a main object of the present invention is to provide such a pistol casing which can be safely concealed, by associating said pistol casing with a leather and/or fabric coating covering and concealing said casing to provide with an aesthetic aspect similar to that of a bag or pouch.
[0010] Yet another object of the present invention is to provide such a pistol casing which can be supported on outer rings of a rucksack, a purse, or a jacket, for example hunting or fishing jackets, even in a vertical position, with the pistol barrel mouth upwardly directed.
[0011] Thus, the aim of the present invention is to provide such a pistol casing which can allow a pistol to be perfectly concealed and easily withdrawn.
[0012] This would allow a pistol user to conceal it and withdraw it in a very easy manner.
[0013] A further object of the present invention is to provide such a pistol casing which can be easily fitted to several types of pistols and revolvers.
[0014] Yet another object of the present invention is to provide such a pistol or revolver casing allowing the pistol to be easily arranged therein and withdrawn, even by a left-handed person.
[0015] Yet another object of the present invention is to provide such a pistol casing which can also hold therein auxiliary devices such as laser pointing devices, silencing devices or the like.
[0016] Yet another object of the present invention is to provide such a pistol casing which can be easily made and customized by using easily available elements and materials and which, moreover, is very competitive from a mere economic standpoint.
[0017] According to one aspect of the present invention, the above mentioned aim and objects, as well as yet other objects, which will become more apparent hereinafter, are achieved by a pistol or revolver casing having the features defined in the accompanying claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Further characteristics and advantages of the present invention will become more apparent hereinafter from the following detailed disclosure of a preferred, though not exclusive, embodiment of a pistol casing, which is illustrated, by way of an indicative, but not limitative, example, in the figures of the accompanying drawings, where:
[0019] [0019]FIG. 1 is a tridimensional side view of the pistol casing according to the invention;
[0020] [0020]FIG. 2 is a side view of the pistol casing according to the invention;
[0021] [0021]FIG. 3 is a further side view of the pistol casing, and specifically showing constructional elements thereof and a pistol arranged inside it;
[0022] [0022]FIG. 4 is a side view of the pistol casing according to the invention, and specifically shows the locking elements allowing a withdrawal of the casing according to the invention;
[0023] [0023]FIG. 5 illustrates only the constructional elements of the pistol casing according to the invention, the pistol being omitted; and
[0024] [0024]FIG. 6 is an exploded view illustrating the inner construction of the pistol casing according to the invention, specifically designed for concealing the pistol and facilitating its withdrawal.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0025] With reference to the number references of the figures of the accompanying drawings, the pistol casing according to the present invention, which has been generally indicated by the reference number 1 , comprises an inner or inside construction, including two C-shape cross section members, i.e. a top section member 2 and a bottom section member 3 , which are connected to a casing element 4 .
[0026] Said casing 1 comprises furthermore a further C-shape section member 5 , coupling the section members 2 and 3 and which perpendicularly extends with respect to the latter.
[0027] The casing 1 is furthermore coated by two half-shells 9 and 10 , made of any suitable plastics, resilient and foamed materials.
[0028] Said half-shells are coated by a textile material, leather or synthetic leather material.
[0029] The mentioned section members form a supporting framework including two guides, i.e. a top and a bottom guide, therebetween a pistol can linearly slide.
[0030] The bottom element 4 , extending the section member 3 , defines an end portion of the bottom guide, thereon the pistol butt slides, bears and is locked.
[0031] In particular, the locking of the pistol or revolver 25 , at an end of stroke or limit position thereof, is achieved by using two locking means.
[0032] The first of said locking means comprise a metal locking element 13 , which can be freely turn about a hinge 15 including a spring 14 .
[0033] Said hinge spring is coupled to the section member 2 through the supporting element 16 , the clamping elements and screws 17 and 18 .
[0034] The screw 17 , in particular, connects the spring 14 to the supporting element 16 which is made rigid with the section member 2 by the screw 18 .
[0035] Said section member 2 is in turn coupled to the section member 5 by a small bracket 6 , which is provided with four tapering holes therein corresponding screws are engaged.
[0036] In turn, the section member 5 is made rigid with the section member 3 , through the small bracket 7 .
[0037] The bottom element 4 is made rigid with the section member 3 by a clamping element, i.e. a screw 12 , which is threaded in a thread formed in the walls of the throughgoing tapering hole 19 of the element 4 and in the walls of the seat 20 of the section member 3 .
[0038] At the opposite end from the hole 19 , the bottom element 4 has its greatest thickness.
[0039] Said element 4 , at its side inside the casing, where it contacts the gripping portion or butt of the pistol, also comprises a seat or recess 23 which is engaged as the pistol is fully introduced into the casing, by a protuberance 22 , operating as a detent element for an anti-fall binding of the pistol.
[0040] In the outside end portion of the element 4 , a throughgoing threaded hole 21 in which is threaded a pressing element 11 is formed.
[0041] As the protuberance 22 enters the seat or recess 23 , it will abut against the deepest wall of the seat 23 , and, by said pressing element 11 , the pistol will be prevented from accidentally exiting its casing.
[0042] Thus, said pistol is held and locked at the loader bottom, owing to the ridge formed by the end ball portion of the pressing element 11 .
[0043] Said pressing element, in particular, will prevent the pistol from exiting, by cooperating with a detent level 13 held by the spring 14 .
[0044] As the pistol user introduces his/her hand into the inlet of the casing between the two foamed material shells 9 and 10 for gripping the pistol, the pressing element will yield under the pulling force characterizing the pistol withdrawing operation, thereby allowing the pistol to freely exit, and the top portion of said pistol will rise the lever 13 which will turn through 90 degrees thereby fully freeing the pistol.
[0045] Different is the condition in which a bag shaped casing, according to the present invention, conventionally holds the pistol.
[0046] In fact, the pressure of the lever 13 , provided by the spring 14 on the top portion of the butt 26 of the pistol 25 and the pressure of the spring of the pressing element provided on the bottom of said butt on the rear of the protuberance 22 , it will be sufficient to hold the pistol 25 in its casing 1 , even if the pistol has been introduced in a reversed condition with the pistol barrel mouth facing upward and the butt 26 facing downward.
[0047] The pressing element 11 provides a dynamical type of detent element, which will be lowered exclusively under a withdrawal force greater than the pistol weight.
[0048] Such a closure allows anyhow an easy and free displacement, while assuring a proper supporting of the pistol and a free and quick withdrawal thereof, since said closure does not comprise straps, snap buttons or other complex holding means.
[0049] Accordingly, the pistol casing will be of a reversible type and, consequently, can also be easily used by a left-handed person.
[0050] The variable fixation of the pistol is achieved by a plurality of riveted holes 24 arranged on the inner side of the casing.
[0051] From the above disclosure it should be apparent that the invention fully achieves the intended aim and objects.
[0052] The invention, as disclosed, is susceptible to several modifications and variations, all of which will come within the scope of the invention.
[0053] Moreover, all the constructional details can be replaced by other technically equivalent elements.
[0054] In practicing the invention, the used materials, as well as the contingent size and shapes, can be any, depending on requirements. | An improved casing for pistols, specifically designed for facilitating the pistol bearing and withdrawing, comprises a box-like body, the inner construction of which comprises two “C”-shape section members, a top section member and a bottom section member, coupled to an element of the casing, and a third section member coupling the other two section members and which is perpendicular to the latter. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of the invention is that of apparatus and techniques for forming pleats in material. The invention is particularly adapted for forming uniform pleats in drapery material especially in connection with the fabrication of drapery swags and cascades.
2. Description of the Prior Art
Reference is made to prior U.S. Pat. No. 3,297,215 of the herein inventor which is thought to be the closest prior art. The prior art patent is a machine for producing pleats in drapery material. The machine of the patent is one for use in the fabrication of swags or cascades and in this respect fulfills the need that exists for machines for reducing the hand operations presently required in the fabrication of these items.
SUMMARY OF THE INVENTION
Preferred exemplary forms of the invention are described in detail hereinafter. In a simplified exemplary form of the invention, a plurality of upstanding members are provided over which fabric material can be layed with folds or pleats being formed over the upstanding members. The members are in parallel relationship and are connected by lazy tongs means so that the members can be adjusted uniformly in their relative spacing. For making cascades, the material is laid over the upright members and folded over them to form the folds or pleats, the material being temporarily secured to the members by slotted elements that fit down over the fabric on the member. For making cascades, the upright members are straight and are hinged so that they can be laid over to hold the fabric temporarily while the edges are being cut and the pleats or folds are being stapled.
For fabricating swags, the upright members are made of flexible material and are curved to correspond to the desired curvature of the folds or pleats in the swag. A plurality of lazy tongs units or assemblies are provided in positions angularly spaced, for example 45° apart, with each of the parallel upright members being attached to spaced points of the lazy tong units. Thus, in a similar manner, the curved upright members can be uniformly adjusted in size and spacing. The fabric is laid over the upright members in a similar manner for purposes of making folds or pleats which can be held in a similar manner. Means are provided at the ends of the upright members for turning or laying them down for termporarily holding the fabric material while the folds or pleats are being stapled and the material is being cut to size.
In the light of the foregoing, the primary object of the invention is to realize, and to provide apparatus for reducing and simplifying hand operations normally required in connection with the formation and fabrication of fabric materials, more particularly, drapery material that is formed into swags and cascades.
A further object of the invention is to realize apparatus which includes upright parallel forming members with means preferably in the form of lazy tongs units for adjusting the members to desired uniform spacing with means for holding the fabric in association with the members after forming of the pleats and moving the members to hold the fabric while the pleats are being stapled or otherwise secured.
A further object is to realize apparatus as in the foregoing wherein the upright members are provided with a hinged mounting whereby they can be laid down or layed over to hold the fabric.
A further object is to provide apparatus as in the foregoing wherein the upright members are made of flexible material and have curved configuration, the members being attached at spaced angular positions to lazy tongs units to provide for adjustment in uniform spacing between the members, the swags being formed by forming folds or pleats over the parallel curved members.
A further object is to realize apparatus as in the foregoing wherein the curved members are provided with adjustable means at their ends for positioning the upright members to hold the folds or pleats being stapled or otherwise secured.
Further objects and additional advantages of the invention will become apparent from the following detailed description and annexed drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a pictorial view of a window provided with drapes, including swags at the top and cascades at the sides;
FIG. 2 is an isometric view of a preferred form of the invention;
FIG. 3 is a bottom view of a form of the invention shown in FIG. 2;
FIG. 4 is a view similar to that of FIG. 3 showing the lazy tongs in another position;
FIG. 5 is an enlarged sectional view of the form of the invention of FIGS. 2-4 illustrating the formation of the folds of pleats;
FIG. 6 is a pictorial view illustrating the formation of the folds or pleats, using the apparatus of FIGS. 2-5;
FIG. 7 is a view of a cascade being fabricated showing the folds staped together;
FIG. 8 is a partial view of one of the cascades of FIG. 1;
FIG. 9 is a plan view of another form of the invention which is for forming swags;
FIG. 10 is a schematic view illustrating certain of the lazy tongs units of the device of FIG. 9;
FIG. 11 is a detailed view showing the devices at the ends of the upright members for folding them downwardly for holding the folds of fabric material;
FIG. 12 is an illustrative view illustrating the placement of the fabric on the upright members;
FIG. 13 is a further illustrative view illustrating the operation to hold the material in folded condition; and
FIG. 14 is an illustrative view illustrating the elements used for holding the fabric in position over the upright members.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a pictorial view of a window having draperies which may be of typical appearance. The draperies include at the top, swags designated at 10, 11 and 12 which are fabric drapery materials having folds or pleats lying along curves which are parallel to each other as shown. At the sides of the swags, that is, at the upper corners of the windows, are cascades 13 and 14 which are made of fabric drapery material having vertical folds or pleats as shown, the lower ends of the cascades being along a slant or bias as shown.
The invention provides apparatus for purposes of forming or fabricating the swags and cascades of the type as shown in FIG. 1.
FIGS. 2-5 show a form of the invention particularly adapted for producing cascades. Numeral 20 designates a platform of rectangular configuration having an extending shelf 22 at one side. On the top surface 21 of the platform, there are secured flat metal strips 24 and 26 which may be made of aluminum or similar material. Graduated scales or rulers may be provided adjacent to strips 20 and 24.
The platform 20 has a longitudinal opening or recess in it having a cross-sectional shape as designated at 30 in FIG. 2. Within this recess or space is a lazy tongs unit designated at 32 in FIGS. 3-5. The lazy tongs unit is of typical construction comprising a plurality of crossed links pivoted to each other with the ends of the links pivotally attached to the ends of the links of an adjacent crossed pair. One end of the lazy tongs unit is attached to a metal strip 34 which is secured to the platform 20 by a rivet 36. The other end of the lazy tongs is attached to a metal strip 40 which can move over an elongated groove 42 in the platform 20 having in it a scale or ruler 44 having graduations so that the end of the piece 40 can be positioned adjacent a graduation to indicate an adjusted length of the lazy tongs unit. At the left end of the lazy tongs unit or assembly, as may be seen in FIG. 5, there is a bracket member 50 which has a portion 51 that is secured to the end of the lazy tongs by way of the pivot member 52a. It has an upper part 53 which is parallel to the top surface of the platform 20. Numeral 56a designates an upright plate member that is attached to the bracket portion 53 by way of a hinge 58a so that the plate 56a can be rotated about the hinge into a substantially flat position.
Additional connecting pivots of the lazy tongs are identified by the numerals 52b, 52c, etc. Additional of the upstanding plate members are identified by numerals 56b, 56c, etc. See FIG. 2. Since these plates and their mountings are alike, they need not be described in further detail.
FIG. 5 illustrates the placement of the fabric material over the plates 56 for purposes of forming the cascade folds or pleats as further illustrated in FIGS. 6-8. FIGS. 6-8 further illustrate the technique of forming the folds in the fabric.
The upright spaced members 56 are first adjusted manually by adjusting them to a position in accordance with the desired spacing between folds or pleats. Preferably, rulers or graduated scales may be provided along the strips 24 and 26 so as to measure or gauge the spacing between plates. The fabric material is laid over the upright plate members and the folds are made by simply folding the fabric material against the sides of the upright members as illustrated in FIGS. 5 and 6. Numeral 64a designates a flat holder member that may be made of plastic or similar material which has a slot in it as designated at 65 so that this member may be fitted down over a plate with the fabric folded over the plate as illustrated in FIGS. 5 and 6. This member holds the folds in position while the cascade is being formed. After the pleats have been formed, as described, the plates 56 can be laid over, that is, moved about their hinges as illustrated in FIG. 6. When laid over in this manner, the folds or pleats are held in uniform configuration. In this position, folds or pleats are stapled at the ends as may be seen at 66a and 66b of FIG. 6. FIG. 7 shows a cascade that has been fabricated having folds or pleats 67a-67f, the ends being stapled as shown at 66a-66f. FIG. 8 illustrates one of the finished cascades 14 which is illustrated in FIG. 1, the cascade having been formed by the apparatus and technique as described.
From the foregoing, those skilled in the art will readily understand and appreciate how the apparatus greatly simplifies and reduces the manual operations normally required in fabricating cascades. Without the apparatus and technique as described, it is required that the operator make all measurements as necessary for purposes of making folds or pleats of the right size and with the correct spacing. By making measurements and by manually working the folds or pleats into the correct configuration and spacing, it can readily seen that the work is extremely tedious, demanding and time consuming with the results being questionable because of a lack of accuracy in the work.
FIGS. 9-14 show another form of the invention that is particularly adapted for fabricating swags. Preferably, the apparatus is constructed in rectangular form so that it can be placed on top of a table or the like, the apparatus having very limited vertical dimension or depth. FIG. 10 is a plan view of a preferred form of the invention. The apparatus embodies a rectangular structure having a flat upper surface or platform as designated at 76. On the surface of the platform are a plurality of curved or arcuate flexible members as designated at 78a-78h.
The members 78 may be made of relatively thin plastic material and may be constructed in sections having overlapping portions as may be seen at the intermediate parts of the arcs. These arcuate flexible members are in parallel relationship and they may or may not be arcs of a circle. Spacing between them is adjustable as will be described.
At the front of the platform is a strip 80 which overlies the surface of the platform 76 and at the right end of this strip is a ruler 82, and at the left end is a ruler 84. The ends of the upstanding arcuate members are attached to a locking handle as will described presently. The spaced relationship between the arcuate members 78 is maintained by a group of five lazy tongs units which are positioned beneath the surface of the platform 76. The ends of the arcuate members 78 are along a straight line and along this line is a slot 88 in the surface of the platform. There is a lazy tongs unit positioned under the left-hand part of the slot as designated at 88; a similar lazy tongs unit is underneath the right-hand part of the slot designated at 88'.
In the surface of the platform are three additional slots spaced at 45° angles as designated at 90, 92 and 93 and there is a lazy tongs unit positioned underneath each of these slots. The lazy tongs units are of conventional construction comprising units of links pivoted to form an X shape with the ends of the links of one unit pivotally attached to the ends of the links of an adjacent unit.
FIG. 10 illustrates schematically the three lazy tongs units associated with the slots 88, 90, and 92, these units being designated by the numerals 94, 96 and 98. There are lazy tongs units beneath slot 93 at 98 and beneath slot 88 as designated at 94. Unit 94 is fixed at its inner end as designated at 102; its left end is attached by a pivot member 104 to a member 106 which has a slider movable in the slot 88, which can be set by knob 132.
The inner end of the lazy tongs unit 96 is fixed at a point 110 and the inner end of lazy tongs 98 is fixed at a point 112. The outer end of the unit 96 is attached by pivot member 114 to a member 115 which has a slider which slides in the slot 90, and is settable by knob 133.
The outer end of the unit 98 is attached to a pivot member 116 to a member 118 which has a slider which slides in the slot 92 and is settable by knob 134. Guideways may be provided on the underside of the platform 76 in which the lazy tongs units themselves may be guided.
The pivot points of the link members of the lazy tongs unit 94 are designated by the numerals 122a-122h. See FIG. 1. The pivots 122a-122h extend through the slot 88 and carried on these pivots are disc members 124-124h. See FIG. 9. FIG. 10 shows the left-hand quadrant of the structure. The right-hand quadrant is the same so that the structure need not be described in detail. Numerals 126a-126h designate handles operative to rotate the discs 124a-124h. A similar group of handles is provided on the right-hand side of the machine, two of these being designated at 127g and 127h associated with discs 125g and 125h, the details of which will be described presently.
Pivots of the lazy tongs 96 which extend through the slot 90 carry a series of discs 130a-130h which carry brackets to which the arcuate members 78 extend so that the arcuate members move correspondingly to adjustments of the lazy tongs.
Lazy tongs 98 has its pivot members connected to the arcuate member 78 in the same manner. Similarly, the lazy tongs underlying the slot 93 has its pivot points connected to the arcuate members in a similar manner. Numerals 132, 133, 134, 135 and 136 designate adjustable knob lock members which can adjust the positions of the outer ends of the respective lazy tong units with respect to their operating slots. Extending along the slots 90, 92 and 93 are additional graduated scales or ruler members 87, 89 and 91.
As can be seen from the foregoing, by adjusting the lazy tong units inwardly or outwardly from the center, the size of the parallel arcs can be adjusted while keeping them in parallelism, and this adjustment is, of course, for the purpose of adjusting the size and depth of the swag to be fabricated.
FIG. 11 shows the right ends of two of the upright flexible members 78g and 78g and their associated discs 125g and 125h and clamping handles 127g and 127h. FIG. 11 shows fabric 140 overlying the members 78g and 78h. Referring to the disc 125g, it carries a hinge 142g having a hinge pin which includes a right angle arm 144g. On the disc 125g is a circular button 146g having an undercut forming a lip as designated at 148g. The construction of the disc associated part for the member 78h is the same. Carried on the inside of the end of the member 78g is a foam rubber pad 150g and on the end of the member 78h is a similar pad 150h. The end part of member 78g can be manually bent down as shown in FIG. 11. As illustrated in FIG. 11, when the handle 127h is rotated into a position in which the handle 127g is shown, the fabric is clamped by the pad 150. The lip 148g on disc 146g locks member 78g in clamped position. Instead of disc 146g, this may simply be a knob that frictionally locks under member 78g to hold it. In this manner, pleats and folds after being made can be held clamped while being stapled.
FIGS. 12-14 illustrate the technique of using the apparatus for fabricating swags. The right and left width adjustments or indicators, that is, knobs 132 and 136, are set to the desired finished width of the swag. The length or drop indicators are set by the adjustment knob locks 133, 134 and 135. The adjustable arcs are now set in parallelism to provide the desired parallel folds or pleats, with the set length or depth.
Precut fabric is now placed onto the apparatus right side up with the fabric covering the scissors cutting channel guide at the front of the platform. The center of the platform is preferably padded and is filled with fabric material. Preferably, a notch is made at the center of the fabric which is positioned covering the cutting guide slot and then the lower first clamp on the left and right, 126h and 127a to hold the fabric. These operations are illustrated in FIG. 14. Then the holding members as indicated at 160a-160h are placed over the folds and the upright arc members as the folds are made as illustrated in FIG. 14. These holding members are similar to the members 64a-64h. After all folds are made and secured, surplus fabric is cut off at the top of the swag by sliding a scissors along the cutting channel. Then the cut edges are stapled securing all the folds, or pins may be used. All the surplus fabric around the base of the swag, that is, the base of the outside adjustable arc, is cut off. The clips or holders may then be removed from the formed swag. Then all of the clamping handles may be released, releasing the folds from pressure and the swag may be removed from the machine. The swag is then ready for hemming and applying a tack strip. The tack strip will cover all of the staples holding the folds.
From the foregoing, those skilled in the art will readily understand the nature of the invention, its construction and the manner in which it is utilized to achieve and realize the objectives as set forth in the foregoing. It will be observed that the elements of the combination cooperate with each other in accordance with the invention in a manner such that a result is achieved that would not follow merely from association of the elements in a way other than that of the invention. Accordingly, there is a synergistic result stemming from the combination of the invention particularly as respects the hand operations that are eliminated and those that are simplified.
The foregoing disclosure is representative of preferred forms of the invention and is to be interpreted in an illustrative rather than a limiting sense, the invention to be accorded the full scope of the claims appended hereto. | Apparatus for use in fabricating pleated materials, particularly for forming pleats in drapery materials such as swags and cascades. The apparatus greatly facilitates and eliminates some certain hand operations. A plurality of parallel upstanding spaced members is provided. The members are connected by adjustable lazy tongs means so that the members are adjustable to a desired uniform spacing. The members may be either straight or they may be of curved configuration for making swags. The material is placed over the members and then uniform pleats are formed over the members with the pleats then being held to the members by holding devices. The members are constructed so that they can be manipulated or actuated to hold all the pleats which are then secured by stapling prior to the removal of the completed material and final fabrication. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a Continuation of U.S. patent application Ser. No. 11/589,280, filed on Oct. 30, 2006, now U.S. Pat. No. 7,702,937 and entitled Method and apparatus for Operating a Computer System By Adjusting a Performance State of a Processor Resource, which is a Continuation of U.S. Pat. application No. 09/850,059, filed May 8, 2001, now U.S. Pat. No. 7,131,016 and entitled Method and Apparatus for Adjusting Clock Throttle Rate Based on Usage of CPU, the entire disclosures of which are incorporated herein by reference.
This application claims priority to Korean Patent Application No. 25787/2000, filed May 15, 2000, the entire disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method and apparatus for adjusting the clock throttle rate of a central processing unit (CPU) included in a computer.
2. Background of the Related Art
A computer (or “system”) 4 , as illustrated in FIG. 1A , is commonly used with external output devices, such as a display monitor 6 and a printer 12 , as well as external input devices, such as a keyboard 8 and a mouse 10 . The power management of a system 4 is often controlled by external input devices.
A power management method in the related art will be described in conjunction with FIG. 1 which illustrates a related method for managing the electric power consumed in a system. Once the system is turned on (Step S 10 ), the system 4 determines whether a signal has been inputted from an external input device, such as a keyboard or mouse, to the system for a predetermined period of time (Step S 11 ). If there is a signal inputted from the external input device within a predetermined period of time, the system is maintained in its ON state. On the other hand, if no signal is inputted from the external input device for the predetermined period of time, the system is switched from its ON state to an idle mode (Step S 12 ) to reduce the electric power consumed in the system.
In systems where an advanced power management (APM) is applied, the operational mode when no signal is inputted from the external input device for a certain period of time is referred to as an “idle mode” or “doze mode”. When the system is switched to the “idle mode”, the basic input/output system (BIOS) of the system conducts an operation for reducing the clock speed supplied to the CPU and decreasing LCD brightness, etc., thereby reducing the consumption of electric power.
For instance, a dedicated power management chipset such as an Intel PIIX4E power management chipset is mainly used as a means for conducting the above mentioned APM power management operation. Typically, this power management chipset adjusts the clock throttle rate of the CPU among 7 different levels of 12.5%, 25%, 37.5%, 50%, 62.5%, 75%, and 87.5%. That is, assuming that the maximum speed of the CPU corresponds to 100%, the clock throttle rate of the CPU can be stepwise adjusted in a range from 100% to 12.5% at a reduction rate of 12.5% per step using the dedicated power management chipset (Intel PIIX4E).
In order to control the clock rate of the CPU, a clock throttle operation is also carried out by controlling desired registers of the power management chipset (Intel PIIX4E). A user controls desired registers to adjust the set-up of the BIOS to enable an idle mode supporting item and the clock rate of the CPU selects one of 7 different levels designated by the BIOS of the system, typically, 50%.
Meanwhile, in a system where an advanced configuration and power interface (ACPI) is applied and the system is in a state of use by an application program, the system sets the CPU at a clock throttle rate of 100% and the switching of the system to an “idle mode” by the BIOS of the system is not carried out. On the other hand, when the CPU is not being used by an application program, the system conducts a power management operation setting the CPU to a lower clock throttle rate.
However, the above mentioned power management methods of the related art have problems. In the case of the system to which the APM is applied, the clock throttle rate is reduced to a predetermined rate (typically, 50%) only when the system is switched from its ON state to an idle state. For this reason, there is a problem in that no power management is carried out in the ON state of the system.
Furthermore, although it is not necessary to use external input devices when operating a digital video disk (DVD) or a video file to allow the user to watch a movie or a program broadcasted on the Internet, the system should be in the ON state because the system remains in operation. In this case, however, the system may maintain or switch into the idle state because of a lack of external input by the user, thus resulting in slower or intermittent reproduction of the data.
In the case of the system to which the ACPI is applied, it is possible to conduct power management while the system is in the ON state. However, the power management is very simple, in that clocks are operated at a clock throttle rate of 100% in the operating state of the CPU, but the clocks are cut off in the non-operating state of the CPU. In accordance with such a very simple power management, clocks are supplied to the CPU at a maximum clock throttle rate even in a situation in which an application program involving a less CPU usage is used. For this reason, an increased consumption of electric power occurs unnecessarily in the system.
The above references are incorporated by reference herein where appropriate for appropriate teachings of additional or alternative details, features and/or technical background.
SUMMARY OF THE INVENTION
An object of the invention is to solve at least the above problems and/or disadvantages and to provide at least the advantages described hereinafter.
Therefore, an object of the invention is to provide a method for adjusting the clock throttle rate of a CPU in a system, in which the usage of the CPU is measured, so that the clock throttle rate of the CPU can be adjusted in a stepwise fashion, based on the measured usage of the CPU, thereby allowing the CPU to be supplied with clocks at a rate necessary for the execution of a desired program without any influence on the performance of the system, and more particularly to a method for adjusting the clock throttle rate of a CPU included in a computer, in which the usage of the CPU is measured, so that the clock throttle rate of the CPU can be automatically adjusted, based on the measured usage of the CPU, thereby reducing the consumption of electric power without any influence on the performance of the computer.
Another object of the invention is to provide a method for adjusting the clock throttle rate of a CPU in a system, in which the usage of the CPU is measured, so that the clock throttle rate of the CPU can be adjusted in a stepwise fashion, based on the measured usage of the CPU, thereby reducing the consumption of electric power.
In order to accomplish these objects, the present invention provides a method for adjusting a clock throttle rate of a central processing unit (CPU), comprising measuring a usage of the CPU, comparing the measured CPU usage with a predetermined reference CPU usage range, and adjusting the clock throttle rate of the CPU, based on a result of the comparison. The measurement of the CPU usage is carried out at every refresh time. The CPU usage is measured by calculating an idle thread value of the CPU for a predetermined period of time. The CPU usage is measured by detecting registry information of the system.
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 objects and advantages of the invention may be realized and attained as particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in detail with reference to the following drawings in which like reference numerals refer to like elements wherein:
FIG. 1A illustrates a diagram of a computer system in the related art.
FIG. 1 is a flow chart illustrating a power management method in the related art used in a computer system;
FIG. 2 illustrates the display window of an application program for carrying out a method for adjusting the clock throttle rate of a CPU in accordance with a preferred embodiment of the present invention;
FIG. 3 is a flow chart illustrating the method for adjusting the clock throttle rate of the CPU in accordance with a preferred embodiment of the present invention; and
FIG. 4 is an architectural block diagram illustrating layers of an architecture configured in the system where a device driver is used.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
As shown in FIG. 2 , the display window includes a plurality of sub-windows 20 for setting parameters required for the adjustment of the clock rate of a central processing unit (CPU), and menu bars. The sub-windows may, for example, include a sub-window “Hold Usage” representing a minimum reference usage of the CPU, a sub-window “Recov, Usage” representing a maximum reference usage of the CPU, a sub-window “CPU Usage” representing the current usage of the CPU, “Port 0x 1010h” representing an input/output register address, and “Refresh Time” representing a refresh time for refreshing the measurement of the CPU usage although other sub-windows may also be included.
In accordance with a preferred embodiment method of the present invention, desired parameters displayed on the display window are set to adjust the clock rate of the CPU at an environment setting step. For example, where the CPU usage is reduced to a value less than the minimum reference CPU usage set in the sub-window “Hold Usage” or set in a predetermined minimum reference CPU usage amount, the contents of those, which are associated with addresses 10 H and 11 H of input/output registers in a dedicated power management chipset (PIIX4E), that is, a register for determining a clock throttle rate and a register for enabling a clock throttle operation, are changed to reduce the clock rate of the CPU. Also, where the CPU usage is increased to a value more than the maximum reference CPU usage set in the sub-window “Recov, Usage” or set in a predetermined maximum reference CPU usage amount, the set register values are changed to increase the clock rate of the CPU. The CPU usage can be periodically measured at intervals of the refresh time set in the sub-window “Refresh Time” or at a predetermined interval of time that can be preset.
FIG. 3 is a flow chart illustrating the method for adjusting the clock throttle rate of the CPU in accordance with a preferred embodiment of the present invention. In accordance with the method illustrated in FIG. 3 , when the user enables a power management setting based on a CPU clock throttle rate adjustment, it is first determined whether the refresh time has elapsed (Step S 30 ) and if the refresh time has elapsed, the usage of the CPU is measured (Step S 31 ). The usage of the CPU may be measured by measuring an idle thread value of the CPU for a predetermined period of time or by detecting the CPU usage from the registry information of the system.
Thereafter, the measured CPU usage is compared with the minimum reference usage and maximum reference usage previously set using the display window of FIG. 2 (Step S 32 ) or preset values. If the measured CPU usage is less than the minimum reference usage, the clock throttle rate of the CPU is stepwise increased, thereby reducing the clock rate of the CPU (Step S 34 ). If the CPU usage measured after the reduction of the CPU clock throttle rate is still less than the minimum reference usage, the CPU clock throttle rate is then adjusted to a next higher value, thereby further reducing the clock rate of the CPU. This procedure is repeated until the measured CPU usage is not less than the minimum reference usage.
If the measured CPU usage is between the minimum and maximum reference usages, the current clock rate of the CPU is maintained as an optimum rate (Step S 33 ). If the measured CPU usage is more than the maximum reference usage, the clock throttle rate of the CPU is initialized (Step S 35 ) by recovering the clock rate of the CPU to a normal rate for improving system performance. The minimum and maximum reference usages may be appropriately determined, depending on the performance of the CPU.
Since the performance and power consumption of the system may vary considerably depending on the set values of the minimum and maximum reference usages, it may be desirable for those reference values to be set by the manufacturer rather than by the user. In this connection, it may be desirable to allow the user to determine whether it is necessary to enable the power management setting.
As shown in FIG. 4 , the architecture of the computer where a device driver is used includes a ring- 3 layer, a ring- 0 layer, and a hardware layer. The ring- 3 layer is a user interface layer for enabling the clock throttle rate adjustment based on the usage of the CPU. The ring- 0 layer is an intermediate layer that allows the user program to directly control the hardware layer with a device driver. When information set in the ring- 3 layer is transmitted to the device driver in accordance with an input/output control of the ring- 0 layer, the device driver reads the usage of the CPU, thereby controlling the dedicated power management chipset to reduce or increase the clock throttle rate of the CPU.
As apparent from the above description, the present invention provides a method of preventing degradation in the performance of a system by measuring the usage of the CPU included in the system, and appropriately controlling the clock throttle rate of the CPU based on the measured CPU usage. The present invention also reduces the consumption of electric power in the system by measuring the usage of the CPU included in the system, and appropriately controlling the clock throttle rate of the CPU based on the measured CPU usage. Additionally, where the preferred method of the present invention is applied to a notebook computer, it is also possible to extend a life time of a battery used in the notebook computer.
The foregoing embodiments and advantages are merely exemplary and are not to be construed as limiting the present invention. The present teaching can be readily applied to other types of apparatuses. The description of the present invention is intended to be illustrative, and not to limit the scope of the claims. Many alternatives, modifications, and variations will be apparent to those skilled in the art. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. | A method, apparatus or stored program for adjusting the clock throttle rate of a central processing unit (CPU) included in a computer, in which the usage of the CPU is measured, so that the clock throttle rate of the CPU can be automatically adjusted on the measured usage of the CPU, thereby reducing the consumption of electric power without any influence on the performance of the computer. | 8 |
RELATED APPLICATIONS
This application claims priority of U.S. Provisional Application Ser. No. 60/379,569, filed on May 10, 2002, the contents of which are incorporated herein by reference.
GOVERNMENT FUNDING
The U.S. Government has a paid-up license in the present invention and the right in limited circumstances to require the patent owner to license others on reasonable terms as provided for by the terms of a contract awarded by the U.S. Army Research Office under funding numbers DAAD199910333 and DAAD1999C0045.
TECHNICAL FIELD
The present invention relates generally to microscopes and microscopy and, more specifically, to subwavelength imaging in the terahertz (THz) frequency range.
BACKGROUND OF THE INVENTION
THz radiation (T-rays) occupies a large portion of the electromagnetic spectrum between the infrared and microwave bands, namely the frequency interval from 0.1 to 10 THz, and is a developing frontier in imaging science and technology. In contrast to the relatively well-developed techniques for medical imaging at microwave and optical frequencies, however, there has been only limited basic research, new initiatives and advanced technology developments in the THz band. THz waves have been increasingly used to characterize the electronic, vibrational and compositional properties of solid, liquid and gas phase materials.
Unlike X-rays, T-rays have low-photon energies (4 meV @ 1 THz), low average power (nW to μW) and do not subject biological tissue to harmful radiation. T-rays can be focused to give sharper pictures. In addition, T-rays give spectroscopic information about the chemical composition as well as the shape and location of the targets they are imaging. This combination of information of the physical and the biochemical nature of the imaged tissue may be of particular value for clear and early diagnosis and detection of diseases such as cancer, allowing for a choice of treatment options.
Unlike common optical spectroscopes, which only measure the intensity of light at specific frequencies, THz time-domain spectroscopic techniques directly measure the THz wave's temporal electric field. Fourier transformation of this time-domain data gives the amplitude and phase of the THz wave pulse, therefore providing the real and imaginary parts of the dielectric constant without the use of the Kramers-Kronig relations. This allows precise measurements of the refractive index and absorption coefficient of samples that interact with the THz waves. Many rotational and vibrational spectra of various liquid and gas molecules lie within the THz frequency band, and their unique resonance lines in the THz wave spectrum allow us to identify their molecular structures. Raman spectroscopy directly uses the frequency domain to fingerprint the lattice vibrations. Similarly, THz wave spectroscopy describes molecular rotational and vibrational spectra from 10 GHz to 10 THz using the real and imaginary parts of the dielectric function that are obtained by measuring the THz wave in the time-domain. Current optical or microwave techniques cannot achieve this functionality.
Due to the diffraction-limit, the standard imaging resolution for 1 THz has historically not been much smaller than 300 μm. Near-field imaging techniques are known that can greatly improve the spatial resolution of a THz wave sensing and imaging system. Collection mode near-field imaging has been demonstrated to improve spatial resolution as low as a 7 μm imaging resolution with 0.5 THz pulses. A limitation of such a system, however, is the extremely low throughput of the THz wave past the emitter aperture, because the throughput THz wave field is inversely proportional to the third power of the aperture size of the emitter aperture. Therefore, pre-existing THz wave generation and detection technologies are inadequate for obtaining sub-micron spatial resolution.
A newly developed dynamic-aperture method with the introduction of a third gating beam can image objects with a sub-wavelength resolution (λ/100), but the drawback of this method is the difficulty in coating a gating material on the surface of biomedical samples such as cells and tissues.
Thus, there is a need in the art for a T-ray imaging technique and system that can provide imaging with submicron resolution using THz radiation.
SUMMARY OF THE INVENTION
One aspect of the invention comprises a microscope for producing an image of a target, the microscope comprising:
a source for providing an optical pump pulse and an optical probe pulse; a THz emitter having a first surface and a second surface substantially parallel and opposite said first surface and a THz detector also having a first surface and a second surface substantially parallel and opposite said first surface; means for impinging said pump beam onto said THz emitter through said first surface of said emitter; means for impinging said probe beam onto said detector through said first surface of said detector; wherein at least one of said means for impinging said pump beam and said probe beam comprise an optical focusing means for focusing one of said pump beam and said probe beam to a substantially optical wave length limited spot size; and wherein at least one of said second surface of said emitter and said second surface of said detector is adapted to receive a sample within a near field of said THz radiation.
In a particular embodiment of the invention, the invention comprises a microscope for producing an image of a target, wherein the microscope comprises:
a source for providing an optical pump pulse and an optical probe pulse; a THz emitter for activation by the optical pump pulse to emit a THz pulse that irradiates the target to form of a target-modified THz pulse said THz emitter comprising an EO crystal having first, pump beam side, surface and a second, target side surface, opposite said first surface the target side surface adapted to support said target within a near field of said THz irradiated pulse; a focal lens for focusing at least said pump beam onto said THz emitter; one of a hemispherical lens or super-hemispherical lens between said focal lens and said emitter in contact with said first surface; a THz detector for modulating the probe pulse with the target-modified THz pulse to create a modulated optical probe pulse characteristic of the target; an optical detection system for modifying and detecting the modulated optical probe pulse and converting the modulated optical probe pulse to electronic information; a processor for receiving the electronic information and producing an image of the sample using the electronic information.
The THz emitter and the THz detector may comprise a single THz transceiver, and the target-modified THz pulse may comprise a reflected component. The THz emitter may comprise a first EO crystal and the THz detector comprises a second EO crystal, and the target-modified THz pulse comprises a transmitted component. The target may be placed on a top surface of the THz emitter, and the pump beam may be directed to the THz emitter from underneath the emitter. In another embodiment, the target may be placed on a top surface of the THz detector, the THz pulse directed to the THz detector from above the detector, and the probe beam directed to the THz detector from underneath the detector.
The microscope may further comprise noise reduction components. The noise reduction components comprise a first modulator for modulating the pump beam at a first frequency and integrated with a first lock-in amplifier positioned between the optical detector and the processor. The noise reduction components may further comprise a second modulator for modulating the probe beam at a second frequency and integrated with a second lock-in amplifier connected in series with the first lock-in amplifier. The first frequency may be greater than or equal to about 1 MHz and the second frequency may be greater than or equal to about 1 kHz.
The microscope may further comprise a delay stage positioned in a pathway of one of the pump pulse or the probe pulse for enabling characterization of a complete waveform of the THz pulse. In another embodiment, optical detection system may comprise a Charge Coupled Device (CCD) camera. The microscope may further comprise means for scanning the target across an x-y plane.
The microscope may comprise a focal lens through which at least the pump beam is focused onto the THz emitter, the focal lens comprising an optical microscope objective in optical alignment with an optical microscope eyepiece to provide optical monitoring of the sample.
The microscope may further comprising a focal lens through which the pump beam and probe beam are focused onto the THz transceiver and a hemispherical lens between the focal lens and the THz transceiver, the hemispherical lens having an index of refraction that is the same as an index of refraction of the THz transceiver, the hemispherical lens and the focal lens having identical numerical apertures. Preferably a super-hemispherical lens is used as a solid immersion lens. The laser may be a Ti:sapphire laser. The one or more EO crystals may comprise ZnTe or LiNbO 3 .
The microscope may further comprise a vacuum chamber in which at least the target and the THz emitter and/or THz detector are located.
In another embodiment, the THz emitter comprises an EO crystal having a top surface and an optically-reflective coating, such as GaAs, on the top surface. The EO crystal also may comprise a bottom surface and an anti-reflective coating on the bottom surface. The EO crystal may further comprise a conductive coating, such as gold, over the reflective coating, the conductive coating having at least one aperture therein.
The EO crystal may comprise a top surface, a conductive coating on the top surface, and at least one aperture in the conductive coating.
In another aspect of the invention, a microscope may comprise a source for providing an optical pump pulse and an optical probe pulse; a THz transceiver comprising an EO crystal having a first surface adapted for contacting the target and having an index of refraction, the THz transceiver adapted to generate a THz pulse when activated by the optical pump pulse and to modulate the optical probe pulse with a reflection of the THz pulse off of the target, creating a reflected modulated optical probe pulse; a hemispherical lens mounted on a second surface of the EO crystal opposite the first surface, having an index of refraction identical to the index of refraction of the EO crystal, and having a numerical aperture; a focal lens adapted to focus the optical pump pulse and optical probe pulse onto the hemispherical lens, the focal lens having a numerical aperture identical to the numerical aperture of the hemispherical lens; a polarizer adapted to receive, isolate, and analyze the reflected modulated optical probe pulse; an optical detection system for modifying and detecting the modulated optical probe pulse and converting the modulated optical probe pulse to electronic information; and a processor for receiving the electronic information and producing an image of the sample using the electronic information.
Still another aspect comprises a microscope comprising: a source for providing an optical pump pulse and an optical probe pulse; a THz emitter comprising an EO crystal adapted to generate a THz pulse when activated by the optical pump pulse and having a first surface for receiving the target; a focal lens through which the optical pump pulse is focused onto the THz emitter; a THz detector comprising an EO crystal adapted to receive a target-modified THz pulse produced by transmission of the THz pulse through the target and to modulate the optical probe pulse with the target-modified THz pulse to produce a modulated optical probe pulse; an optical detection system for modifying and detecting the modulated optical probe pulse and converting the modulated optical probe pulse to electronic information; and a processor for receiving the electronic information and producing an image of the sample using the electronic information.
Yet another aspect of the invention comprises a microscope comprising: a source for providing an optical pump pulse and an optical probe pulse; a THz emitter comprising an EO crystal adapted to generate a THz pulse when activated by the optical pump pulse; a THz detector comprising an EO crystal having a first side coated with a reflective coating and adapted to receive the target, and a second side coated with an anti-reflective coating, the THz detector adapted to receive the THz pulse as modified by the target from the first side, to receive an optical probe pulse from the second side, and to modulate the optical probe pulse with the THz pulse as modified by the target to produce a modulated optical probe pulse; an optical detection system for modifying and detecting the modulated optical probe pulse and converting the modulated optical probe pulse to electronic information; and a processor for receiving the electronic information and producing an image of the sample using the electronic information.
The T-ray microscope may further comprise a conductive coating over the reflective coating, the conductive coating having at least one aperture. The microscope may also further comprise a focal lens for focusing the optical probe pulse on the THz detector and means for providing an x-y scan of the target. In another embodiment the optical probe pulse may have a relatively large beam waist illuminating the target, and the optical detection system comprises a Charge Coupled Device (CCD) camera.
Yet another aspect of the invention is a method for a microscopic examination of a target using T-rays, the method comprising:
(a) providing an optical pump pulse and an optical probe pulse along a pump optical path and a probe optical path; focusing said optical pump pulse onto a THz emitter comprising an EO crystal, by transmitting said optical pump pulse along said pump optical path through a an optical means to an optical spot size limited by the optical probe pulse wavelength on a first surface of said EO crystal thereby emitting a THz radiation pulse from said THz transmitter having a THz radiation near field resolution substantially the same as said optical spot size; (b) positioning said target in said THz radiation near field and transmitting or reflecting the THz pulse through or off of the target, creating a target-modified THz pulse; (c) modulating the probe pulse with the target-modified THz pulse in a THz detector EO crystal to create a modulated optical probe pulse characteristic of the target; (d) modifying and detecting the modulated optical probe pulse and converting the modulated optical probe pulse to electronic information; and (e) receiving and processing the electronic information to produce a microscopic image of the target.
Still another aspect of the invention comprises a method for a microscopic examination of a target using T-rays, the method comprising:
(a) providing an optical pump pulse and an optical probe pulse along a pump optical path and a probe optical path; focusing said optical pump pulse onto a THz emitter comprising an EO crystal, by transmitting said optical pump pulse along said pump optical path through a focal lens and one of a hemispherical or super hemispherical lens located on a first surface of said EO crystal thereby emitting a THz pulse from said THz transmitter wherein said hemispherical or super hemispherical lens has a refractive index substantially the same as the refractive index of said EO crystal; (b) positioning said target in a near field of said THz pulse and transmitting or reflecting the THz pulse through or off of the target, creating a target-modified THz pulse; (c) modulating the probe pulse with the target-modified THz pulse in a THz detector EO crystal to create a modulated optical probe pulse characteristic of the target; (d) modifying and detecting the modulated optical probe pulse and converting the modulated optical probe pulse to electronic information; and (e) receiving and processing the electronic information to produce a microscopic image of the target.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is best understood from the following detailed description when read in connection with the accompanying drawing. It is emphasized that, according to common practice, the various features of the drawing are not to scale. On the contrary, the dimensions of the various features are arbitrarily expanded or reduced for clarity. Included in the drawing are the following figures:
FIG. 1A is a schematic diagram of an exemplary T-ray microscope system;
FIG. 1B is a schematic illustration of a portion of an exemplary transmitted mode T-ray microscope embodiment similar to the system shown in FIG. 1A , in which the emitter includes an optical reflective coating;
FIG. 2A is a schematic illustration of a portion of an exemplary transmitted mode T-ray microscope embodiment in which the sample is placed on the detector;
FIG. 2B is a schematic illustration of a portion of an exemplary transmitted mode T-ray microscope embodiment in which the sample is placed on a detector having a metallic film and aperture;
FIG. 3 is a schematic illustration of a portion of an exemplary transmitted mode T-ray microscope embodiment comprising a CCD camera for detecting the optical beam;
FIG. 4 is an illustration of a portion of an exemplary reflected mode T-ray microscope embodiment;
FIG. 5 is an illustration of the same portion of the exemplary reflected mode T-ray microscope embodiment showing the use of a super-hemispherical lens in accordance with an alternate embodiment of the present invention.
DETAILED DESCRIPTION OF INVENTION
Currently, there are two basic approaches for generating THz beams using ultrafast laser pulses: photoconduction and optical rectification. One preferred optical source for the generation of THz waves is an ultrafast Ti:sapphire laser having a pulse energy from nJ to μJ and a pulse duration of 100 fs and a center wavelength at 800 nm. The photoconductive approach employs high-speed photoconductors as transient current sources for radiating antennas. The optical rectification approach uses electro-optic crystals as rectification media. Rectification can be a second order (difference frequency generation) or a higher order nonlinear optical process, depending on the optical power density.
Optical rectification is the inverse process of the electro-optic effect. In contrast to photoconducting elements where the optical beam functions as a trigger, the energy of THz wave radiation generated by the transient optical rectification process comes from the excitation laser pulse. The conversion efficiency (10 −4 to 10 −6 ) depends on the value of the nonlinear coefficient and the phase matching condition. In the optical rectification mode, the THz pulse duration is comparable to the optical pulse duration, and the frequency spectrum is mainly limited by the spectral broadening of the laser pulse, as determined by the uncertainty principle.
Similar to the generation of THz waves, both photoconductive and electro-optic methods can be used to detect THz waves. Photoconductive antennas were first used to detect freely propagating THz waves, but electro-optic detection has more recently become widely used in many research laboratories due to its ultra-wide bandwidth and parallel imaging capability. THz wave transceivers, which alternately transmit THz radiation (by optical rectification) and receive the returned signal (by the electro-optic effect), have been recently developed, as disclosed in U.S. patent application Ser. No. 09/826,458, filed Apr. 5, 2001, by Zhang et al. and incorporated herein by reference. Transceivers provide known advantages in THz wave ranging, remote sensing, time-of-flight imaging, and tomographic imaging applications. Use of a transceiver is ideal for the measurement of THz waves reflected from a target. Compared to traditional THz tomography setups in reflection geometry, imaging systems with electro-optic transceivers are simpler and easier to align. In addition, the normal incidence of the THz beam on the sample can be maintained.
In an electro-optic sampling setup, the field-induced birefringence of the sensor crystal due to an applied electric field (THz wave), modulates the polarization ellipticity of an optical probe beam that passes through the crystal. The ellipticity modulation of the optical beam can then be polarization analyzed to provide information on both the amplitude and phase of the applied electric field. The balanced detection system analyzes a polarization change from the electro-optic crystal and correlates it with the amplitude and phase of the THz electric field. The time delay is provided by changing the relative length of the beam path between the THz radiation pulses and the optical probe pulses (pump-probe sampling method). Detection sensitivity is significantly improved by increasing the interaction length of the pulsed field and optical probe beam within the crystal, accomplished by using a thicker crystal. The signal-to-noise ratio of electro-optic detection can exceed 10,000:1.
With a Ti:sapphire laser as the optical source, an ideal crystal for THz generation and detection is zinc telluride (ZnTe) because ZnTe satisfies the phase matching condition (the group velocity of the optical beam at 800 nm equals the phase velocity of the THz wave at 2 THz). The analysis of the electro-optic tensor of zincblende crystals predicts that the best orientation to generate and detect THz waves in a ZnTe is the <110> cut. If optical sources with different wavelengths are used, the phase matching condition may be different, meaning that other electro-optical crystals may be more favorable. For example, GaAs is more favorable for the 1.5 μm optical beam and GaP is more favorable for the 1.3 μm optical beam.
Referring now to FIGS. 1A and 1B there are shown schematic diagrams of an exemplary transmitted mode microscope system of this invention. An electro-optic (EO) crystal 12 , such as but not limited to ZnTe or LiNbO 3 , is used to generate THz wave signals 16 from a laser pulse 14 focused by a lens or lens system 15 onto the crystal. A tissue sample 18 is directly mounted on the surface of EO crystal 12 . As shown in FIG. 1B , EO crystal 12 may have a reflective coating 13 b , such as but not limited to highly-reflective coating such as GaAs that blocks the optical portion of laser beam 14 from being transmitted through crystal 12 . THz pulse 16 is generated in crystal 12 by optical rectification and detected by a THz wave detector crystal 20 by the electro-optic effect.
In the transmitted mode shown in FIG. 1A , the THz waves emitted by crystal 12 and transmitted through sample 18 are typically bounced off of one or more parabolic mirrors such as R 1 and R 2 and then directed to a separate THz detector 20 . An optical probe pulse P 2 is used for sampling the THz wave in the THz detector.
In the exemplary embodiment shown in FIG. 1A , pulse 14 from laser L 1 is split by beam splitter 42 a into a pump pulse P 1 and a probe pulse P 2 . Pump pulse P 1 travels through delay stage 44 comprising mirrors 48 a , 48 b , 48 c and is then directed into modulator 45 a , such as an acousto-optic (AO) modulator, which is integrated with lock in amplifier 37 a and function generator 39 as is explained in more detail below. Delay stage 44 provides a variable distance through which pulse P 1 travels by moving closer to and further away from splitter 42 a along arrow A.
Pump pulse P 1 next is directed through beam expander 46 and is focused through objective lens system 15 and, optionally, through hemispherical lens H 1 onto crystal 12 . The reason for using a hemispherical lens or super-hemispherical lens in contact with crystal 12 is discussed later in this specification. Crystal 12 generates THz waves 16 that are transmitted through sample 18 . Sample 18 is placed within THz radiation the near field area, shown as dotted line boundary NF in FIG. 1B . Near field is defined as a distance less than a wavelength of the THz radiation from the point of the THz radiation generation.
Between beam expander 46 and objective lens 15 may be beam splitters 42 b and mirror 48 f which allow a reflected optical view of sample 18 to be visualized through optical eye piece 50 of a standard optical microscope. It should be noted herein that flat mirrors 48 a – 48 f and beam splitters 42 a and 42 b are illustrated herein as needed to show a logical schematic diagram. More or fewer mirrors and beam splitters may be provided, however, as is required or allowed the physical space provided for the microscope system.
The THz waves 16 transmitted through sample 18 are collimated and focused by parabolic mirrors R 1 and R 2 onto detector crystal 20 after passing through pellicle 26 . Probe pulse P 2 is directed to pellicle 26 , which is typically 2 to 4 microns thick such that the long wavelength of THz pulse 16 passes through pellicle 26 without reflection. In detector 20 , the E-field of the THz waves 16 induces birefringence inside the ZnTe crystal of EO detector 20 , which in turn tunes (changes the polarization of) probe pulse P 2 by modulating it to include a component proportional to the THz waves. Thus, optical pulse 31 leaving detector 20 contains information relating to THz waves 16 .
A quarter waveplate 33 , a Wollaston prism 34 , and photodetectors 38 a , 38 b comprise a typical EO sampling system, which is known in the art. Quarter waveplate 33 changes the linear polarization of pulse 31 to a circular polarization. Wollaston prism 34 splits the circular polarization of pulse 31 back into linearly polarized pulses 31 a and 31 b , each polarized 90° relative to the other. Each pulse 31 a and 31 b is directed onto photo detectors 38 a and 38 b , respectively, which may be photodiodes. Photo detectors 38 a and 38 b are connected to circuitry (not shown), known in the art, which subtracts the waveform of pulse 31 b from the waveform of pulse 31 a to eliminate the common current with reduced noise. The modulation of pulse P 2 by output pulse 16 within EO detector 20 can be detected because the intensity components in pulses 31 a and 31 b proportional to the THz electric field have the same value but opposite sign. Thus, the change in probe pulse P 2 induced by THz waves 16 is doubled after subtraction of pulse 31 a from pulse 31 b.
The sensitivity of the T-ray microscope may be improved using any method for improving signal-to-noise ratio (SNR) known in the art. A number of SNR improvement techniques for THz systems are known in the art. An exemplary single lock-in amplifier system, comprising lock-in amplifier 37 a , modulator 45 a , and function generator 39 is shown in FIG. 1A . As is known in the art, pump pulse P 1 may be modulated on/off with modulator 45 a in accordance with a square wave function generated by function generator 39 that is synchronized with lock-in amplifier 37 to reduce noise.
Another known noise reduction technique comprises differential spectroscopy, which is described by Zhiping Jiang, Ming Li, and X.-C. Zhang, in “Dielectric constant measurement of thin film by differential time-domain spectroscopy,” Appl. Phys. Lett., 76, 3221(2000), incorporated herein by reference. Another noise reduction technique is a double modulation technique, described generally by S. V. Frolov and Z. V. Verdeny in “Double-modulation electro-optic sampling for pump-and-probe ultrafast correlation measurement,” Review of Scientific Instruments, 69, 1257 (1998), incorporated herein by reference. Differential spectroscopy allows measurement of a change in T-ray field transmission (ΔT/T) as low as 10 −5 , and the two-frequency modulation and double lock-in amplifier methods may further improve the signal-to-noise ratio by a factor of 10.
Optional components capable of converting the single lock-in amplifier set-up shown in FIG. 1A to a two-frequency modulation and double lock-in amplifier set-up are shown in dashed lines. The two-frequency modulation and double lock-in amplifier set-up provides means for modulating the T-ray and optical probe beams at 1 MHz and 1 kHz rates, respectively. This method greatly reduces noise from laser power fluctuations, mechanical vibration and other external noises. In such a system, modulator 45 may comprise a RF modulator (MHz) and lock-in amplifier, 37 b may comprise an RF lock-in amplifier, and a galvanometer 45 b and audio frequency (AF) lock-in amplifier may be used to produce and detect the optical pulse modulation (kHz), respectively. The dual modulation method, compared to the use of a single lock-in amplifier method, overcomes low frequency external noise at kHz frequencies, but is still benefited by the better system performance of the AF amplifier. A computer 37 c may be used to control the system, process imaging data and display captured images.
The physical relationships among the sample, emitter, detector, and probe beam for a transmission-mode system are not limited to the layout schematically shown in FIGS. 1A and 1B . What is important is to create an arrangement where the sample is in a THz near field (shown as a dotted line boundary NF in the figures) and either the target sample is scanned in the near field by the THz beam generated by an optical pump beam spot whose diameter is reduced to substantially the theoretical diffraction limits, or, in an alternative arrangement discussed later in this specification, by placing the target sample on a detector surface such that the THz radiation transmitted through the target sample to the detector is scanned by an optical probe spot size again reduced to substantially its theoretical limits, again as discussed later on in this description.
For example, as shown in FIG. 2A , the system may be set up with sample 18 disposed on THz detector 220 rather than on THz emitter (not shown) shown in FIG. 1A . In such a layout, the emitter crystal and collimating parabolic mirrors (not shown) are located before sample 18 to create a THz pulse 216 that is transmitted through the sample into the detector 220 . The probe beam P 2 is reflected off beam splitter 242 through lens 215 from below detector 220 . The sample is so located that the THz near field of radiation through the sample enters the detector crystal and is probed by the probe beam P 2 which is again focussed to a substantially diffraction limited spot. Preferably, a hemispherical or super-hemispherical lens H 2 shown in dotted line is used to focus the probe beam onto the detector.
Detector crystal 220 preferably has an anti-reflective coating 213 a on the bottom surface and reflective coating 213 b on the top surface. The coatings help prevent optical loss in the crystal and leakage of the optical beam into the tissue sample. THz pulse 216 as modulated by sample 18 modulates the reflection of optical probe beam RP 2 off of reflective coating 213 b , thereby creating a modulated optical beam that passes through beam splitter 242 to the detection optics (not shown). The components of the system not shown in FIG. 2A may be the same or similar to those shown in FIG. 1A , or may be set up in accordance with any THz system known in the art. Because of the use of beam splitter 242 , beam dumping elements 243 are provided, as are known in the art, to dispose of the portion of the probe beam P 2 transmitted through beam splitter 242 .
As shown in FIG. 2B , detector crystal 220 may also comprise a conductive metallic film 215 , such as but not limited to a highly-conductive metallic film such as gold, having at least one aperture 216 , over reflective coating 213 b on the top surface of emitter crystal 218 . Metallic film 215 and aperture 216 limit the amount of THz signal passed through the metallic film to a beam the size of the aperture. This is particularly helpful for a detector crystal 220 that has a thickness greater than the dimensions of the sample. Although shown in FIG. 2B with both metallic film 215 and coatings 213 a and 213 b , detector crystal 220 may be provided with only the coatings 213 a and 213 b (such as is shown in FIG. 2A ) or only one of the coatings (not shown), with only the metallic film 215 (not shown), or with no coatings or films at all. The use of various coatings, however, is helpful in improving the overall system performance.
To collect information across a desired length and width of a sample, the EO crystal, the sample, or the THz beam can be scanned laterally to obtain a two-dimensional image. As a practical matter, because sample 18 is placed on the top of EO crystal 12 , both are typically scanned together. For example, two-dimensional scanning may be performed by using an x-y mechanical stage with a step size of 0.1 μm. The use of a highly focussed optical spot rather than THz radiation in the present invention permits higher resolution limited by the wavelength of the optical beam rather than the THz radiation wavelength. Thus, sub-micron spatial resolution is achievable even though the imaging wavelength is about 300 μm at 1 THz.
Another method of getting two-dimensional information with a transmission mode microscope system is schematically shown in FIG. 3 . This system has a similar physical layout to that shown in FIG. 2A , without the focal lens between the probe beam and the beam splitter. Thus, probe beam P 2 has a relatively wide waist, providing a modulated optical beam 331 having a similarly large waist. Modulated optical beam 331 then passes through a polarizer 300 and focal lens 301 and is ultimately read by a charge-coupled device (CCD) camera 302 . The use of CCD cameras for two-dimensional imaging is discussed generally by Wu, Hewitt, and Zhang, in “Two-dimensional electro-optic imaging of THz beams,” Appl. Phys. Lett. 69 (8) pp. 1026–1028 (1996), incorporated herein by reference.
The spatial resolution in the above systems is typically limited only by the optical focal size of the laser on the crystal and can be less than 1 μm due to the large refractive index of 2.8 for ZnTe under a moderate optical power, and is independent of the THz wave wavelength.
When a Ti:sapphire laser with λ=0.8 μm is used as the optical source, the smallest optical focal spot a in the air is calculated by the standard equation of d=1.22λ2f/D, where d is the spot diameter, f is the wavelength, D is the beam diameter, and D/2f is the numerical aperture NA of the microscope objective lens. Assuming the ideal case with NA=1, then d=1 μm. One way to achieve sub-micron lateral resolution is to focus the optical beam into a high refractive index medium. The refractive index of the ZnTe is greater than 1; therefore, the focal spot in a ZnTe must be smaller than that in air by the factor of the refractive index value. It is difficult, however, to achieve a much smaller focal spot by directly focusing a laser beam from the air into a ZnTe plate, because of the change of the numerical aperture after the optical refraction at the interface of the ZnTe in accordance with Snell's Law.
An alternate embodiment of this invention is to use a T-ray microscope in a reflection mode. In a reflection mode, the EO crystal on which the sample is mounted acts as both an emitter and a detector, otherwise known as a transceiver. THz transceiver systems are described generally in U.S. patent application Ser. No. 09/826,458, filed Apr. 5, 2001, by X. C. Zhang et al., incorporated herein by reference.
A pertinent portion of an exemplary reflected mode microscope 410 , is shown schematically in FIG. 4 . In the reflected mode microscope 410 , both the THz emitter and receiver functions are combined in a single transceiver crystal 412 , such as a <110> cut ZnTe crystal, in the near-field range NF. In the transceiver crystal 412 , both pump pulse P 1 and probe pulse P 2 , having different wavelength between one and the other are transmitted through beam splitter 442 and then focused by focal lens 415 through hemispherical lens 428 onto crystal 412 , which generates THz waves. The numerical apertures of focal lens 415 and hemispherical lens 428 are identical, and the refractive index n of hemispherical lens 428 and crystal 412 are the same resulting in an expected overall improvement in spot size reduction of 1/n as compared with the case of air, that is where there is no hemispherical lens present.
In the case of ZnTe, n=2.8 the expected spot diameter reduction when compared to no hemispherical lens present would be of the order of 1/2.8 (or about 0.36 times the diameter of the spot).
Preferably a super-hemispherical lens H 2 is used as a solid immersion lens instead of the hemispherical lens H 1 shown in FIG. 4 , as shown in FIG. 5 . The use of the super-hemispherical lens can improve NA and also decrease wavelength resulting in an overall minimum focused spot size reduction of 1/n 2 compared to air, where n is the refractive index of the super hemispherical lens and the terahertz transceiver. When a super-semispherical lens is used instead of the hemispherical ZnTe example above, one may expect a spot diameter reduction of the order of 0.13D where D is the diameter possible without the super-hemispherical lens.
The different wavelength of the pump and probe beams is used to separate the pump beam from the probe beam after the beams reflect from the crystal/tissue interface.
The pump pulse generates the THz wave in the ZnTe crystal by optical rectification. The THz waves that reflect off of tissue sample 418 modulate the optical component of the reflected probe pulse. The modulated optical probe pulse (as well as a reflected portion of the optical pump pulse) are transmitted back through lenses 428 and 415 and are reflected off of beam splitter 442 . Filter 429 located in front of polarizer 430 separates the pump beam from the probe beam and polarizer 430 also analyzes the polarization change of the modulated probe beam induced by the THz waves. The analyzed optical pulse 431 is focused by lens 432 onto diode 438 , where the signal is optically received. Because target sample 18 is placed on top of transceiver crystal 412 , the THz wave is generated and detected at the same focal spot within the transceiver crystal 412 . The T-ray imaging spot on the tissue is comparable to the focal spot of the optical beam. The reflected mode geometry allows measurements to be made in-vivo.
The optical beam is focused in the ZnTe through the matching refractive index lens to a spot size comparable to a 1.22λ/n (assuming NA=1). If λ=0.8 μm and n=2.8, in theory the focal spot can be a small as 0.35 μm. A smaller focal spot can be provided by using a shorter optical wavelength, such as the second harmonic wave from the Ti:sapphire laser.
For high precision measurements, the THz wave microscope or a portion thereof, particularly at least the target, the THz emitter, and the THz sensor, may be placed in a vacuum chamber, for instance having a pressure of 10 −4 Torr. The vacuum system may be especially important for sensing and imaging studies of nanolayer biomedical samples (such as monolayer DNA and protein) because any guest molecules from the air might otherwise contaminate the sample. The vacuum chamber also allows atmospheric moisture and other contaminant gases to be removed.
Due to the intense power density at an optical focal spot (micron or sub-micron), some higher order nonlinear phenomena other than optical rectification may limit THz wave generation and detection. For example, two-photon absorption (a third order nonlinear optical effect) in ZnTe generates free carriers. At a tight focal spot, extremely high free-carrier density changes the ZnTe local conductivity, screens the THz wave, and saturates the THz wave field. A reduction in optical peak power may be accommodated by increasing the pulse repetition-rate. The trade-off between the average power and the peak power may be optimized to provide efficient THz wave generation.
The microscope system may be calibrated using several commonly used imaging calibration charts, including the U.S. Air Force Target, the IEEE Chart, and the FBI standard chart, which are well known in the art. All of these imaging charts contain micron size structure patterns and may be placed directly on the top of the EO crystal. It has been observed that the imaging resolution is different for the polarization of the THz wave parallel or perpendicular to a metallic line. This is due to the induced current in the metallic line. Charts fabricated on dielectric films may avoid such effects.
The THz microscope may dramatically enhance pathological inspection and analysis of tissues. In addition to helping in diagnosis, it may also be useful in helping to discover causes of the pathology, by giving new molecular-level information that is linked with morphological changes in the tissue/cells. The microscope may also be used to investigate rapid biochemical responses to selected stimuli, giving new insight into biological processes.
The microscope may be applied to tissue characterization, starting from the biomolecules and monolayers of cells. A detailed analysis of specific changes in spectroscopic signatures with subtle changes in molecular structure or composition in the biomolecules may be compiled.
Although illustrated and described above with reference to certain specific embodiments, the present invention is nevertheless not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope and range of equivalents of the claims and without departing from the spirit of the invention. | A microscope for producing an image of a target using THz radiation. The microscope comprises a source for providing an optical pump pulse and an optical probe pulse; a THz emitter for activation by pump pulse to emit a THz pulse that irradiates the target to form a target-modified THz pulse; a THz detector for modulating the probe pulse with the target-modified THz pulse to create a modulated optical probe pulse characteristic of the target; an optical detection system for modifying and detecting the modulated optical probe pulse and converting the modulated optical probe pulse to electronic information; and a processor for receiving the electronic information and producing an image of the sample using the electronic information. The THz emitter and detector comprise one or more EO crystals. The target is positioned on one of the EO crystals in a near-field of the THz pulse. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates to rolls of the type which are used in paper machines as well as to methods for manufacturing such rolls.
The present invention relates in particular to that type of roll which has an inner roll body which may be solid or in the form of a hollow sleeve and which is covered at its exterior surface by an elongated covering strip which may be helically wound onto the inner roll body with successive turns of the strip engaging the exterior surface of the roll body and pressing against each other. The strip may be formed at the region of its outer edge surface which is directed away from the inner roll body with one or more shoulders which thus provide for the covering strip grooves at the exterior surface of the finished roll, or the side surfaces of the strip can directly engage each other at the outer edge surface of the strip so as to provide the roll with a smooth exterior surface, or any desired combination of smooth and grooved exterior surfaces may be provided for the roll.
Thus, with such a construction the strip has circumferential portions situated one next to the other and surrounding the inner roll body, these circumferential portions forming, for example, successive turns of a helically wound strip. One of the problems encountered with a construction of this type is in connection with the interlocking of the successive turns or circumferential strip portions in such a way that they will not become displaced radially away from the inner roll body. A strip of the latter type is generally made of a corrosion-resistant material, and it is important to prevent moisture from having access to the exterior surface of the inner roll body. Problems are also encountered in known constructions of the above type in connection with preventing moisture from having access to the inner roll body so as to prevent corrosion thereof.
Also, in connection with constructions of the above type it is important to prevent the successive turns of the strip from becoming displaced axially apart from each other. Furthermore, one of the problems encountered in the prior art is in connection with constructing the strip with the degree of precision required in maintaining the successive turns of the strip reliably in engagement with each other at all times.
Thus, the invention relates to a roll of the type which is adapted to be used in a paper machine and which is provided with a roll covering which preferably is of a corrosion-resistant material and which may be either grooved or ungrooved over its exterior surface, or which is made up of grooved and ungrooved portions situated one next to the other along the axis of the roll.
Paper machine roll coverings made of a continuous covering strip by winding such a strip on an inner roll body are already known. For example reference in this connection may be made to U.S. Pat. No. 3,718,959.
SUMMARY OF THE INVENTION
It is accordingly a primary object of the present invention to provide a roll manufacturing method and a roll resulting therefrom which will avoid the above drawbacks.
Thus, it is an object of the present invention to provide a roll and roll manufacturing method according to which it is possible to secure to an inner roll body an elongated covering strip in a manner which is easy to manufacture while nevertheless affording a positive and reliable securing or interlocking of the successive turns of the strip with respect to each other and with respect to the inner roll body.
It is also an object of the present invention to provide a securing or interlocking of the successive strip turns in such a way that these successive strip turns will be situated directly next to each other in a manner according to which they are pressed tightly against each other.
It is furthermore an object of the present invention to provide a method and structure of the above type according to which the interlocking of the successive circumferential strip portions also serves to provide a fluid-tight seal and barrier against corrosion.
In addition it is an object of the present invention to provide a method and structure of the above type according to which it becomes unnecessary to manufacture components with a high degree of precision.
According to the invention the interlocking is carried out by providing the opposed side surfaces of the strip with grooves which register with each other at the interface between engaging side surfaces of successive strip turns so as to form in this way from the registering grooves an elongated bore circumferentially surrounding the inner roll body. An elongated interlocking member is situated in the latter bore, this elongated interlocking member preferably being situated in the latter bore simultaneously with the winding of the strip onto the inner roll body.
BRIEF DESCRIPTION OF DRAWINGS
The invention is illustrated by way of example in the accompanying drawings which form part of this application and in which:
FIG. 1 is a fragmentary schematic sectional elevation of part of a roll of the invention, the section of FIG. 1 taken in a plane which contains the roll axis;
FIG. 2a fragmentarily and schematically illustrates in a section which contains the roll axis part of a roll structure at a stage prior to the finished roll structure;
FIG. 2b shows the structure of FIG. 2a in the completed roll structure;
FIG. 3a shows another embodiment of the method and structure of the invention at a stage prior to the finished structure;
FIG. 3b shows the construction of FIG. 3a after the roll structure has been completed;
FIG. 4 is a fragmentary schematic sectional illustration of a further embodiment of a method and structure of the invention, the section of FIG. 4 also being taken in a plane which contains the roll axis;
FIG. 5a schematically and fragmentarily illustrates in a section containing the roll axis a further embodiment of a method and structure of the invention as shown in FIG. 5a at a stage prior to completion thereof;
FIG. 5b shows the construction of FIG. 5a when the roll structure has been completed;
FIG. 6 is a schematic elevation, in a plane normal to the roll axis, illustrating one possible method of the invention; and
FIG. 7 is a schematic top plan view of the structure of FIG. 6, further illustrating one possible method of the invention for manufacturing a roll of the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring first to FIG. 1 there is fragmentarily illustrated therein in a sectional manner part of an inner roll body 10 which may be a solid roll body or which may be in the form of a hollow cylindrical sleeve. This inner roll body 10 is covered with an elongated strip 1, made, for example, of stainless steel and helically wound onto the roll body 10 so that the strip 1 has a plurality of successive turns surrounding the roll body 10. A pair of such turns 1a and 1b are illustrated fragmentarily in FIG. 1. In the example of FIG. 1 the strip 1 has been formed at an outer edge surface region 5 thereof with a shoulder extending longitudinally along the strip so that the successive turns define for the roll covering a groove 4 which helically surrounds the inner roll body 10 in the manner apparent from FIG. 1. However, it is to be understood that the invention is also applicable in connection with an ungrooved roll covering, in which case the strip has a uniform thickness throughout so that there will be no grooves at the exterior of the roll covering. Thus, in this case the roll covering 6 will have a smooth surface. FIG. 1 illustrates how the inner edge surface 7 of the strip 1 directly engages the exterior surface of the inner roll body 10.
As is apparent from FIG. 1, the elongated strip 1 is formed at its opposed side surfaces with a pair of grooves 3a which extend longitudinally along the strip initially parallel to the opposed edge surfaces thereof, so that the grooves 3a are respectively situated at equal distances from the inner edge surface 7 of the strip 1. As a result, when the strip is wound onto the roll body 10 and the successive turns of the strip are pressed against each other, the grooves 3a at adjoining side surfaces of successive turns come in to register with each other so as to form in this way an elongated bore circumferentially surrounding and spaced from the roll body 10 at the adjoining surfaces of each pair of successive turns of the strip 1. Situated within this elongated bore formed by the registering grooves 3a is an elongated interlocking member 2a. This interlocking member 2a in the example of FIG. 1 has the same cross section as the bore which is formed by the registering grooves. In the illustrated example this cross section is circular inasmuch as each groove 3a is of a semicircular cross section. The elongated interlocking member 2a may be made of a material such as lead or a plastic and is longitudinally fed into the grooves 3a as they come together to register each other and define the circumferential bore at each pair of successive turns of the strip 1. Thus, because the interlocking member 2a extends across the interface between successive strip turns and fills the bore defined by the grooves 3a, this interlocking member 2a will interlock the strip turns in a manner preventing their radial displacement one with respect to the other outwardly away from the roll body 10. In addition, the exterior surface of the interlocking member 2a presses against the surfaces which define the grooves 3a so as to achieve in this way a fluid-tight seal and a barrier which will not permit moisture or water to pass across the location of the interlocking member 2a. Thus, in this way the structure of the invention will constitute a barrier against corrosion.
In the embodiment of the invention which is illustrated in FIGS. 2a and 2b, the successive strip portions 1a and 1b are substantially identical with those of FIG. 1 and are respectively formed with the grooves 3b which are also substantially identical with the grooves 3a. However, in this embodiment the elongated interlocking member 2b is initially of the square cross section illustrated in FIG. 2a. The size of the cross section of the interlocking member 2b is such that initially, while the interlocking member 2b retains its original cross-sectional configuration, the successive turns 1a and 1b of the strip cannot come into engagement with each other and instead are maintained at the distance Δ apart from each other. However, during winding of the strip 1 onto the inner roll body 10, the successive turns thereof are pressed against each other. The interlocking member is made of lead or a deformable plastic such as polyvinyl chloride, polybutadiene, or polyurethane or the like, with the result that the harder material of the strip causes the interlocking member to become deformed when the adjoining side surfaces of successive turns of the strip are pressed into engagement with each other. Thus, the pressing of the turns of the strip into engagement with each other serves to work and deform the interlocking member 2b so that it assumes in the example of FIGS. 2a and 2b the configuration 2b' shown in FIG. 2b. Thus, when the grooves 3b, come into registry with each other so as to define a continuous bore this bore will be substantially filled by the deformed interlocking member 2b'.
With this embodiment of FIGS. 2a and 2b, there is thus an assurance that there will be well-sealed interfaces formed between the interlocking member 2b' and the surfaces which define the grooves 3b. In addition, it will be seen that the interlocking member will not provide any excessive binding even if the shape and depth of the grooves 3b are not of a precise size and configuration. Thus with this particular embodiment there is no requirement of an extremely high degree of accuracy with respect to the dimensions and configuration of the grooves 3b, so that in this respect the embodiment of FIGS. 2a and 2b is superior to that of FIG. 1.
Referring now to FIGS. 3a and 3b, it will be seen that according to this embodiment of the invention the strip 1 is formed at its opposed side surfaces with elongated grooves 3c which are of a dovetail cross section. Thus, at the side surface where the grooves 3c is situated this groove has a lesser width than inwardly from this side surface. The elongated interlocking member 2c, which in the same way as the elongated interlocking member 2b may be made of lead or any deformable plastic such as those referred to above, is initially of the substantially star-shaped cross section apparent from FIG. 3a. Thus, initially the deformable strip 2c has its opposed side surfaces formed with the substantially V-shaped shallow grooves apparent from FIG. 3a, the elongated interlocking member 2c initially having its outer side edges at the outer sides of these grooves situated apart from each other by a distance small enough to enable the elongated interlocking member 2c to enter freely into the grooves 3c in the manner apparent from FIG. 3a. At this time the size of the cross section of the interlocking member 2c is such that the successive turns 1a, 1b, will be spaced from each other by the distance Δ apparent from FIG. 3a.
Subsequently, however, when the turns of the strip 1 are pressed against each other so that the turns 1a, 1b assume the position with respect to each other shown in FIG. 3b, the interlocking member 2c will be deformed to have the configuration of the interlocking member 2'c apparent from FIG. 3b. The result of the movement of the turn 1b into pressing engagement with the turn 1a is that the opposed side edges of the interlocking member 2c at each side thereof are spread apart from each other to become spaced from each other by a distance greater than the minimum width of each groove 3c at the side surface of the strip 1, so that in this way there will be provided, as shown in FIG. 3b, an interlocking not only in a radial direction but also in an axial direction. Thus, with this construction the successive turns 1a, 1b, etc., of the strip 1 will be interlocked not only in the radial direction A--A shown in FIG. 3b, but also in the axial direction B--B shown in FIG. 3b. Thus, with this embodiment the successive turns of the strip 1 are interlocked so that they will not become displaced from each other either radially or axially.
Several embodiments differing from those described above are also included within the invention. For example, as shown in FIG. 4, it is possible to provide for the strip 1, at each of its opposed side surfaces, two or even more grooves 3a, thus providing around the inner roll body 10 a plurality of circumferential bores, resulting from the registering grooves 3a, with these bores including inner bores surrounded by outer bores, as illustrated in FIG. 4. Thus in this case a plurality of elongated interlocking members 2a will be provided as shown in FIG. 4. The several interlocking members 2a are thus radially spaced from each other. Moreover, they need not be identical. It is possible of course to use different interlocking members of different configurations as well as different grooves of different configurations. Furthermore, the elongated interlocking member need not be continuous. It may be made up of several sections.
Moreover, while in all of the above described embodiments the interlocking member is of a symmetrical cross section, with respect to the radial plane A--A, such a construction also is not essential. Thus, the grooves respectively situated at the opposed side surfaces of the strip 1 may have different cross sections and the interlocking member may be of an asymmetric cross section.
Such a construction is shown in FIGS. 5a and 5b. Thus, in this case the strip 1 is formed in one side surface with a groove 3d which is of a substantially semicircular configuration in the same way as the grooves 3a or 3b. However, at its opposed side surface the strip 1 is formed with a groove 3e which is of a dovetail cross section similar to the grooves 3c.
The elongated interlocking member 2d of FIG. 5a has at its right, as viewed in FIG. 5a, an elongated portion of a dovetail configuration matching that of the groove 3e. This elongated interlocking member 2d is initially situated in the groove 3e, as illustrated in FIG. 5a, and an elongated portion of substantially square cross section projects beyond the groove 3e to be received in the groove 3d in the manner apparent from FIG. 5a. Thus at the stage of manufacture shown in FIG. 5a the successive turns 1a and 1b of the strip are spaced from each other by the distance Δ indicated in FIG. 5a. This elongated interlocking member 2d is made of the same deformable material as the interlocking members 2b or 2c. Thus, when the successive turns are pressed against the preceding turns, the projecting portion of the elongated member 2d which is of substantially square cross section initially becomes deformed in the groove 3d so as to provide in this way the construction shown in FIG. 5b where the elongated interlocking member 2'd is provided with the sealed arrangement as well as with the interlocking arrangement referred to above. Thus not only is it not essential to provide a symmetrical construction for the interlocking member and for the grooves, but in addition it is possible to situate the interlocking member initially in one of the grooves so that it need only be displaced into the other of the grooves as is apparent from FIGS. 5a and 5b.
Referring to FIGS. 6 and 7, the elongated cylindrical inner roll body 10 is mounted, for example, in a suitable lathe so as to be driven in rotation about its axis in the direction of the arrow 12 indicated in FIG. 6. The elongated strip 1 is derived from any suitable source and passes through straightening rollers 14 and a braking device 16 schematically indicated in FIGS. 6 and 7. The straightening rollers 14 and braking device 16 are carried by a carriage 18 of the lathe, this carriage 18 of course being fed in a direction parallel to the axis of the roll body 10 while the strip 1 is wound onto the roll body in a manner apparent from FIGS. 6 and 7. The free end of the strip 1 is initially fixed as by welding to a ring 20 (FIG. 7) fixed to one end of the roll body 10. Thus as the latter turns in the direction of the arrow 12 the strip 1 will be pulled through the straightening rollers 14 and the braking device 16 which will maintain a suitable tension on the strip 1. The braking device 16 is adjustable in a well known manner so as to control at the braking device 16 the frictional resistance to advance of the strip 1 so as to maintain a desired tension in the latter. As the strip 1 is wound onto the roll body 10, the end convolution of the strip 1 is engaged by one or more pressing rollers 22 which are freely turnable about axes which extend radially with respect to the axis of the roll body 10 and which are maintained through suitable hydraulic pressure devices or the like in pressing engagement with the end convolution, urging the latter at all times against the previously wound turn of the strip 1. Thus, in this manner the roll body 10 will be covered with the strip 1, and at the end of the operation the strip 1 is cut so as to leave a free end thereof which may also be fixed to a ring such as a ring 20 at the opposite end of the roll body 10.
As is shown most clearly in FIG. 7, simultaneously with the feeding of the strip 1 to the roll body 10, the elongated interlocking member 2a is fed from any suitable source to the roll body 10, this member 2a also passing through an additional set of straightening rollers 24 and an additional braking device 26 which serve to straighten the elongated interlocking member 2a and maintain a suitable tension therein, respectively, in the manner most clearly apparent from FIG. 7. As the member 2a thus travels beyond the braking device 26 as a result of the tension therein resulting from the turning of the roll body 10, this elongated interlocking member 2a enters into the space between the end convolution and the immediately preceding turn of the strip 1, so that in this way the elongated interlocking member 2a becomes automatically fed into the pair of grooves 3a which come into registry with each other to define the bore in which the elongated interlocking member 2a is situated. Of course, the free end of the elongated interlocking member 2a may be initially fixed to the free end of the strip 1 which is fixed to the member 20. Thus, in this way in one continuous operation the strip 1 is wound onto the roll body 10 to form a covering 6 for the latter while at the same time simultaneously with this operation the interlocking member 2a is fed into the grooves 3a as they come together into register to form the bore in which the interlocking member 2a is housed. Naturally, while the structure and method of FIGS. 6 and 7 have been described in connection with FIG. 1, the same structure and method may be utilized in connection with the other embodiments of the invention.
The material of the strip 2 is selected so as to be appropriate in view of its particular purpose. Thus, the strip 2 may be made, for example, of lead or of a suitable plastic material, as referred to above. The use of a relatively soft material, with respect to the hard material of the strip 1, which is made of stainless steel, for example, is highly favorable inasmuch as the comparatively soft material of the elongated interlocking member is enabled to easily be deformed so as to fit closely into the grooves while at the same time the resulting joint will not bind because of the use of a relatively soft material for the interlocking member, and such binding will not occur even if the grooves should be somewhat inaccurate with respect to their shape and dimensions.
With respect to the claims which follow, of course various details of the invention may vary within the scope of the inventive concept defined by the claims. | A roll manufacturing method and roll, particularly for paper machines, wherein an inner roll body is surrounded by a strip having circumferential portions such as windings which engage and extend outwardly from an exterior surface of the inner roll body with the successive windings or circumferential strip portions engaging each other so that the engaging side surfaces of successive strip turns define an interface between themselves. The side surfaces of the strip are formed with registering grooves which thus define a bore extending across the interface, and an elongated interlocking member is situated in the latter bore so as to interlock the successive turns or circumferential strip portions against radial displacement outwardly away from the inner roll body. The interlocking member preferably has a fluid-tight sealing engagement with the groove surfaces which define the bore which receives the interlocking member, so that the interlocking member also forms a moisture barrier. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation-in-part of co-pending U.S. patent application Ser. No. 09/809,927 filed on Mar. 15, 2001.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
REFERENCE TO AN APPENDIX
[0003] Not Applicable.
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] The present invention relates to a cover for a scanning system, and more particularly to a cover with a variable reflective backing.
[0006] 2. Background
[0007] An optical scanner is used to generate an electronic file, a bitmap file for example, which is representative of a scanned object such as a document or photograph. This is typically accomplished by passing a controlled light source across the surface of the object. Light reflects off the surface of the object and back onto an array of photosensitive devices such as a charge coupled device, or CCD, array. As the light source passes over the object, the CCD array converts the reflected light intensity into an electronic signal that is ultimately digitized into an electronic file once the entire object is scanned.
[0008] In a conventional flatbed scanner, the light source and CCD array are located in a base covered by a plane of transparent glass. The object being scanned is placed, or sandwiched, between the glass plane and a cover. The inside surfaces of some covers are constructed of a high reflectance white material. The high reflectance white surface enables the conventional scanner to reduce or eliminate dark borders around the document, black circles where punch holes exist, and dark borders around multiple images such as multiple receipts on a single scan. Moreover, the high reflectance white surface enables the conventional document scanner to improve the contrast of the document's image by reflecting the light that is transmitted through the object back to the CCD array. For example, when scanning a transparency, the light passing through the transparency reflects off the white cover and is detected by the CCD array.
[0009] Although a high reflectance white surface will allow a conventional scanner to eliminate unwanted dark areas, this white surface limits the ability of the conventional scanner. More specifically, scanners have the ability to detect the location of the object being scanned. This detection enables the scanner to provide electronic registration and electronic skew correction. Moreover, the detection of the location of the object's edges enables the scanner to provide automatic magnification selection. However, this edge detection depends upon the ability of the scanner to sense the difference in the reflectance between the object and the cover. Thus, some objects would better be scanned with a black rather than white background on the cover.
[0010] A scanner with this low reflectance background cover allows for reliable edge detection, but the same background fails to suppress the black borders or punch holes. Moreover, the low reflectance background provides very low contrast when attempting to scan objects such as transparencies or semi opaque objects.
[0011] Since there are problems with using just a high or a low reflectance background with a scanner, a scanner with at least two modes of reflectance is ideal. Liquid crystal display technology has been used for scanning systems to provide a set of reflectance options. These scanning systems offer a good solution to the problem, but they are expensive. Also, if a problem arises with the liquid crystals it is not easy or inexpensive to repair. In many cases it is less expensive to purchase a new scanner rather than attempting to repair a liquid crystal cover.
SUMMARY
[0012] The present invention is directed to a variable reflectance cover for a scanning system. The cover comprises a backing moveable through a plurality of positions. Moving the backing through the plurality of positions varies the reflectance of the cover. In one embodiment, the backing is an endless rotatable belt. In a second embodiment, the backing is a removable panel having a first side with a first reflectance and a second side with a second reflectance. In yet a third embodiment, the backing includes polarizers placed adjacent to a reflective panel. Rotating one polarizer relative to another varies the reflectance of the cover.
[0013] In a basic aspect, the present invention provides a variable reflectance cover apparatus for a scanning system including: a reflective panel for covering an object to be scanned; associated with the panel, a device for creating a transmissive optical gradient such that reflectance level of the panel is controlled.
[0014] In another aspect, the present invention provides a method of controlling document reproduction using a optical scanning apparatus, the method including: aligning the document with a reflective background; and changing a transmissive optical gradient of a surface between said document and said background.
[0015] In another aspect, the present invention provides a document scanner apparatus including: a platen; an optical scanner device; an outer cover, the cover including a reflective inner surface and a subjacent optical transmissive device abutting said document on the platen, the device including means for creating a transmissive optical gradient with respect to the reflective surface such that the reflectance level is variable.
DESCRIPTION OF THE DRAWINGS
[0016] [0016]FIG. 1 is a perspective view of a flat bed optical scanner with a conventional cover.
[0017] [0017]FIG. 2 is a side view of the scanner of FIG. 1 having a cover with a high reflectance backing.
[0018] [0018]FIG. 3 is a side view of the scanner of FIG. 1 having a cover with a low reflectance backing.
[0019] [0019]FIGS. 4 and 5 are side views of a cover having a rotatable endless belt with high and low reflectance sections.
[0020] In FIG. 4, a high reflectance section is positioned adjacent to a scanning surface.
[0021] In FIG. 5, a low reflectance section is positioned adjacent to a scanning surface.
[0022] [0022]FIG. 6 is a side view of the cover of FIGS. 4 and 5 wherein the endless belt is rotated by a motor.
[0023] [0023]FIG. 7 is a side view of an endless belt with an increased circumference.
[0024] [0024]FIG. 8 is an isometric view of a cover having a removable panel.
[0025] [0025]FIG. 9 is a top plan view of a cover having adjacent rotatable polarizers.
[0026] [0026]FIG. 10 is a section view taken along the line 10 - 10 in FIG. 9 wherein the adjacent polarizers allow light to pass through and reflect off the backing.
[0027] [0027]FIG. 11 is a section view taken along the line 11 - 11 in FIG. 9 wherein the adjacent polarizers are rotated to absorb light before reaching the backing.
[0028] [0028]FIG. 12 is a section view of the cover of FIG. 9 including a motor for rotating one of the polarizers.
[0029] [0029]FIGS. 13, 13A and 13 B depict an alternative embodiment of the present invention.
DETAILED DESCRIPTION
[0030] FIGS. 1 - 3 illustrate a conventional scanner 10 used in conjunction with a computer system (not shown) for acquiring an electronic image of an object 12 (shown in FIGS. 2 and 3) such as a photograph or text document. Scanner 10 generally includes housing 14 containing guide 16 allowing linear movement of scanner carriage 18 . Carriage 18 is mounted below a transparent scanning surface 20 that supports object 12 . To illuminate object 12 carriage 18 includes lamp 22 and reflector 24 . Lamp 22 and reflector 24 are mounted in carriage 18 to focus light up through scanning surface 20 onto object 12 . Scanner 10 also includes cover 26 having backing 28 .
[0031] Referring to FIGS. 2 and 3, an object 12 to be scanned is placed on scanning surface 20 and cover 26 is closed sandwiching object 12 between scanning surface 20 and backing 28 . With lamp 22 illuminated, carriage 18 passes linearly underneath object 12 . Light from lamp 22 reflects off object 12 back onto an array of photosensitive devices such as a charge coupled device (CCD) array 30 in carriage 18 . Discerning the intensity of the reflected light, CCD array 30 generates an electrical signal allowing the computer system to produce a digitized representation of object 12 .
[0032] Some light also reaches backing 28 . This occurs in areas outside the edges or within punch holes of object 12 . Where object 12 is transparent or opaque, some light passes directly through object 12 reaching backing 28 . The backing 28 illustrated in FIG. 2 is constructed a high reflectance and generally light colored or white material. Consequently, much of the light reaching backing 28 , either directly or through object 12 is reflected back to CCD array 30 . The backing 28 ′ illustrated in FIG. 3 is constructed from a low reflectance and generally dark or black material. Consequently, much if not all of the light reaching backing 28 ′ is absorbed rather than reflected.
[0033] Referring now to FIGS. 4 - 12 , the present invention lies in the construction of cover 40 . In the embodiment illustrated in FIGS. 4 - 7 , backing 42 is an endless belt 44 rotatable around tension rollers 46 and 48 and partially enclosed within shell 50 . Endless belt 44 has a first high reflectance section 52 and a second low reflectance section 54 . For example, first section 52 may be white, while second section 54 may be black. In FIGS. 4 and 5, crank 56 coupled to tension roller 48 allows endless belt 44 to be manually rotated into a desired position. Referring to FIG. 6, endless belt 44 may instead be automatically rotated by motor 58 engaging tension roller 48 . It is envisioned that motor 58 will be a stepper motor accurately directed by a series of electrical pulses generated by controller 60 . Advantageously, endless belt 44 can be easily removed and replaced when damaged or interchanged with another belt having sections with different levels of reflectance.
[0034] With first section 52 rotated into place adjacent to object 12 , as shown in FIG. 4, light reaching first section 52 is reflected back to CCD array 30 . With cover 40 closed and second section 54 rotated into place adjacent to object 12 , light reaching backing 42 is absorbed rather than reflected. Alternatively, endless belt 44 may have more than two sections each having a specified reflectance. For example, in addition to including high and low reflectance sections, endless belt 44 can include additional sections having varying levels of reflectance. The possible combinations are infinite. The increased area needed for additional sections can be obtained by increasing the circumference of endless belt 44 . This increased circumference can be managed with additional tension rollers 62 , 63 , and 64 as illustrated in FIG. 7.
[0035] In the embodiment of cover 40 illustrated in FIG. 8, backing 42 is a removable panel 66 held in a slot created by grips 68 and 70 . Panel 66 has a first side 72 having a first reflectance and a second side 74 having a second reflectance. With cover 40 open, panel 66 can be manually removed and replaced so as to expose either the first or the second side 72 or 74 . For example, first side 72 may be white and second side 74 may be black. Where a backing with a high reflectance is desired, panel 66 is placed between grips 68 and 70 such that first side 72 is exposed. When cover 40 is then closed, first side 72 will be immediately adjacent to the object being scanned. When a backing with a low reflectance is desired, panel 66 is removed and replaced such that second side 74 is exposed. Panel 66 can be easily replaced if damaged or can be interchanged with another panel when other reflectance levels are desired.
[0036] In the embodiment of cover illustrated in FIGS. 9 - 12 , backing 42 includes a first polarizer 76 , second rotatable polarizer 78 affixed to reflective panel 80 . Polarizers 76 and 78 are rotatable relative to one another in order to vary the amount light from lamp 22 that reaches reflective panel 68 . Light can be represented as a transverse electromagnetic wave. Imagine, for example, a length of rope held by two children at opposite ends, the children begin to displace the ends of the rope in such a way that the rope moves in a plane either up and down, left and right, or any angle in between. Ordinary white light is made up of such waves that fluctuate at all possible angles.
[0037] Light is considered to be linearly polarized when it contains waves that only fluctuate in one specific plane. It is as if the rope in the example is strung through a picket fence. The wave can only move up and down in a vertical plane. A polarizer is a material that only allows only light with a specific angle of vibration to pass through while it absorbs the rest. The direction of fluctuation passed by the polarizer is referred to as the polarizer's optical axis. If two polarizers are set up in series so that their optical axes are parallel, light passes through both. However, if the polarizers are rotated relative to one another until their optical axes are perpendicular, the polarized light passing through the first will be absorbed by the second. As the polarizers are rotated in relation to one another and the angle between their optical axes varies from zero to ninety degrees, the amount of light passing through both polarizers decreases proportionally.
[0038] In FIG. 10, the optical axes of the first and second polarizers 76 and 78 are parallel. In FIG. 11, polarizer 78 is rotated until those axes are perpendicular to one another. FIG. 10 illustrates the configuration generating a maximum effective reflectance with the greatest amount of light reaching reflective panel 80 and reflecting back to CCD array 30 . FIG. 11, on the other hand, illustrates the configuration producing a minimum effective reflectance with polarizers 76 and 78 absorbing all light before it reaches reflective panel 80 . The effective reflectance can be tuned to any desired level between the minimum and maximum levels by adjusting the angle between the optical axes of polarizers 76 and 78 .
[0039] In the embodiment illustrated in FIGS. 9 - 11 , second polarizer 78 and attached reflective panel 80 are manually rotated using dial 82 . Dial 82 includes knob 84 coupled to shaft 86 passing through shell 50 . Shaft 86 is then coupled to reflective panel 80 . Turning knob 84 rotates reflective panel 80 and the attached second polarizer 78 . In one version, dial 82 may also include lever 88 and gauge 90 . Lever 88 extends radially outward from knob 84 across the surface of shell 50 allowing for a more accurate rotation and placement of second polarizer 78 . Lever 88 is placed such that when it points to one end of gauge 90 , the optical axes of polarizers 76 and 78 are parallel. When lever 88 is rotated so that it points to the other end of gauge 90 , the optical axes of polarizers 76 and 78 are perpendicular. Cover 40 may include stops 92 for holding dial 82 and joined second polarizer 78 stationary in one of many predetermined positions. Alternatively, second polarizer 78 can be automatically rotated by motor 94 as illustrated in FIG. 12. It is envisioned that motor 94 will be a stepper motor accurately directed by a series of electrical pulses generated by controller 96 .
[0040] [0040]FIGS. 13, 13A and 13 B show an alternative embodiment of the present invention. This embodiment uses the principle of magnetic polarization in order to vary the apparent shade of the transparent scanning surface 20 . As with the previous embodiments, an object 12 to be scanned is delivered appropriately to the scanning surface 20 for imaging by the scanner optical devices 18 , 22 , 30 . The object cover 40 is stratified, having a backing layer 1301 , a reflecting layer 1302 , and a background shading layer 1303 . The backing layer 1301 is provided with a controllable electromagnetic variable field inducer 1304 . The field inducer 1304 may be any conventional device such as a coil (represented by the “waved” diagram shading) via which a variable magnetic field can be generated. The reflecting layer 1302 is a substantially uniform, bright white material. The shading layer 1303 is provided with a substantially homogeneous set of louver elements 1305 which are susceptible to proximate magnetic field variation. Depending on how close or how strong the field is at a given time, the elements 1305 will have varying degrees of orthogonality with respect to the surface upon which they rest, namely in this case with respect to the outer surfaces of the shading layer 1303 .
[0041] In operation, the inducer 1304 is controlled to change the emitted magnetic radiation. Depending on how strong (or close) the field is with respect to the shading layer 1303 , will cause the elements 1305 to shift position, acting like mini-blinds allowing varied amount of light to pass through the shading layer 1303 to the reflecting layer 1302 . FIG. 13A demonstrates the elements 1305 in a relaxed state and FIG. 13B demonstrates the elements in a highly influenced state. The apparent shade of the platen cover background is effectively controlled, enhancing the copying or scanning quality.
[0042] It is intended that the magnetic field be variable not only in intensity, but also across the areal dimensions of the subjacent reflecting layer. In this manner, an analysis of the document—e.g., by doing a first scan with the louvers open to obtain data which may then be analyzed—to determine if a varying background reflectivity is desirable may be employed.
[0043] Although the invention has been shown and described with reference to the foregoing exemplary embodiments, it is to be understood that other embodiments are possible, and variations of and modifications to the embodiments shown and described may be made, without departing from the spirit and scope of the invention as defined in following claims. | A variable reflectance cover for a scanning system. The cover comprises a backing moveable through a plurality of positions. Moving the backing through the plurality of positions varies the reflectance of the cover. In one embodiment, the backing is an endless rotatable belt. In a second embodiment, the backing is a removable panel having a first side with a first reflectance and a second side with a second reflectance. In yet a third embodiment, the backing includes polarizers placed adjacent to a reflective panel. Rotating one polarizer relative to another varies the reflectance of the cover. In another embodiment, magnetic louvers are provided for changing the reflectivity of the cover. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an electrolysis method and apparatus wherein a positive electrode and a negative electrode are immersed in electrolyte to cause electrolysis to occur so that atoms or molecules may be occluded into or stick to the negative electrode or/and the positive electrode.
2. Description of the Related Art
An electrolysis apparatus typically has such a configuration as schematically shown in FIG. 1 . Referring to FIG. 1, a positive electrode 1 and a negative electrode 2 are immersed in electrolyte 3 so that atoms or molecules are occluded into or stick to the negative electrode 2 or/and the positive electrode 1 by electrolysis. In the electrolysis apparatus, main electric current and ion current by ions flow from the positive electrode 1 to the negative electrode 2 through the electrolyte 3 . If the currents are regarded as an electric current flux as seen in FIG. 2, a circular electric field is generated in accordance with the Fleming's left-hand rule by the electric current flux, and electromagnetic force directed perpendicularly toward the center axis of the electric current flux is generated by the magnetic field. Here, where the current density is represented by J and the magnetic flux density is represented by B, the electromagnetic force F is given by F =J×B.
Now, if it is assumed that the electrolysis apparatus is utilized to occlude hydrogen into a hydrogen occluding substance such as palladium used for the negative electrode, then since hydrogen atomic nuclei have the positive charge, they are acted upon by the electromagnetic force F and movement thereof toward the hydrogen occluding substance such as palladium of the negative electrode is disturbed. As a result, occlusion of the hydrogen atomic nuclei into the hydrogen occluding substance is suppressed. This similarly applies to plating or the like.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an electrolytic method and apparatus by which occlusion of hydrogen or sticking of atoms or molecules in plating and so forth is not disturbed by electronic magnetic force generated by main electric current and ion current flowing from the positive electrode to the negative electrode through electrolyte.
In order to attain the object described above, according to an aspect of the present invention, there is provided an electrolysis method wherein a positive electrode and a negative electrode are immersed in electrolyte in an electrolysis tank to cause electrolysis to occur, comprising the step of applying an opposite magnetic field for canceling a magnetic field produced by main electric current and ion current flowing in the electrolyte from the positive electrode to the negative electrode.
Electric current of a direction opposite to that of the main electric current and the ion current flowing in the electrolyte from the positive electrode to the negative electrode may be supplied to an electric circuit provided between but separate from the positive electrode and the negative electrode to produce the opposite magnetic field which cancels the magnetic field produced by the main electric current and the ion current flowing in the electrolyte.
As an alternative, the opposite magnetic field which cancels the magnetic field produced by the main electric current and the ion current flowing in the electrolyte may be produced using a permanent magnet or an electromagnet.
Preferably, an electric field is increased by an auxiliary positive electrode coated with an electric insulating material and disposed at a position in the proximity of the positive electrode remote from the negative electrode.
The negative electrode may be made of a hydrogen occluding substance and occludes hydrogen atomic nuclei.
According to another aspect of the present invention, there is provided an electrolysis method wherein a positive electrode and a negative electrode are immersed in electrolyte in an electrolysis tank to cause electrolysis to occur, comprising the step of using, as the electrolysis tank, an electrolysis tank which is partitioned into a positive electrode tank and a negative electrode tank by an electrically insulating nonmagnetic partition having an opening through which the electrolyte can communicate between the positive electrode tank and the negative electrode tank and in which the positive electrode is disposed in the positive electrode tank and the negative electrode is disposed in the negative electrode tank to perform electrolysis wherein main electric current and ion current flowing in the electrolyte from the positive electrode through the opening to the negative electrode flows in the opposite directions to each other at a place from the positive electrode to the opening and another place from the opening to the negative electrode across the partition thereby to produce magnetic fields which cancel each other.
With the electrolysis methods and also electrolysis apparatus by which the electrolysis methods are carried out, an opposite magnetic field for canceling a magnetic field produced by main electric current and ion current flowing in the electrolyte from the positive electrode to the negative electrode is applied to cancel electromagnetic force acting in a direction toward the center of the magnetic field. Consequently, occlusion of hydrogen or sticking of molecules (plating) is not disturbed by such electromagnetic force, and therefore, the hydrogen occlusion efficiency, the plating efficiency, the hydrogen gas production efficiency or the like efficiency is improved.
The above and other objects, features and advantages of the present invention will become apparent from the following description and the appended claims, taken in conjunction with the accompanying drawings in which like parts or elements are denoted by like reference symbols.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view showing a general configuration of an electrolysis apparatus;
FIG. 2 is a diagrammatic view illustrating electromagnetic force generated by electric current flowing from a positive electrode to a negative electrode in electrolyte during electrolysis;
FIG. 3 is a schematic and diagrammatic view showing an electrolysis apparatus to which the present invention is applied;
FIG. 4 is a front elevational view of an arrangement of permanent magnets where a magnetic field produced by main electric current and ion current flowing from a positive electrode to a negative electrode through electrolyte; and
FIG. 5 is a perspective view, partly broken, showing another electrolysis apparatus to which the present invention is applied and wherein an electrolysis tank is partitioned into a positive electrode tank and a negative electrode tank by a partition.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 3, there is shown an electrolysis apparatus to which the present invention is applied. A positive electrode 1 and a negative electrode 2 are immersed in electrolyte 3 in an electrolysis tank 10 , and a positive voltage is applied to the positive electrode 1 while a negative voltage is applied to the negative electrode 2 to perform electrolysis for occlusion or plating in the electrolysis tank 10 . When such electrolysis is performed, such electromagnetic force F as illustrated in FIG. 2 is generated. Now, if it is assumed that the electrolyte 3 is heavy water or light water while the negative electrode 2 is made of a hydrogen occluding substance such as a palladium and is used to occlude hydrogen (hydrogen atomic nuclei), then since the hydrogen atomic nuclei have the positive charge, they are acted upon by the electromagnetic force F and movement thereof toward the negative electrode 2 is disturbed.
Therefore, in order to supply electric current from the negative electrode 2 side toward the positive electrode 1 side to produce a magnetic field of the opposite direction to that shown in FIG. 2 in the electrolyte 3 to cancel the electromagnetic force, a covered wire 4 is laid in the electrolyte 3 and extends through central holes 1 a and 1 b formed in the positive electrode 1 and the negative electrode 2 without contacting with the positive electrode 1 and the negative electrode 2 , respectively. A diode 5 and a variable resistor 6 are connected in series to the covered wire 4 such that an electric circuit 7 independent of the positive electrode 1 and the negative electrode 2 is formed. Power supply to the electric circuit 7 is common to dc power supply for the positive electrode 1 and the negative electrode 2 , and the direction of the current flowing in the covered wire 4 between the positive electrode 1 and the negative electrode 2 in the electrolyte 3 is the direction from the negative electrode 2 side to the positive electrode 1 side. The value of the current can be adjusted by means of the variable resistor 6 . Meanwhile, the voltage to be applied to the positive electrode 1 can be adjusted by means of another variable resistor 11 .
In the electrolysis apparatus having the configuration described above, when electric current flows in the covered wire 4 from the negative electrode 2 side to the positive electrode 1 side, a magnetic field is produced by the electric current. Since the direction of the magnetic field is opposite to the direction of another electric field produced by main electric current and ion current flowing in the electrolyte 3 from the positive electrode 1 to the negative electrode 2 , the electromagnetic force F by the latter electric field is cancelled by the former electric field. Accordingly, the electromagnetic force F does not act upon hydrogen atomic nuclei any more, and consequently, occlusion of hydrogen atomic nuclei into the negative electrode 2 made of a hydrogen occluding substance is performed efficiently.
Further, in order to raise the electric field by the positive electrode 1 , an auxiliary positive electrode 8 coated with an electrically insulating material is disposed in the electrolyte 3 on the outer side of the positive electrode 1 , that is, on the side of the positive electrode 1 opposite to the negative electrode 2 . The auxiliary positive electrode 8 is connected to the dc power supply through a switch 9 so that, when the switch 9 is switched on, the positive dc voltage is applied to the auxiliary positive electrode 8 . As the voltage on the positive electrode 1 side is raised by the auxiliary positive electrode 8 , the electrolysis performance is improved.
Alternatively, a plurality of permanent magnets 12 may be arranged annularly around the center line of the positive electrode 1 and the negative electrode 2 as seen in FIG. 4 between the positive electrode 1 and the negative electrode 2 so that the magnetic field generated by main electric current and ion current flowing in the electrolyte 3 from the positive electrode 1 to the negative electrode 2 may be canceled by the electric field produced by magnetic force of the permanent magnets 12 . The permanent magnets 12 may be replaced by electromagnets.
Another electrolysis apparatus to which the present invention is applied is shown in FIG. 5 . Referring to FIG. 5, the electrolysis apparatus shown is a modification to the electrolysis apparatus described above with reference to FIG. 3 . In the electrolysis apparatus shown, the electrolysis tank 10 is partitioned into a positive electrode tank 10 a and a negative electrode tank 10 b by an electrically insulating non-magnetic partition 13 , and the positive electrode 1 and the negative electrode 2 are disposed separately in the positive electrode tank 10 a and the negative electrode tank 10 b , respectively, in an opposing relationship to each other with the partition 13 interposed therebetween. The partition 13 has an opening 14 formed at a position thereof displaced from an area across which the positive electrode 1 and the negative electrode 2 are opposed to each other. The opening 14 allows communication of the electrolyte 3 there through between the positive electrode tank 10 a and the negative electrode tank 10 b.
In the electrolysis apparatus shown in FIG. 5, since electrolysis which occurs between the positive electrode 1 and the negative electrode 2 is effected through the opening 14 of the partition 13 , main electric current and ion current flowing in the electrolyte 3 from the positive electrode 1 to the negative electrode 2 passes through the opening 14 . The flow of the main electric current and the ion current is directed as indicated by a solid line arrow mark X within a range from the positive electrode 1 to the opening 14 and then directed as indicated by a broken line arrow mark Y within another range from the opening 14 to the negative electrode 2 , and the directions of the flow are opposite to each other across the partition 13 . Accordingly, the magnetic field produced by the main electric current and the ion current flowing in the direction indicated by the arrow mark X and the magnetic field produced by the main electric current and the ion current flowing in the direction indicated by the arrow mark Y are directed in the opposite directions to each other and therefore cancel each other. Consequently, an influence of electromagnetic force can be eliminated. Gas produced by the positive electrode tank 10 a and gas produced by the negative electrode tank 10 b are collected separately.
The present invention can be applied not only to the technique for occlusion of hydrogen using electrolysis but also to any other technique which utilizes electrolysis such as electroplating. Further, according to the present invention, since a magnetic field produced by main electric current and ion current is canceled, the electrolysis efficiency is improved, and consequently, since the voltage and the current can be increased when compared with those in the prior art, a greater amount of hydrogen gas, oxygen gas or the like can be obtained. Furthermore, where a carbon type substance is used for the negative electrode, a large amount of hydrocarbon type gas can be obtained by reaction of the carbon, and where sea water (3% water solution of NaCl) is used for the electrolyte, a large amount of ethylene type gas and oxygen can be obtained, which contributes also to production of less expensive fuel than gasoline or natural gas. Further, also where palladium is used for the negative electrode and seawater in which a small amount of heavy water is mixed is used for the electrolyte, according to the present invention, a sufficient amount of hydrogen atomic nuclei can be occluded into the negative electrode. Furthermore, if the electrolysis apparatus of the present invention is used afloat on the sea and the sea water is used as the electrolyte, then a large amount of ethylene type gas and oxygen can be produced on the sea.
While preferred embodiments of the present invention have been described using specific terms, such description is for illustrative purposes only, and it is to be understood that changes and variations may be made without departing from the spirit or scope of the following claims. | An electrolytic method is disclosed by which occlusion of hydrogen or sticking of atoms or molecules in plating and so forth is not disturbed by electronic magnetic force produced by main electric current and ion current flowing from the positive electrode to the negative electrode through electrolyte. An electric circuit separate from a positive electrode and a negative electrode is provided between the positive electrode and the negative electrode, and electric current of a direction opposite to that of main electric current and ion current flowing in the electrolyte from the positive electrode to the negative electrode is supplied to the electric circuit to produce an opposite magnetic field which cancels a magnetic field produced by the main electric current and the ion current flowing in the electrolyte. | 8 |
BACKGROUND
[0001] A fire sprinkler system comprises a fire suppression agent supply system, one or more fire sprinklers, and a piping system connected between the supply system and the fire sprinklers. The fire sprinkler system can be installed in a variety of environments, such as factories, commercial buildings, homes, etc. One type of fire sprinkler system is a wet pipe system that comprises a water supply system, water piping, and one or more fire sprinklers.
[0002] In order to install a fire sprinkler system, the piping system needs to be connected to the supply system and to the fire sprinklers. Typically, the pipes are installed close to the ceiling with a roughed-in outlet. A roughed-in outlet is part of plumbing work for the fire sprinkler system that is ready for future connection to a fixture (such as a sprinkler). The sprinklerfitter will then measure the drop from the roughed-in outlet of the pipe to where the sprinkler will connect. For example, in a nine-foot ceiling, the pipes may be installed close to the top of the ceiling. At each point in the piping below which a sprinkler is to be installed, the piping includes a roughed-in outlet. In an installation where the sprinklers are supposed to be installed at the drop-ceiling, the sprinklerfitter measures from the roughed-in outlet to the drop ceiling. In particular, the sprinklerfitter must move the ladder under each roughed-in outlet, climb the ladder, and take the measurement from the roughed-in outlet to the drop ceiling. Doing each of these steps for an installation with dozens (or possible hundreds) of sprinkler heads takes a considerable time.
SUMMARY
[0003] The present embodiments relate to a sprinkler drop ruler. In one aspect, the sprinkler drop ruler is provided. The sprinkler drop ruler may comprise: a rigid frame having an opening; a handle connected to the rigid frame and in fixed relation to the rigid frame; and a ruler with an end shaped to seat in the opening and configured to move inside or along a side of the handle in order to measure a sprinkler drop. The ruler may be positioned at least partly within the handle so that the ruler is configured to move within the handle. Further, the handle may be connected to the rigid frame so that the opening of the rigid frame is co-axial with the handle. Moreover, the end of the ruler can be rectangular in shape and the opening of the rigid frame is also rectangular in shape and matched to seat the end of the ruler. The sprinkler drop ruler may further include a window connected to the handle with the window being at least partly transparent and include indicia so that the ruler is visible through the window.
[0004] In another aspect, a method for measuring a sprinkler drop is provided. The method includes using a sprinkler drop ruler that includes: a rigid frame having an opening; a handle connected to the rigid frame and in fixed relation to the rigid frame; and a ruler with an end shaped to seat in the opening and configured to move inside or along a side of the handle in order to measure a sprinkler drop. The method further includes the sprinklerfitter holding the handle in one hand, and the sprinklerfitter moving the ruler with another hand until the end of the ruler comes in contact with the roughed-in outlet. When the end of the ruler is contacting the roughed-in outlet, the sprinklerfitter may read the measurement of the ruler.
[0005] Other systems, methods, features and advantages will be, or will become, apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description, be within the scope of the invention, and be protected by the following claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a perspective view of the sprinkler drop ruler.
[0007] FIG. 2 is a top view of the rigid frame of the sprinkler drop ruler.
[0008] FIG. 3 is a top view of the top of the ruler of the sprinkler drop ruler.
[0009] FIG. 4 is a perspective view of the handle and the ruler of the sprinkler drop ruler.
[0010] FIG. 5 is a front view of one example of the window, extension piece, and rails.
[0011] FIG. 6 is a perspective view of another example of the extension piece.
[0012] FIG. 7 is a perspective view of the sprinkler drop ruler in operation.
DETAILED DESCRIPTION
[0013] A sprinkler drop ruler 100 embodying one example of the present invention is illustrated in FIG. 1 . The sprinkler drop ruler 100 includes a rigid frame 102 , a handle 108 , and a ruler 116 . The rigid frame 102 may be any type of rigid structure, such as metallic (e.g., aluminum), plastic (e.g., plexiglass), or the like. Further, the rigid frame 102 may be transparent (in order to see through the rigid frame 102 ), translucent or opaque. The rigid frame 102 is shown in FIG. 1 as rectangular in shape. The rigid frame 102 may be composed of other shapes, such as square or round. The rigid frame 102 further includes an opening 104 through which the ruler 116 may slide. The opening 104 is illustrated as rectangular in shape. As discussed in more detail below, the opening 104 may be other shapes, such as square or round.
[0014] As discussed in the background, the sprinkler is positioned at the approximate height of the ceiling tile lattice structure (the structure that holds the ceiling tiles in place). The length of the sprinkler drop from the roughed-in outlet to the sprinkler is measured from the roughed-in outlet to the ceiling tile lattice structure. In order to obtain this measurement with the sprinkler drop ruler 100 , the rigid frame 102 may be pushed against the ceiling tile lattice, and the ruler 116 is slid upward until it contacts the roughed-in outlet in order to measure the sprinkler drop. Thus, in one embodiment, the size of the rigid frame 102 is equal to or larger than an opening in the ceiling tile lattice. This is depicted in FIG. 7 , discussed below. For example, the ceiling tile lattice may comprise 2′×2′. So that, in one embodiment, the rigid frame 102 in one dimension is equal to or greater than 2′ (and in another dimension can be 2′ or less, such as 1′ or less). As another example, the ceiling tile lattice may comprise 1′×1′. So that, in one embodiment, the rigid frame 102 in one dimension is equal to or greater than 1′. In this way, when the operator presses the rigid frame 102 against the ceiling tile lattice, the rigid frame 102 is stopped by the ceiling tile lattice.
[0015] The sprinkler drop ruler 100 further includes the handle 108 . A perspective view of the handle 108 is illustrated in FIG. 4 . The handle 108 can be a variety of lengths, such as 4′-0″ for an 8′ ceiling and 5′-6″ for a 10′ ceiling. These lengths are merely for illustration purposes. The handle 108 is connected to rigid frame 102 . As shown in FIG. 1 , the handle 108 is in fixed relation to the rigid frame 102 so that the opening 104 of the rigid frame 102 is coaxial with the handle 108 . In one embodiment, the cross-section of the handle 108 is identical to the opening 104 , as shown in FIG. 1 . In an alternate embodiment, the cross-section of the handle 108 may be different from the opening 104 , such as bigger than the opening 104 .
[0016] The shape of the handle 108 may be such that the ruler 116 slides adjacent to or within the handle 108 . As illustrated in FIG. 4 , the handle 108 is illustrated as having a C cross-section, with element 109 indicating the “C” shape; though other shapes may be used which enable the ruler 116 to slide therein. Alternatively, the ruler 116 may slide inside the handle 108 . For example, the ruler 116 may slide along a side of the handle 108 . Moreover, one end of the ruler 116 may extend beyond an end of the handle 108 even when the top 106 of the ruler is seated in rigid frame 102 . For example, ruler 116 can extend 1′, 2′, 3′, or more from the end of the handle, as shown in FIG. 1 .
[0017] The sprinkler drop ruler 100 may further include extension piece 110 . The extension piece 110 may be connected to handle 108 , or the extension piece 110 may be integral with handle 108 . As discussed in more detail with respect to FIG. 6 , the extension piece 110 may be used to calibrate the sprinkler drop ruler 100 . Extension piece 110 may further include a window 112 . The window 112 may be transparent so that the ruler 116 may be seen therethrough. The window 112 may include one or more indicia 114 to indicate how far the top 106 of the ruler 116 is above the rigid frame 102 . For example, when the top 106 of the ruler 116 is flush with the rigid frame 102 , the indicia 114 points to “0” of the ruler, indicating that the distance from the top 106 of the ruler 116 to the rigid frame 102 is zero inches. Calibration of the sprinkler drop ruler 100 is discussed below with respect to FIGS. 5-6 .
[0018] FIG. 2 is a top view of the rigid frame 102 of the sprinkler drop ruler 100 . The dimensions of the rigid frame 102 may be 2′ 6″×4″, as shown in FIG. 2 . These dimensions are merely for illustration purposes. Other dimensions are contemplated. As discussed above, the rigid frame 104 includes an opening 104 through which the ruler 116 may slide. The opening 104 may further include a seat or a lip 118 upon which an underside of the top 106 of the ruler 116 may be seated. FIG. 3 is a top view of the top 106 of the ruler 116 of the sprinkler drop ruler 100 . The top 106 may be composed of a rubberized or other elastic material and may be shaped such that the top 106 fits into opening 104 and abuts seat 118 . Further, the top 106 may be a 2″×2″ square or may be rectangular in shape.
[0019] FIG. 7 illustrates the sprinkler drop ruler 100 in operation. When the ruler 116 is in the fully retracted position (with the top 106 of the ruler 116 flush against the seat 118 ), the top 106 of the ruler is flush with the top of the rigid frame. This is considered the “0” position of the ruler for calibration purposes (e.g., the indicia 114 point to “0” on the ruler 116 ). Further, the sprinklerfitter may hold the handle 108 in one hand up against the ceiling tile lattice. Typically, the ceiling tile lattice is installed, but the ceiling tiles have not yet been installed. In this way, the sprinklerfitter can see the roughed-in pipe outlet. With the other hand, the sprinklerfitter can move the ruler 116 upward until the top 106 of the ruler reaches the roughed-in pipe outlet. When the top 106 of the ruler 116 contacts the roughed-in pipe outlet, the sprinklerfitter can then read the measurement in the window 112 , thereby recording the distance of the sprinkler drop. In this way, the measurement is a face-to-face measurement from the ceiling grid to the roughed-in pipe outlet.
[0020] As discussed above, the sprinkler drop ruler may 100 be calibrated. The calibration may be done at manufacture or may be done after purchase. Calibration may comprise “zeroing” out the ruler so that when the top 106 of the ruler 116 is flush with the rigid frame 102 , the indicia 114 in the window 112 indicates “0” for the ruler. There are a variety of ways in which to calibrate the sprinkler drop ruler 100 . One way is to keep the extension piece 110 stationary and move the window 112 and the indicia 114 . The window 112 and the indicia 114 are in fixed relation to one another. The sprinkler drop ruler 100 may be calibrated by moving the window 112 so that the indicia 114 (fixed relative to the window 112 ) moves as well. When the top 106 is flush with the rigid frame 102 , the window 112 is moved until the indicia 114 point to “0” in the ruler. FIG. 5 illustrates one example of adjusting the window 112 in which the window 112 may be moved either up or down based on one or more guides or rails 120 . In practice, the window 112 may be moved so that the indicia 114 points to “0” when the top 106 is flush with the rigid frame 102 .
[0021] Another way is to move the extension piece 110 along with the window 112 and the indicia 114 . The extension piece 110 , the window 112 and the indicia 114 are in fixed relation to one another. The sprinkler drop ruler 100 may be calibrated by moving the extension piece 110 so that the window 112 and the indicia 114 (which are both fixed relative to the extension piece 110 ) moves as well. In practice, when the top 106 of the ruler 116 is flush with the rigid frame 102 , the extension piece 110 may be moved upward or downward (with the window 112 and the indicia 114 moving along with the extension piece 110 ) so that the indicia 114 points to “0”.
[0022] Still another way to calibrate the sprinkler drop ruler 100 is to move the indicia 114 . The indicia 114 may be movable upward or downward independent of the window 112 . In practice, when the top 106 of the ruler 116 is flush with the rigid frame 102 , the indicia 114 may be moved so that the indicia 114 points to “0”.
[0023] While the invention has been described with reference to various embodiments, it should be understood that many changes and modifications can be made without departing from the scope of the invention. It is therefore intended that the foregoing detailed description be regarded as illustrative rather than limiting, and that it be understood that it is the following claims, including all equivalents, that are intended to define the spirit and scope of this invention. | A sprinkler drop ruler is provided for measuring the sprinkler drop from a roughed-in outlet. The sprinkler drop ruler includes a rigid frame having an opening, a handle connected to the rigid frame and in fixed relation to the rigid frame, and a ruler with an end shaped to seat in the opening and configured to move inside or along a side of the handle in order to measure a sprinkler drop. The sprinklerfitter may thus use the sprinkler drop ruler in order to measure the sprinkler drop. In this way, the sprinklerfitter does not need to climb a ladder to measure the sprinkler drop. | 4 |
BACKGROUND OF THE INVENTION
[0001] This invention relates generally to gas turbine engines, and more specifically to gas turbine engine assemblies and methods of assembling the same.
[0002] At least some known gas turbine engines include a fan assembly, a core engine, and a low-pressure or power turbine. The core engine includes at least one compressor, a combustor, and a high-pressure turbine that are coupled together in a serial flow relationship. Air entering the core engine is mixed with fuel and ignited to form a high energy gas stream. The high energy gas stream flows through the high-pressure turbine to rotatably drive the high-pressure turbine and thus the compressor via a first drive shaft. The gas stream further expands through the low-pressure turbine, which rotatably drives the fan assembly through a second drive shaft.
[0003] To improve engine efficiency, it is desirable to operate the fan assembly at a relatively lower speed than the operating speed of the high-pressure turbine. However, operating the fan at a relatively slow speed may be detrimental to the operation of a booster compressor. As such, additional booster stages may be required in order to produce the desired overall pressure ratio, thus increasing the overall cost, design complexity, and weight of the gas turbine engine.
BRIEF DESCRIPTION OF THE INVENTION
[0004] In one aspect, a method of assembling a gas turbine engine is provided. The method includes coupling a low-pressure turbine to the core gas turbine engine, coupling a booster compressor to a gearbox, and coupling the gearbox to the low-pressure turbine such that the booster compressor is driven by the low-pressure turbine.
[0005] In another aspect, a turbine engine assembly is provided. The turbine engine assembly includes a core gas turbine engine including a high-pressure compressor, a combustor, and a turbine. The turbine engine assembly also includes a low-pressure turbine coupled to the core gas turbine engine, a booster compressor, and a gearbox coupled between the low-pressure turbine and the booster compressor such that the booster compressor is driven by the low-pressure turbine.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a cross-sectional view of a portion of an exemplary gas turbine engine assembly that includes a gear-driven booster;
[0007] FIG. 2 is an enlarged cross-sectional view of a portion of the turbine engine assembly shown in FIG. 1 ; and
[0008] FIG. 3 is a cross-sectional view of a portion of another exemplary gas turbine engine assembly that includes a gear-driven booster.
DETAILED DESCRIPTION OF THE INVENTION
[0009] FIG. 1 is a schematic illustration of an exemplary gas turbine engine assembly 10 having a longitudinal axis 11 . Gas turbine engine assembly 10 includes a fan assembly 12 , and a core gas turbine engine 13 that includes a high-pressure compressor 14 , a combustor 16 , and a high-pressure turbine 18 . In the exemplary embodiment, gas turbine engine assembly 10 also includes a low-pressure turbine 20 and a multi-stage booster compressor 22 .
[0010] Fan assembly 12 includes an array of fan blades 24 extending radially outward from a rotor disk 26 . Gas turbine engine assembly 10 has an intake side 28 and an exhaust side 30 . Fan assembly 12 and low-pressure turbine 20 are coupled together via a gearbox 100 driven by a first rotor shaft 31 , and compressor 14 and high-pressure turbine 18 are coupled together by a second rotor shaft 32 .
[0011] FIG. 2 is an enlarged cross-sectional view of a portion of the turbine engine assembly shown in FIG. 1 . As shown in FIG. 2 , booster 22 includes a plurality of circumferentially-spaced structural vanes 34 that function as inlet guide vanes (IGV) to facilitate channeling airflow entering gas turbine engine assembly 10 downstream through booster 22 . In the exemplary embodiment, booster 22 also includes a plurality of outlet guide vane (OGV) assemblies 36 . Moreover, in the exemplary embodiment booster 22 includes two stages 40 , wherein each stage includes a rotor section and a disk section. Specifically, each rotor section includes a plurality of rotor blades 42 that are each coupled to a respective rotor disk 44 . Booster compressor 22 is positioned downstream from inlet guide vane assembly 34 and upstream from core gas turbine engine 13 . Although booster compressor 22 is shown as having only two rows of rotor blades 42 , it should be realized that booster compressor 22 may have a single row of rotor blades 42 , or three or more rows of rotor blades 42 that are interdigitated with a plurality of rows of guide vanes 46 . In one embodiment, inlet guide vanes 34 are fixedly coupled to a booster case 50 . In another embodiment, inlet guide vanes 34 are movable during engine operation to facilitate varying a quantity of air channeled through booster compressor 22 .
[0012] In the exemplary embodiment, booster compressor 22 is rotatably coupled to a gearbox 100 such that booster compressor 22 rotates at a rotational speed that is different than a rotational speed of fan assembly 12 and low-pressure turbine 20 . Specifically, gearbox 100 is coupled between shaft 31 and booster compressor 22 to facilitate rotating booster compressor in either the same or an opposite direction than fan assembly 12 .
[0013] In the exemplary embodiment, gearbox assembly 100 has a gear ratio of approximately 2 to 1 such that fan assembly 12 rotates at a rotational speed that is approximately one-half the rotational speed of booster 22 . Accordingly, in the exemplary embodiment, booster compressor 22 rotates at a rotational speed that is faster than the rotational speed of fan assembly 12 . In the exemplary embodiment, gearbox 100 is an epicyclic gearbox that substantially circumscribes shaft 31 and includes a support structure 102 , at least one gear 103 coupled within support structure 102 , an input 104 gear, and an output gear 106 .
[0014] More specifically, gearbox 100 is supported by, and maintained in a substantially fixed orientation within gas turbine engine assembly 10 , utilizing support structure 102 which is coupled to structural vanes 34 . Gas turbine engine assembly 10 also includes a fan thrust bearing assembly 110 that is configured to support fan assembly 12 . Fan thrust bearing assembly 110 is coupled between structural vanes 34 and shaft 31 such that the residual thrust generated by fan assembly 12 and low-pressure turbine 20 is transmitted to structure 34 . More specifically, and in the exemplary embodiment, fan bearing assembly 110 includes a rotating inner race 112 and a stationary outer race 114 that is coupled to bearing housing 116 . As such, fan bearing assembly 110 includes a plurality of rolling elements 118 that are disposed between races 112 and 114 , respectively.
[0015] Gas turbine engine assembly 10 also includes a second bearing assembly 120 and a third fan bearing assembly 130 . Specifically, second and third bearing assemblies 120 and 130 are coupled radially outwardly from a drive shaft extension 140 that is coupled to gearbox 100 via a flex connection 142 . In the exemplary embodiment, second bearing assembly 120 is a roller bearing that is utilized to provide radial support for drive shaft extension 140 , and thus gearbox 100 . Bearing assembly 130 is a thrust bearing that is utilized to provide axial support for drive shaft extension 140 , and also to absorb thrust generated by booster 22 .
[0016] Moreover, and in the exemplary embodiment, gas turbine engine assembly 10 may also include a generator 180 , a generator drive shaft 182 that includes a first end 184 that is coupled to generator 180 , a second end 186 , and a bevel gear 188 that is coupled to drive shaft second end 186 . To operate generator 180 , shaft 140 includes a bevel gear 190 that is splined to a downstream end of shaft 140 that is configured to mesh with bevel gear 188 . As such, generator 180 may provide additional electrical energy to peak demand periods during normal engine operation and during idle speeds, for example. More specifically, during operation, power generated by booster compressor 22 is utilized to drive shaft 140 . Since shaft 140 is coupled to generator drive shaft 182 utilizing bevel gears 188 and 190 , work is extracted from booster compressor 22 to drive generator 180 . As a result, additional energy is extracted from the booster compressor to drive the generator 180 to support ever increasing electrical demands. Specifically, newer aircraft are designed to require an atypically large amount of electrical power. As a result, generator 180 may be utilized to meet the ever increasing electrical demands of newer aircraft.
[0017] During assembly, input gear 104 is splined to shaft 31 utilizing a cone or disk 150 such that the rotational force generated by low-pressure turbine 20 through shaft 31 is transmitted to gearbox 100 and also to fan assembly 12 . Output gear 106 is splined to drive shaft extension 140 via flex connection 142 such that the rotational force is transmitted from gearbox 100 to drive shaft extension 140 . As shown in FIG. 2 , booster rotor disk 44 is coupled to an aft end of drive shaft extension 140 utilizing a shaft 160 .
[0018] During operation, core gas turbine engine 13 causes low-pressure turbine 20 to rotate and thus causes shaft 31 to rotate. Since shaft 31 is coupled to gearbox 100 via drive shaft extension 140 , torque developed by low-pressure turbine 20 is provided to both fan assembly 12 and gearbox 100 . The torque transferred by gearbox 100 is then utilized to drive booster 22 . In the exemplary embodiment, gearbox 100 is located within a sump 170 . During operation, gearbox 100 is continuously lubricated.
[0019] FIG. 3 is a cross-sectional view of a portion of another exemplary gas turbine engine assembly 200 that includes a gear driven booster 22 . As discussed above, gearbox 100 includes an input gear 104 and an output gear 106 , and a plurality of gears 108 . In this embodiment, booster 22 is coupled to output gear 106 utilizing a disk 202 , and shaft 31 is coupled to input gear 104 utilizing an extension apparatus 204 .
[0020] More specifically, gas turbine engine assembly 200 includes a bearing 210 that is coupled between disk 202 and shaft 31 . In the exemplary embodiment, bearing assembly 210 is a thrust bearing that acts as a differential bearing assembly in combination with a bearing assembly 220 to support booster 22 and fan assembly 12 and/or transfer thrust loads and/or forces from booster compressor 22 to a frame 208 . In one embodiment, bearing assembly 210 includes a radially outer race 212 that is mounted to cone 202 , and a radially inner race 214 that is mounted with respect to shaft 31 . Bearing assembly 210 also includes a plurality of rolling elements 216 that are mounted between outer and inner races 212 and 214 . As shown in FIG. 3 , gas turbine engine assembly 200 also includes a bearing assembly 230 . In the exemplary embodiment, bearing assembly 230 is a thrust bearing assembly that is utilized to transfer the residual thrust generated by fan assembly 12 , low-pressure turbine 20 , and booster 22 to a frame 208 . In one embodiment, bearing assembly 230 includes a radially outer race 232 that is mounted to frame 208 and to gearbox 100 such that both gearbox 100 and outer race 232 are maintained in a substantially fixed position within gas turbine engine assembly 200 . Bearing assembly 230 also includes a radially inner race 234 that is coupled to shaft 31 utilizing a shaft extension 236 . Bearing assembly 230 also includes a plurality of rolling elements 238 that are mounted between outer and inner races 232 and 234 . In this embodiment, gas turbine engine assembly includes a three stage booster compressor 22 .
[0021] The gas turbine engine assemblies described herein each include a low-pressure turbine that is configured to drive both the fan assembly and the booster compressor. Specifically, the turbine engine assemblies described herein each include a smaller, high speed, higher pressure ratio, booster that is driven by the low-pressure turbine utilizing a gearbox. In the exemplary embodiment, the gearbox has a ratio of between approximately 1.5 to 1 and approximately 2.4 to 1. Moreover, the booster compressor is coupled to the low-pressure turbine via a flex connection to facilitate smoothly transferring torque generated by the low-pressure turbine to the gearbox. As such, the geared booster enables a smaller core gas turbine engine to be utilized with reduced stage count.
[0022] Exemplary embodiments of a gas turbine engine assembly that includes a gearbox coupled to a fan assembly are described above in detail. The components are not limited to the specific embodiments described herein, but rather, components of each system may be utilized independently and separately from other components described herein. The gearbox driven booster compressor described herein can also be used in combination with other known gas turbine engines.
[0023] While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims. | A method of assembling a gas turbine assembly includes providing a core gas turbine engine including a high-pressure compressor, a combustor, and a turbine, coupling a low-pressure turbine to the core gas turbine engine, coupling a booster compressor to a gearbox, and coupling the gearbox to the low-pressure turbine such that the booster compressor is driven by the low-pressure turbine. | 5 |
FIELD OF THE INVENTION
The present invention generally relates to ink-jet printing, and in particular to a specific ink formulation for photo printing. This ink formulation provides for improved ink-jet print quality.
BACKGROUND OF THE INVENTION
Inkjet printing is a non-impact printing process in which droplets of ink are deposited on a print medium in a particular order to form alphanumeric characters, area-fills, and other patterns thereon. Low cost and high quality of the hardcopy output, combined with relatively noise-free operation, have made ink-jet printers a popular alternative to other types of printers used with computers. Notwithstanding their recent success, intensive research and development efforts continue toward improving ink-jet print quality. A surge in interest in ink-jet printing especially in the area of photographic printing has resulted in the need to produce high quality prints at a reasonable cost. The challenge remains to further improve the print quality of ink-jet prints. The emerging use of ink-jet prints for digital photos, requires high-resolution images that have accurate color, are durable, and do not show banding of colors.
Color ink-jet printers, such as a DesignJet® printer available from Hewlett-Packard Company, typically use three inks of differing hues: magenta, yellow, and cyan, and optionally black. The particular set of colorants, e.g., dyes, used to make the inks is called a “primary dye set.” A spectrum of colors, e.g., secondary colors, can be generated using different combinations of the primary dye set. In printing processes such as lithography, dye transfer, and some types of thermal transfer, it is possible to vary spot size so that less is demanded of the primary colored inks when producing a good secondary color. When the color inks are used in a binary printing device, that is, one in which a dot of color is either present or absent, e.g., a thermal ink-jet printer, the ability of the primaries to give recognizable secondary colors is even more important. When such device is to be used for printing images that will also be printed and compared to images printed by other modalities such as offset presses or dye sublimation printers, it is important that the colors produced by the inkjet printer are capable of encompassing and matching commonly accepted industry color descriptions, such as the color gamut (color space) for a Kodak Duralife® silver halide print. If such ink is to be used in an ink-jet printing device, characteristics such as crusting, long-term stability, and materials compatibility must also be addressed. If the ink is to be used in a thermal ink-jet printer, the further constraint of being thermally stable (kogation-resistant) is added.
In general, a successful ink set for color ink-jet printing must be compatible with the ink-jet pen and the printing system. Some of the required properties for the ink-jet ink include: good crusting resistance, good stability, the proper viscosity, the proper surface tension, little color-to-color bleed, rapid dry time, no deleterious reaction with the printhead components, high solubility of the dyes in the vehicle, consumer safety, low strike through, high color saturation, good dot size which affects the banding, and suitable color characteristics.
Inks are known which possess one or more of the foregoing properties. However, few inks are known that possess all the foregoing properties, since an improvement in one property often results in the degradation of another property. Thus, many inks used commercially represent a compromise in an attempt to achieve an ink evidencing at least an adequate response in each of the foregoing considerations. For example, inks are known which can obtain the color gamut of silver halide prints, such as those used obtained in photographic prints, but cannot obtain the smooth appearance of non-banding of such silver halide prints. Accordingly, investigations continue into developing ink formulations which have improved properties and which do not improve one property at the expense of the others. Thus, there remains a need in the art to further improve the print quality, color gamut, and banding properties of the ink-jet prints without sacrificing pen performance and reliability, particularly when trying to reproduce the color gamut of silver halide prints.
SUMMARY OF THE INVENTION
In accordance with the invention, inks suitable for use in ink-jet inks and method for formulating the same are provided. It has been found that a synergy can be produced by the combination of certain branched alcohols or diols with 1,2-diols containing a polar head group and a non-polar region. This combination provides a basis for an ink formulation that provides for good photo print attributes, especially good dot size which results in a non-banded appearance of the printed image, with improved reliability. Alcohols and diols have often been added to ink vehicles as humectants to reduce crusting in inks. However, humectants often increase the viscosity of the ink and hurt the dot size of the resultant ink. The synergy present between the selected alcohols or diols and the 1,2-diols results in higher reliability and increased dot size, a powerful combination. This formulation works best with glossy, coated paper mediums as compared to plain paper mediums. Further, this combination allows for a surfactant-free formulation. In fact, a preferred embodiment herein is an ink formulation substantially free of surfactants or other organic or inorganic solvents besides the alcohol or diol/1,2-diol combination.
In the practice of this invention, yellow, cyan, and magenta aqueous inks each comprise from about 0.1 to about 20 wt % of at least one colorant in the color ink formulations; with black ink comprising from about 1 to about 20 wt % of at least one black colorant in the black ink formulations; from about 0.5 to about 2.0 wt % of at least one mono- or di-hydric alcohol, and from about 7 to about 20 wt % of at least one 1,2-diol having a suitable hydrophile-lipophile balance (HLB). Additionally other independently selected ingredients can be added including those from the group consisting of buffers, biocides, and metal chelators; and the balance water.
The present ink compositions offer good dot size which results in a non-banded appearance of the printed image and are reliable in an ink-jet printing engine.
DETAILED DESCRIPTION OF THE INVENTION
While the specification concludes with claims particularly pointing out and distinctly claiming that which is regarded as the present invention, the advantages of this invention can be more readily ascertained from the following description of the invention.
All concentrations herein are in weight percent of total ink composition unless otherwise indicated. The purity of all components is that employed in normal commercial practice for ink-jet inks.
Colorants
In the practice of this invention, yellow, cyan, and magenta aqueous inks each comprise from about 0.1 to about 20 wt % of at least one colorant in the color ink formulations, with black ink comprising from about 1 to about 20 wt % of at least one black colorant in the black ink formulations. The dye set of the present invention may optionally include a black ink. The black ink can also be a composite of the three primary colors, yellow, cyan, and magenta.
Dyes—Dyes, whether water-soluble or water-insoluble, may be employed in the practice of the present invention. Examples of water-soluble dyes include the sulfonate and carboxylate dyes, specifically, those that are commonly employed in ink-jet printing. Specific examples include: Sulforhodamine B (sulfonate), Acid Blue 113 (sulfonate), Acid Blue 29 (sulfonate), Acid Red 4 (sulfonate), Rose Bengal (carboxylate), Acid Yellow 17 (sulfonate), Acid Yellow 29 (sulfonate), Acid Yellow 42 (sulfonate), Acridine Yellow G (sulfonate), Nitro Blue Tetrazolium Chloride Monohydrate or Nitro BT, Rhodamine 6G, Rhodamine 123, Rhodamine B, Rhodamine B Isocyanate, Safranine O, Azure B, Azure B Eosinate, Basic Blue 47, Basic Blue 66, Thioflacin T (Basic Yellow 1), and Auramine O (Basic Yellow 2), all available from Aldrich Chemical Company. Examples of water-insoluble dyes include azo, xanthene, methine, polymethine, and anthroquinone dyes. Specific examples of water-insoluble dyes include Ciba-Geigy Orasol Blue GN, Ciba-Geigy Orasol Pink, and Ciba-Geigy Orasol Yellow. Any dye available and compatible with the other formulated ingredients of this invention may be used as colorants.
Vehicle
The inks of the present invention comprise an aqueous vehicle comprising the following components (in wt % of total ink composition): from about 0.5 to about 2.0, preferably from about 1 to about 2, wt % of at least one mono- or di-hydric alcohol, and from about 7 to about 20, preferably from about 7 to about 11, more preferably from about 8.5 to about 9.5, wt % of at least one 1,2-diol having a suitable hydrophile-lipophile balance (HLB). Because of solubility limitations, the more preferred 1,2-diol is 1,2 hexanediol. Additionally other independently selected ingredients can be added, each in an amount ranging of up to 3% (from 0 to about 3%) by wt, including those from the group consisting of buffers, biocides, and metal chelators; and the balance water.
Alcohol: Any mono- or di-hydric, straight or branched chain alcohol of C5-C10 chain length can be used.
1,2-Diol: The diols of this invention preferably have a 1,2-diol polar side and a hydrophobic side of 4 to 6 carbons. Thus, the diols of this invention are 1,2-hexanediol, 1,2-heptanediol, and 1,2-octanediol, preferably 1,2 hexanediol.
The formulation is substantially free of surfactants or other organic solvents. By “substantially free” is meant that no conventional surfactant is added; thus, less than about 0.1%, preferably less than 0.01% is present. The alcohol/diol combination itself provides the necessary surface activity.
Buffer: The inks of the present invention optionally comprise 0 to about 3 wt % buffer. More preferably, the inks comprise from about 0.1 to about 0.5 wt % buffer, with a concentration from about 0.1 to about 0.3 wt % being the most preferred.
Buffers employed in the practice of the invention to modulate pH can be organic-based biological buffers or inorganic buffers, preferably, organic-based. Further, the buffers employed should maintain a pH ranging from about 3 to about 9 in the practice of the invention, preferably about 6.5 to about 8 and most preferably from about 7.2 to 7.8. Examples of preferably-employed buffers include Trizma Base, available from companies such as Aldrich Chemical (Milwaukee, Wis.), 4-morpholineethanesulfonic acid (MES), b-hydroxy-4-morpholinepropanesulfonic acid (MOPSO), and 4-morpholinepropanesulfonic acid (MOPS). Most preferably, MOPS is employed in the practice of the invention.
Metal Chelator: The inks of the present invention optionally comprise 0 to about 3 wt % metal chelator. More preferably, the inks comprise from about 0.1 to about 0.5 wt % metal chelator, with a concentration from about 0.1 to about 0.3 wt % being the most preferred.
Metal chelators employed in the practice of the invention are used to bind metal cations that may be present in the ink. Examples of preferably-employed metal chelators include: Ethylenediaminetetraacetic acid (EDTA), Diethylenetriaminepentaacetic acid (DTPA), trans-1,2-diaminocyclohexanetetraacetic acid (CDTA), (ethylenedioxy) diethylenedinitrilotetraacetic acid (EGTA), or other chelators that can bind metal cations. More preferably, EDTA, and DTPA; and most preferably EDTA in its disodium salt form is employed in the practice of the invention.
Biocide: The inks of the present invention optionally comprise 0 to about 3 wt % biocide. More preferably, the inks comprise from about 0.1 to about 0.5 wt % biocide, with a concentration from about 0.1 to about 0.3 wt % being the most preferred.
Any of the biocides commonly employed in ink-jet inks may be employed in the practice of the invention, such as Nuosept 95, available from Huls America (Piscataway, N.J.); Proxel GXL, available from Zeneca (Wilmington, Del.); and glutaraldehyde, available from Union Carbide Company (Bound Brook, N.J.) under the trade designation Ucarcide 250. Proxel GXL is the preferred biocide. The specific ink set disclosed herein is expected to find commercial use in ink-jet color printing.
EXAMPLES
Inks were formulated and different properties of the formulated inks were measured in an effort to assess the benefits attained in the practice of the invention, namely, effect of dot size on glossy, photo quality paper.
Example I
Print Sample Generation Method
The print media used included one or more of the following: uncoated paper such as HP colorfast photo paper C7013A, available from Hewlett-Packard Company, Palo Alto, Calif.; and glossy coated paper media such as HP C6034A available from Hewlett-Packard Company.
Exemplary aqueous vehicle for the ink sets comprised:
Reference 1 Vehicle
Component
Preferred Component
Quantity
1,2-Diol
1,2-hexanediol
10%
Mono- or Di-hydric
Neopentyl Alcohol
0.5%
Alcohol
Buffer
MOPS
0.15%
Metal chelator
EDTA
0.10%
Biocide
Proxel GXL
0.20%
Black dye
PRB31
1.5%
Water
Balance
Reference 2 Vehicle
Component
Preferred Component
Quantity
Humectant 1
Glycerol
8%
Dihydric Alcohol
Ethylene Glycol
5%
Surfactant
Surfynol 465
0.1%
Humectant 2
EDPD
8%
Biocide
Proxel GXL
0.20%
Black dye
PRBK31
4.6%
Water
Balance
TABLE 1
Dot Size of Black Inks
Alcohol Added
Dot size on
Replacing the NPA
Glossy coated
Standard
in Reference Vehicle 1
% added
media (microns)
deviation
3,3-Dimethyl-1-Butanol
0.75
121
12
2-Ethyl-1-butanol
0.75
129
32
2-Methyl-1-pentanol
0.75
125
38
3-Methyl-1-pentanol
0.75
125
26
4-Methyl-1-pentanol
0.75
85
8
Hexyl Alcohol
0.75
101
14
1-Heptanol
0.75
120
18
3,5-Dimethyl-1-hexyn-3-ol
0.5
103
10
1-Butoxy-2-propanol
0.5
81
9
Tert-Amyl Alcohol
0.75
88
10
2-Ethyl-1-Hexanol
0.5
104
12
1-Octanol
0.5
129
25
2,2,4-Trimethyl-1,3-
2
92
8
propanediol
2-Butyl-2-ethyl-1,3-
2
83
8
propanediol
Neopentylglycol
2
135
45
1,2 Octanediol
2
98
10
1,2-Decanediol
1.5
97
19
2,2,4-Trimethyl-1-pentanol
0.5
110
18
Reference 1 same vehicle with
0
84
13
0.5 Neopentyl Alcohol
Reference 2 high
0
40
1
humectant vehicle
Humectant vehicle ink (Bottom of table, Reference 2) has poor spreading ability on glossy coated media. The dot size is small. Reference 1 vehicle with 10% 1,2-hexanediol has much improved spreading ability over Reference 2 vehicle, but the dot size still needs to be bigger. In addition, BINO (Bubble induced nozzle outs) occur without the high humectant co-solvents of Reference 2. What is needed is an additive that improves dot size on photo-like, glossy coated media while retaining robustness to BINO.
Table 1 shows the dot size obtainable by exchanging the 0.5 neopentyl alcohol in Reference 1 with the indicated mono- or di-hydric alcohols listed. The resultant dot size is as indicated. As shown above, the hydrophobic alkyl chains of the selected alcohols (Table 1) interact synergistically with the 1,2-hexanediol in the Reference 1 vehicle. The interaction varies with the length and branching of the alcohol hydrophobic chain. This synergy has the effect of making the vehicle even more hydrophobic on the surface of the media, and acts to spread across the media. The spreading vehicle carries the dye colorant to give larger dot size.
Example II
In the experiment with results shown in Table 2, below, humectants (ethylhydroxy-propanediol and glycerol) were added to Vehicle 1 to increase reliability. In all cases, BINO is reduced to zero; thus, all inks are found to be reliable. However, as shown, the dot size is negatively impacted in almost all cases. The dot size is shown to decrease with increasing viscosity. In the last example, NPA (neopentyl alcohol) is removed and is replaced by a low level of NPG (neopentyl glycol). In this case, NPG is able to act as both the humectant and the spreading agent through a synergistic interaction with the 1,2 HDO (1,2 hexanediol) in this vehicle. Because hydrophobic/hydrophilic interactions are taking place, the NPG is a much more effective humectant as well. That is 2% added NPG is as effective in elimination of BINO as 5% added EHPD (ethylhydroxy-propanediol) or glycerol. Since it is more effective, less is used. The viscosity is kept low, and the dot size can be larger than the Vehicle 1 example even as the humectant has been added to give good reliability. As shown, if 5% NPG were necessary, the dot size would be negatively impacted. Other humectants could also be used in this manner as long as they have the correct balance of hydrophobic/hydrophilic portions to interact with the 1,2 diol.
TABLE 2
Dot size on
glossy coated
Solution
media
viscosity
Humectant added
% added
(microns)
at 60 rpm
Vehicle 1
0
77
1.53
Vehicle 1 + EHPD
5
54
1.88
Vehicle 1 + Glycerol
5
65
1.80
Vehicle 1 + neopentyl glycol
5
59
1.89
Vehicle 1 + NPG
2
84
1.67
Vehicle 1 − NPA + NPG
2
84
1.62 | The inks provide excellent ink-jet prints having excellent imaging onto glossy inkjet media with increased dot size leading to improved dot visibility and banding robustness of the image. The aqueous inks each comprise from about 0.1 to about 20 wt % of at least one colorant (CMYK) with the black ink comprising from about 0.5 to about 20 wt % of at least one colorant; from about 7 to about 20 wt % of at least one 1,2-diol, from about 0.5% to about 2 wt % of a mono- or di-hydric alcohol; 0 to about 1.5 wt % of at least one component independently selected from the group consisting of buffers, biocides, and metal chelators; and the balance water. The formulations are substantially free of surfactants and other solvents. | 2 |
This application is a 371 of PCT/EP00/02025, filed Mar. 8, 2000, which claims priority to Germany 199 10 986.9, filed Mar. 11, 1999.
FIELD OF THE INVENTION
The present invention relates to the use of xenon for treating neurointoxications. More particularly, the present invention relates to a use of xenon in which the neurointoxication is caused by a neurotransmitter excess.
BACKGROUND OF THE INVENTION
The uncontrolled release of neurotransmitters, particularly glutamate, noradrenalin and dopamine, is responsible for many acute and chronic intoxications of the brain. These are called neurointoxications or neuropoisonings. These neurotransmitters kill the affected neurons either by induction of apoptosis (controlled cell death) and/or secondarily by their metabolites, by forming oxygen radicals which in turn have toxic effects. An uncontrolled release of neurotransmitters which result in a strongly increased concentration of the neurotoxins in the affected tissue, can be due to various endogenous or exogenous causes. For example, an increased release of glutamate or dopamine may result in an acute craniocerebral trauma. An increase in the neurotransmitter release has also been observed as a response to oxygen deficiency in the brain, e.g. in the case of apoplexy (ischemia) or in the case of other hypoxias, particularly during childbirth. Drug abuse represents another cause of impaired neurotransmitter release. In certain forms of schizophrenia, stress-induced relapses back into schizophrenia (acute episodes) are also accompanied by increased neurotransmitter release. Finally, a chronic shift of neurotransmitter balance, particularly of dopamine balance, has also been observed in various regions of the brain in the case of Parkinson's disease. Increased dopamine release and subsequent formation of free radicals occur in that case as well. Various investigations made with cell cultures and experimental animals have proven the release of neurotransmitters, particularly as a result of oxygen deficiency.
For example, it can be shown that in rats into which the dopamine neurotoxin 6-hydroxy-dopamine was infused unilaterally into the substantia nigra, which resulted in a unilateral depletion of dopamine in the ipsilateral striatum, an experimentally induced ischemia in the regions of dopamine depletion led to damage which was less than that in other regions of the brain. These results suggest that dopamine plays a part in ischemia-induced striatal cell death (Clemens and phebus, Life Science, Vol. 42, p. 707 et seq., 1988).
It can also be shown that dopamine is released in great amounts from the striatum during cerebral ischemia (Kahn et al., Anest.-Analg., Vol. 80, p. 1116 et seq., 1995).
The release of neurotransmitters during cerebral ischemia was investigated in detail and seems to play a key role for excitotoxic neural death. For example, Kondoh et al., Neurosurgery, Vol. 35, p. 278 et seq., 1994, showed that changes in the neurotransmitter release and metabolization can reflect changes in the cellular metabolism during ischemia. The increase in the extracellular dopamine concentration in the striatum of experimental animals in which experimental apoplexies were induced, is well documented.
The contribution of excess dopamine to neuronal damage can be derived from the ability of dopamine antagonists to obtain protection of the neurons in ischemia models (Werling et al., Brain Research, Vol. 606, p. 99 et seq., 1993). In a cell culture, dopamine primarily causes apoptosis of striatal neurons, without damaging the cells by a negative effect on the oxidative phosphorylation the (ATP/ADP ratio remains unchanged). However, if its effect is combined with a minimum inhibition of mitochondrial functions, the neurotoxic effect of dopamine will be increased significantly (McLaughlin et al., Journal of Neurochemistry, Vol. 70, p. 2406 et seq., 1998).
In addition to the direct hypoxic toxicity on neurons, the stress induced by oxygen deficiency, particularly during a birth, effects an increased dopamine release, which results in a negative conditioning of the brain for dopaminergic regulations. This means that even children who seem to survive a hypoxic birth phase uninjured, have a tendency towards convulsions and epileptic conditions when they are older.
Another cause of a disturbed neurotransmitter release is represented by drug abuse. In particular, if drugs such as designer drugs (e.g. ecstasy, etc.) or heroin are consumed, and amphetamines are overdosed, the persons will show signs of intoxication and often spasmophilia, which is based on an increased neurotransmitter release.
The causes of schizophrenia are also due to a complex impairment of the neurotransmitter regulation. Schizophrenia patients are often asymptomatic over a prolonged period of time, but they have a tendency towards spontaneous schizophrenia attacks which are obviously triggered by a stress-induced dopamine release, even in minor stress situations. Here, one speaks of catatonic schizophrenia. Further neuropsychiatric diseases which are based on an increased neurotransmitter release are depressions and Gilles de la Tourette syndrome (“maladie de tics”, “Tics impulsif”).
Finally, one cause of Parkinson's disease is presently believed to be in dopamine modulation and in dopamine metabolism. In Parkinson's disease, dopaminergic neurons in the striatum are especially damaged. References exist to the effect that Parkinson's disease is caused by a dopamine excess in the affected region of the posterolateral hypothalamus and the substantia nigra. Many neurons which have lost their functionality but not their vitality are found in this region. These neurons, referred to as “orphan neurons,” continuously release neurotransmitter amounts having pathologic effects.
With the exception of Parkinson's disease, where dopa precursors are used as preparations, basically of schizophrenia, no therapeutic approaches presently exist which focus on a reduction of the dopamine concentration in the environment of endangered cells.
Therefore, there is a demand for a preparation which reduces or prevents the damaging effects of uncontrolled neurotransmitter release, e.g. of dopamine, glutamate or noradrenalin, from neurons. It is therefore an object of the present invention to provide such a preparation which can be of use in the above-mentioned, as well as in other fields of application.
SUMMARY OF THE INVENTION
In accordance with the present invention, these and other objects have now been realized by the discovery of a method for treating a mammal for neurointoxication comprising treating the mammal with a xenon-containing gas. Preferably, the xenon-containing gas comprises a mixture of gases.
In accordance with one embodiment of the method of the present invention, the neurointoxication is caused by an excess of neurotransmitter in the mammal.
In accordance with another embodiment of the method of the present invention, treating of the mammal with the xenon-containing gas comprises reducing the release of neurotransmitters in the mammal. Preferably, the neurotransmitters are dopamine, glutamate and/or noradrenalin.
In accordance with another embodiment of the method of the present invention, the neurointoxication is caused by apoplexy. In other embodiments, the neurointoxication is caused by drug abuse, oxygen deficiency during birth, a craniocerebral trauma, loss of hearing, or migraine.
In accordance with another embodiment of the method of the present invention, the neurointoxication is correlated with a condition such as Parkinson's disease, schizophrenia, or Gilles de la Tourette syndrome.
In accordance with another embodiment of the method of the present invention, the treating of the mammal with the xenon-containing gas comprises using a cardiopulmonary bypass machine.
In accordance with another embodiment of the method of the present invention, the xenon-containing gas comprises an administered preparation containing from 5 to 90% by volume of the xenon.
In accordance with another embodiment of the method of the present invention, the xenon-containing gas comprises an administered preparation containing from 5 to 30% by volume of the xenon.
In accordance with another embodiment of the method of the present invention, the xenon-containing gas comprises an administered preparation containing a gas such as oxygen, nitrogen or air. Preferably, the xenon-containing gas comprises oxygen, and the ratio of the xenon to the oxygen is from about 80 to 20% by volume.
In accordance with another aspect of the present invention, a treatment method has been discovered comprising using xenon as a neuroprotectant.
In accordance with yet another aspect of the present invention, a method of providing neuroprotection in a mammal has been discovered, the method comprising administering to the mammal a therapeutically effective amount of xenon. Preferably, the method includes administering the xenon in combination with a compound such as a pharmaceutically acceptable carrier, diluent and/or excipient.
In accordance with another embodiment of this method of the present invention, the method includes treating the mammal for a condition associated with NMDA receptor activity.
In accordance with another embodiment of this method of the present invention, the method includes treating the mammal for a condition associated with NMDA receptor activation.
In accordance with another embodiment of this method of the present invention, the xenon reduces the level of activation of the NMDA receptor.
In accordance with yet another aspect of the present invention, a process has been provided for the preparation of a pharmaceutical composition suitable for neuroprotection, the process comprising adding xenon to a component such as a pharmaceutically acceptable carrier, excipient and/or diluent, and using the xenon as a neuroprotectant.
In accordance with the present invention, it has been found that the noble gas xenon surprisingly now reversibly suppresses the release of neurotransmitters, particularly dopamine and glutamate. This unexpected discovery has thus created the possibility of producing preparations for treating cell damage and diseases, respectively, which are caused by an increased neurotransmitter release, and particularly dopamine release or glutamate release.
Correspondingly, the present invention generally relates to the use of xenon for treating neurointoxications, and on the production of a preparation containing xenon for treating neurointoxications, respectively. The present invention also relates to the preparations per se and to a method of producing same. Such neurointoxications particularly concern an excess of neurotransmitter. The present invention is particularly based on the insight that xenon reduces the release of dopamine and/or glutamate.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention may be more fully appreciated with reference to the following detailed description, which, in turn, refers to the Figures wherein:
FIG. 1A is a graphical representation of the release of dopamine under various hypoxic situations;
FIG. 1B is a graphical representation of relative dopamine concentration as a result of various hypoxic situations; and
FIG. 2 is a graphical representation showing release of dopamine in various stress situations.
DETAILED DESCRIPTION
According to the present invention neurointoxications are understood to mean acute or chronic “states of poisoning” of the central nervous system (CNS), and particularly of the brain, which in most cases result in severe deficiency symptoms of the affected areas. These states of poisoning result from an excess of neurotransmitter, particularly of glutamate, noradrenalin and/or dopamine, which can be due to a variety of causes. The above-mentioned diseases, such as apoplexy, hypoxias, oxygen deficiency during a birth, Parkinson's disease, craniocerebral trauma, drug abuse, schizophrenia, depressions and Gilles de la Tourette syndrome are among those that can be mentioned here. The inventors have also found that patients who must be connected to a cardiopulmonary bypass machine often suffer from cerebral deficiency symptoms which are due to an excess of neurotransmitter caused by hypoxia. For example, the use of a cardiopulmonary bypass machine can cause an often unidentified neurointoxication, which delays the patient's reconvalecence to a considerable extent. It has also been found that any prolonged artificial respiration can result in undesired neurointoxication as a side-effect. In recent investigations conducted by the inventors, the surprising insight has been gained that the hearing loss (e.g. due to noise, presbycusis, tinnitus, or sudden deafness) can also be caused by neurointoxication. The excess neurotransmitter release, particularly excessive glutamate and dopamine release, which can have been caused e.g. by an impairment in the body, an acoustic trauma, or an ischemia, results in an acute destruction of the nerve endings and subsequently death of the corresponding nerves in the hearing organs. Migraine has to be considered another disease which is most likely due to an impaired dopamine balance, and thus to neurointoxication.
The discovery that the neurotransmitter release can be influenced by xenon enables an entirely new field of application for this noble gas, which has up to now been used increasingly as an inhalation anesthetic agent in the field of anesthetics. The treatment of the differing neurotransmitter excess diseases of the brain, such as those discussed above, can be carried out on the basis of the present invention by a simple inhalation therapy. The uptake of xenon by means of the respiratory system, and transport into the brain, are already proved by its use as anesthetic agent. It can also be assumed that the use of xenon has no damaging effect on the human organism, since many corresponding experiences can be realized by its use as an anesthetic agent. Xenon can be applied by various techniques, which can be chosen as a function of the location of use. For example, inhaling apparatus can be used in the clinics, which are also used for anesthesia by inhalation. If a cardio-pulmonary bypass machine or other artificial breathing apparatus is used, xenon can be added directly in the machine, and thus requires no further apparatus. In this case, standard xenon addition can prevent the formation of neurointoxications in the model case (prophylaxis) or at least reduce the deficiency symptoms. On an ambulant basis, e.g. in the primary treatment of victims of an accident, it is possible to use simpler inhalators which mix the xenon with the ambient air during the process of inhalation. In this connection, it is also possible to adapt the xenon concentration and the timing of xenon use, a in simple manner, to the therapeutic requirements. For example, it is advantageous to use mixtures of xenon with other gases, it being possible to mix the xenon with oxygen, nitrogen, air or other gases which are harmless for humans.
In patients suffering from a severe craniocerebral trauma, respiration with a xenon-oxygen mixture, as also used in anesthesia, can prevent, or at least reduce, the release of dopamine and thus the secondary neurotoxic effects accompanying this trauma. In such accidents, the additional anesthetic side-effect is desired, since the patient can be freed from pain thereby.
An essential feature of acute ischemia in the brain is represented by the secondary neurotoxic effects which form by an increase in the neurotransmitter release, and are responsible for the death of the neurons in the ischemic marginal region. Although an immediate xenon treatment, e.g. by the emergency physician who carries out the initial treatment in the case of an apoplexy patient, cannot prevent ischemia per se, but it can at least reduce, or even prevent, the neurotoxicity by the secondarily released neurotransmitters. Thus, the permanent damage frequently occurring in the case of apoplexy can be reduced. The same applies analogously to measures which will have to be taken if disease symptoms occur after drug abuse and loss of hearing, or a migraine attack.
In the case of oxygen deficiency during a birth, e.g. during the entrance into the obstetric canal or in the case of problems with the umbilical cord, xenon-(oxygen) respiration of the mother and respiration of the child as soon after the birth as possible, respectively, can prevent the negative effects of increased dopamine release during the oxygen deficiency.
In the case of schizophrenia, patients suffer from periodic schizophrenia (catatonia), the progress is very sudden, the picture of the state being characterized by dramatic symptoms which show varying pictures and are full of delusions and hallucinations. Often a phase disappears as rapidly as it started. Such phases or attacks can be triggered spontaneously by stress situations. Rapid respiration with a xenon gas mixture during the state of stress can at least reduce the intensity of the attack. For this application, it is an obvious thing to equip patients with xenon inhalators which permit self-medication. In this case, it is conceivable to use containers which, similar to asthma sprays, are filled with xenon which will be released if a trigger is pressed. The same applies analogously to the treatment of depressive patients whose moods change almost daily and who as a result thereof require state-related medication.
Chronic Parkinson's disease is accompanied by progressive symptoms. A consequent xenon treatment reduces the neurotransmitter release and slows down the progression, or even brings the progression of the disease to a stand-still. In this case, intermittent treatment offers itself in which the patient is respirated with xenon at certain intervals. The same applies to patients who suffer from the Gilles de la Tourette syndrome. Their tics also become more and more distinct as the disease proceeds.
In the case of acute threatening states, such as a craniocerebral trauma or an ischemia, respiration can advantageously be carried out with a xenon-oxygen mixture of 90:10% by volume, preferably 80:20% by volume, and most preferably 75-70:25-30% by volume, over several hours to one day. As compared thereto, the intermittent respiration by a xenon-air mixture to which less xenon has been added, e.g. 5 to 30% xenon, preferably 10 to 20% xenon, can be considered in chronic progressions of a disease.
Various methods for the inhalation of xenon and xenon mixtures, respectively, can be used which depend on the respective intended use. In clinics, it is possible to use anesthetic apparatus, in which prefabricated xenon-oxygen mixtures can be connected to the corresponding inlets of the anesthetic apparatus. Respiration is then carried out according to a procedure which is common for such apparatus. The same applies analogously to the cardiopulmonary bypass machine.
As an alternative, xenon can be mixed with ambient air instead of oxygen in the mobile use, which due to the smaller size of the required pressure bottles increases the mobility of the apparatus. For example, it is possible to use an inhalator which supplies xenon from a pressure bottle and is accommodated in a support, together with the latter, to a mixing chamber. On one side, this mixing chamber contains a mouthpiece for inhaling the xenon, and on the other side on which the xenon is supplied to the mixing chamber it has at least one additional check valve which enables the inlet of ambient air. The xenon pressure container can be equipped with a pressure reducing valve, for example, which reduces the amount of xenon gas supplied to a suitable value. When the patient breathes in, he sucks in air from the air valves. In the mixing chamber, this air is mixed with the supplied xenon to the desired ratio and then inhaled by the patient. An advantageous inhalator intended for mobile use and serving for inhaling xenon and its mixtures is shown in, for example, European patent No. 560,928.
In a further simplified embodiment, e.g. for self-medication, a mouthpiece is connected directly to the xenon pressure container. During inhalation, the patient opens the pressure valve and inhales xenon simultaneously with the air from the environment. When he breathes out, he releases the valve, so that no more xenon reaches the mouthpiece. In this manner, at least a coarse regulation of the amount of inhaled xenon is possible.
The present invention is explained in more detail below, reference being made to attached FIGS. 1 and 2, which show the dopamine release in cell cultures exposed to hypoxic shock.
The function of the present invention shall be explained in more detail below by means of the following examples.
EXAMPLE 1
An in vitro experiment with PC12 cells is concerned. These PC12 cells are dependants of a pheochromocytoma of rats. Here a catecholamine-producing tumor of the suprarenal cortex is concerned, which shows permanent dopamine release in a malignant form. PC12 cells can be reproduced continuously in vitro. Following the addition of “nerve growth factor”, they start differentiating and become neurons which in many respects have the property of in vivo neurons, particularly the properties which relate to the neurotransmitter release. PC12 cells are acknowledged as neuronal model.
PC12 cells differentiated in such a manner when exposed to a hypoxic situation, release dopamine. Such a hypoxic situation is an artificially induced stress state for the cells, in which e.g. the oxygen supply is dropped or impeded. If the cells are treated under these hypoxic conditions with xenon in defined concentrations over the same period of time, the neurotransmitter release will be dropped. The time course of such an experiment is shown in FIG. 1 by way of example. The curve of the non-stressed controls, illustrated by solid squares, shows a low dopamine concentration throughout the time course, which is subject to certain fluctuations. If a hypoxic situation is triggered by a dose of helium instead of oxygen, the curve of the dopamine concentration will result as shown in the curve produced from the solid triangles. A maximum dopamine concentration is shown in this case after about 40 minutes. However, if xenon is given in a hypoxic situation, the cells will virtually no longer differ from the control cell population, as shown by the plot illustrated by solid circles. In connection with the relative dopamine concentration shown in part B of FIG. 1 it can also be clearly seen that the dopamine release is reduced down to values of the control cells. In this connection, it was found that the xenon effect is fully reversible, so that the cells treated in this way cannot be distinguished from untreated cells after the xenon is washed out. In the above-described experiment, the gases used were given to the cells by mixing them with the growth buffer for the cells. In this case, saturated gas buffer solutions are involved.
EXAMPLE 2
The differentiated PC12 cells described in Example 1 were distributed to various vessels and exposed to differing conditions. The results are shown in FIG. 2 . These conditions are defined as follows:
Control: incubation in normal atmosphere (ambient air)
N2: incubation in nitrogen (N2) for 30 minutes [=hypoxia]
Xenon: incubation in xenon for 30 minutes
Glu: addition of 10 M glutamate for 30 minutes of incubation in a normal atmosphere
Glu+N2: addition of 10 M glutamate for 30 minutes of incubation in N2
Glu+Xe: addition of 10 M glutamate for 30 minutes of incubation in xenon.
A hypoxic condition and an increased release of dopamine resulted in the cells incubated with nitrogen (group: N2). The dopamine release may even be increased if, in addition to the nitrogen atmosphere, glutamate, which represents a neurotransmitter and has a neurotoxic effect in greater doses, was given as well (group: Glu+N2). However, if 10 M glutamate was given in the simultaneous presence of xenon (Group: Glu+Xe), a slightly increased dopamine release would still result, but which was nevertheless reduced by two-thirds as compared to the corresponding (glutamate+N 2 ) experiment.
The results shown in FIG. 2 demonstrate that in stress situations such as hypoxia, the neurotransmitters glutamate and dopamine are released in large quantities. This results in a) direct damage to the neighboring neuronal tissues, mainly by inducing apoptosis and b) indirectly, an additional increased release of other neurotransmitters. Thus, the addition of glutamate to the cells effects an increased dopamine release, particularly when the cells are kept under hypoxic conditions. The unintentional neurotransmitter release could be reduced many times over by the simultaneous supply of xenon.
It can therefore be shown, on an overall basis, that in the present invention xenon can stop rapidly and without other permanent side-effects the neurotransmitter release temporarily. Hence it follows that xenon can be used in defined concentrations in a therapeutically useful manner in all pathologic conditions characterized by unregulated neurotransmitter release. The simple application by inhalation and the harmlessness of xenon render this therapy especially attractive. Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims. | Methods for treating mammals for neurointoxication are provided comprising treating the mammal with a xenon-containing gas. Methods of providing neuroprotection in mammals are also disclosed comprising administering therapeutically effective amounts of xenon, preferably in combination with pharmaceutically acceptable carriers, diluents or excipients. | 0 |
FIELD OF THE INVENTION
[0001] The invention relates to fluid connections, in particular the fluid connection devices for connecting a fluid pipe to another pipe or to a container, in the field of biopharmaceutical applications.
BACKGROUND OF THE INVENTION
[0002] Specifically, the tubes or pipes used in the biopharmaceutical field are flexible or highly flexible pipes which are used to convey various biopharmaceutical substances, most often with the necessary aseptic precautions.
[0003] Fluid connection devices commonly comprise a first male connector (in other words forming a male interface) able to be received in a second complementary connector forming a female interface, which is a simple and well-understood solution. However, a male connector cannot be connected to another male connector, nor can a female connector be connected to another female connector.
[0004] In the context of assembling a flexible pipe to another pipe or container by means of a fluid connection, there is a need to improve the interoperability of the connectors in order to facilitate the construction of modular biopharmaceutical assemblies.
[0005] There are known fluidic connections for connecting together two “genderless” connectors that are functionally equivalent in terms of coupling. However, the known genderless fluid connectors generally require an axial insertion movement followed by a rotational movement about the axis.
[0006] In addition, the sterile or aseptic precautions for such applications necessitate good verification of the fluid connections established between the various entities in a biopharmaceutical assembly such as pipes, bags, filters, etc.
[0007] We therefore seek ways to check the coupling position in a simple and reliable manner, meaning to verify that the coupling movement has reached the correct final position, possibly being secured in this position by locking means.
[0008] For genderless connectors with axial translational movement followed by rotation, proper completion of the rotation is difficult to verify.
[0009] There is therefore a first need to provide a connection device for connecting together two genderless connectors with a coupling movement that only involves axial translational movement.
[0010] In biopharmaceutical applications, the flexible pipes allow the circulation, passage, and communication of a fluid, such as a biopharmaceutical fluid, and can either be connected to a similar flexible pipe or to a vessel or container which may be rigid or flexible.
[0011] The vessel or container in question may, in the current case, be a container for storing and/or processing content such as a biopharmaceutical product. In the current case, such a container is understood to mean a rigid or semi-rigid reusable container or a flexible disposable container such as a bag or even a filter cartridge.
[0012] This bag may be one of the substantially thin “2D” bags, such as those marketed by Sartorius Stedim Biotech under the brand Flexboy®, having a typical volume of between 50 ml and 50 liters. This flexible bag may also be a “3D” bag, such as those marketed by Sartorius Stedim Biotech under the brand Flexel®, having a larger volume and a substantial size in all three dimensions. Note that a pipe such as the pipe to which the invention applies can be placed between two bags or a larger number of bags.
[0013] A pipe such as that to which the invention is applied, usually of circular cross-section, is typically made of a plastic such as silicone, thermoplastic elastomers (TPE), or PVC, this list being non-limiting. It has a certain general stability and simultaneously both a certain overall flexibility and a certain local flexibility, allowing, when sufficient force is applied, crimping the pipe or substantially deforming it radially.
[0014] In a typical embodiment, for example, the pipe has an outer diameter between 8 mm and 30 mm for example, with the thickness depending on the material, the diameter, and the applications.
[0015] In the prior art, to couple such a flexible pipe, it is slipped over a tubular nozzle, whereupon a pipe clamp is placed around the pipe and then the clamp is tightened. The tightened clamp thus exerts a radial inward pressure to maintain the hose on the nozzle, on the one hand to ensure a good seal against the nozzle and on the other hand to prevent the pipe from detaching from the nozzle when pulled.
[0016] For such pipe clamps, a plastic clamp can be used for example, of polyamide for example such as Rilsan®. This type of plastic clamp, also sometimes called Serflex®, comprises a system of notches on a strip cooperating with a locking hook arranged in the head, such that the tightening is irreversible. In other words, once the strip is engaged in the head to form a loop, the strip is pulled to reduce the diameter of the loop and tighten the clamp; all return movement is prevented by the engagement of the hook in one of the strip notches. After tightening, to prevent the strip from projecting too far beyond the diameter of the clamp loop, the free portion of the strip is cut off near the head of the clamp. The undetached remaining portion of the strip often has a sharp edge which can cut.
[0017] As an alternative to the plastic clamp, a metal clamp can be used which is in the form of a preformed ring having one or two “ears” projecting outward with respect to the general shape of the ring of the clamp, this type of clamp sometimes being called an Oetiker® clamp. After insertion of the clamp onto the pipe to be retained, a tool is used to crimp the ear (or ears) of the clamp which causes permanent deformation and thus a narrowing of the major diameter of the ring and as a result tightens the clamp on the pipe. This type of clamping with a metal ring is particularly robust and reliable. However, at the point where the ear was crimped by the tool, there may be a burr or roughness which forms a sharp edge that can be damaging.
[0018] Whether plastic or metal, once such clamps are installed in biopharmaceutical assemblies, these assemblies may need to be transported or moved and therefore there is a risk of damage by the damaging parts of these clamps to other elements of the biopharmaceutical assembly, particularly the flexible bags or flexible pipes, which can cause a leakage or loss of sterilization that is detrimental to the biopharmaceutical application.
[0019] In addition, these clamps are easy to access (and thus can be removed) and does not guarantee a satisfactory image or aesthetics.
[0020] There is therefore a second need to prevent the pipe clamp from posing a danger to the surrounding elements.
OBJECTS AND SUMMARY OF THE INVENTION
[0021] Below is provided a description of the invention as characterized in the claims, offering an improvement intended to overcome, at least in part, one of the aforementioned disadvantages of the known prior art.
[0022] According to a first aspect, the invention relates to a fluid connection device adapted and intended for connecting a first wall forming a first flexible pipe defining a first fluid space, to a second wall defining a second fluid space in the form of a second flexible pipe or flexible enclosure that is semi-rigid or rigid and disposable, in a biopharmaceutical assembly, comprising:
a first connector defining a first hollow passage, adapted and intended for connection to the first fluid space, a second connector, similar to the first connector, defining a second hollow passage, adapted and intended for connection to the second fluid space,
the first connector and the second connector being adapted and intended to be coupled together in a genderless manner, by an insertion movement that is essentially an axial translation along the axis A, into a relative coupling position, which defines a mating plane P perpendicular to the main axis,
each of the first and second connectors comprising, in an alternating manner along the circumferential direction, N flexible snap-fitting tabs and N stop surfaces, N being a strictly positive integer,
the flexible snap-fitting tabs projecting axially forwards relative to the mating plane, and the stop surfaces being set back from the mating plane so that, in the coupling position, the snap-fitting tabs of one of the connectors clip into place beyond the stop surfaces of the other connector, such that the resulting position is locked by the snap-fitting tabs.
[0025] In this manner, a fluid connection device is proposed that is based on genderless connectors, which facilitates interoperability, modularity, and the formation of modular biopharmaceutical assemblies, because all the genderless connectors so formed can be connected to any another connector of the same genderless type, with no need to worry about the gender of each connector to be connected. In addition, there is no need to perform a rotational operation on the connection after the axial translational movement, which facilitates visual verification of the correct coupling position.
[0026] Advantageously, the snap-fitting tabs of one of the two connectors are formed integrally from the body of this connector, and each of the snap-fitting tabs move into the coupling position through a slot formed in a collar of the other connector. A collar is therefore provided which facilitates gripping and manually connecting the device, compatible with the compact arrangement of the clip-on means, in a genderless connector.
[0027] Advantageously, the snap-fitting tabs move apart outwardly during the coupling movement and return towards their rest position at the end of the coupling movement where they bear on the stop surfaces; in this manner the operator establishing the coupling has visual and/or auditory and/or haptic feedback on the proper coupling of the connectors.
[0028] Advantageously, each connector comprises a substantially cylindrical body, and in the coupling position the snap-fitting tabs lie adjacent to the body of the opposite connector and external thereto, and are resiliently biased radially inward if someone attempts to move them away from their rest position, such that they must all be moved apart simultaneously to unlock the connection. In this manner, the radial footprint of the locking device for this type of genderless connectors is quite optimized, and in addition the locking is particularly robust.
[0029] In one embodiment, each snap-fitting tab has a stirrup shape. This provides the snap-fitting tabs with satisfactory mechanical strength.
[0030] In one embodiment, the device may further comprise a protective cover formed by two half portions configured to close together in the radial direction to at least partially surround the first connector and the second connector, the cover serving as an indicator of proper coupling when snap-fitted into its closed position. In this manner, correct positioning of the protective cover is used to indicate proper coupling of the first and second connectors.
[0031] In one embodiment, the protective cover comprises two generally semi-cylindrical complementary portions connected by a flexible hinge portion, and the two portions are adapted to be snap-fitted together in an area diametrically opposite the hinge area, such that the protective cover is easily installed around the first and second connectors, in particular around their respective joined collars. Moreover, the protective cover may advantageously be molded as a single piece of synthetic material.
[0032] In one embodiment, the cover comprises an annular inner groove adapted to form, in the coupling position, a lock that immobilizes the adjacent collars that are respectively part of the first and second connectors. In this manner, the correct position of the protective cover reliably indicates that the first and second connectors are coupled and locked.
[0033] In one embodiment, the annular inner groove provides at least one tapered portion (having a trapezoidal cross-section) so as to exert axial pressure on the collars, which urges the two connectors closer together. The action of clipping the protective cover closed helps complete, if necessary, the movement of coupling the first and second connectors together.
[0034] In one embodiment, in the coupling position, the two connectors are arranged symmetrically relative to the mating plane, furthermore with an angular displacement of 360°/2N. This allows providing a simple genderless interface with several possible angular coupling positions, N possible angular positions in the current case.
[0035] In one embodiment, the number N is between 1 and 10, preferably equal to 4; whereby the number of possible angular positions for the coupling facilitates completion of the coupling.
[0036] In one embodiment, each connector further comprises a seal arranged radially inward within the cylindrical body, pressure being applied to the two seals in the axial direction when the two connectors are snap-fitted into position. This is a well-understood and standard solution for the sealing function of genderless connectors.
[0037] In one embodiment, each connector further comprises a temporary aseptic sealing membrane arranged on the front face of each of the seals, intended to be removed after coupling the connectors so that the two fluid spaces are placed in communication without any communication with the surrounding air; modular biopharmaceutical assemblies can thus be created under conditions of sterility or protection from the ambient air.
[0038] In one embodiment, the closing of the cover causes, after removal of the sealing membranes, additional travel in the coupling which increases the axial pressure between the seals; whereby the pressure on the seals is increased and the quality of the seal is improved.
[0039] In one embodiment, the connection device may further comprise a pipe clamp adapted and intended to be arranged around the end of the first pipe in order to clamp said pipe onto a tubular nozzle of the first connector, and the protective cover comprises at least one tubular extension adapted to be positioned, when the cover is clipped into the snap-fitted position, at least partially facing the pipe clamp in the radial direction, whereby the tubular extension prevents the pipe clamp from coming into direct contact with external elements. In this manner, the pipe clamp cannot come into direct contact with external elements, and this prevents possible damage to adjacent flexible bags or pipes by a damaging portion of the pipe clamp.
[0040] In one embodiment, the pipe clamp is a metal clamp having a general ring shape with at least one “ear”, said ear being intended to be crimped to tighten the clamp, and the tubular extension is at a distance from the outer surface of the pipe. The crimped ear solution is a standard and well-understood solution for the pipe clamp function. In addition, several different diameters of flexible pipe and tubular nozzle are compatible with a single definition of the tubular extension of the protective cover.
[0041] In one embodiment, one of the connectors or the protective cover may further comprise an identifier such as a barcode or RFID tag or color code. In this manner, it is easy to access information concerning the flexible bag and/or the biopharmaceutical product contained therein, and traceability is facilitated.
[0042] In one embodiment, the snap-fitting tabs of the connectors each comprise a longitudinal extension which projects forward, so as to provide a gripping area for spreading apart the snap-fitting tabs in order to unlock the coupling position; this provides a solution for releasing the coupling of the first and second connectors.
[0043] In one embodiment, the device may further comprise a pipe clamp adapted and intended to be arranged around the end of the pipe in order to clamp said pipe onto a tubular nozzle of the first connector, and the snap-fitting tabs of the second connector each comprise a longitudinal extension which projects forward so as to cover, in the coupling position, the pipe clamp in the radial direction; whereby the extensions prevent the clamp from damaging nearby external elements, being without the addition of a cover as a separate part.
[0044] According to a second aspect, the invention relates to a genderless connector for fluid connection, adapted and intended for coupling to another similar genderless connector, in a fluid connection device as described above,
[0000] the connector comprising, in an alternating manner along the circumference, N flexible snap-fitting tabs and N stop surfaces where N is a strictly positive integer, the flexible snap-fitting tabs projecting axially forward relative to the mating plane and the stop surfaces being set back from the mating plane such that, in the coupling position, the snap-fitting tabs of one of the genderless connectors clip onto the stop surfaces of the other similar genderless connector so that the resulting position is locked by the snap-fitting tabs, the mutual coupling being achieved in a substantially axial translational movement along axis A.
[0045] According to a third aspect, the invention relates to a biopharmaceutical assembly comprising a fluid connection device as described above.
[0046] According to a fourth aspect, the invention also concerns a method for forming a connection device as described above, the method comprising the steps of:
[0000] /a/ providing a first connector and a second connector, both with a compatible genderless interface, and each equipped with a collar and a seal with aseptic membrane closing off the opening defined by the seal,
/b/ establishing a primary coupling of the first and second connectors,
/c/ removing the aseptic sealing membranes,
/d/ inserting a protective cover comprising an annular inner groove having a cross-section comprising two tapered shapes, the closing of the cover causing additional axial travel in the coupling to increase the contact pressure between the two seals.
[0047] In a fifth aspect, the invention also concerns a kit of parts comprising the first and second genderless connectors described above, optionally with a protective cover and optionally with at least one pipe clamp and a flexible pipe. In addition, the invention concerns the assembly of the above parts into an assembled state, optionally with the pipe clamp protected by the protective cover, or longitudinal extensions of the snap-fitting tabs.
BRIEF DESCRIPTION OF THE DRAWINGS
[0048] The figures of the drawings will now be briefly described.
[0049] FIG. 1 is an exploded view of the connection device according to the invention.
[0050] FIG. 2 is an axial sectional view of the connection device of FIG. 1 , in the coupled position, along section line II-II shown in FIG. 3 .
[0051] FIG. 3 is a cross-sectional detailed view of the connection device of FIG. 1 , in the coupled position, along section line shown in FIG. 2 .
[0052] FIG. 4 is a perspective view of the connection device of FIG. 1 in the assembled position, shown without a protective cover.
[0053] FIG. 5 represents another embodiment, in an axial sectional view, where the second connector comprises a base fixed to a biopharmaceutical enclosure.
[0054] FIG. 6 illustrates an alternative embodiment wherein the snap-fitting tabs comprise an axial extension of extra length.
[0055] FIGS. 7A-7C represent an alternative embodiment, with temporary aseptic sealing membranes enabling the connection of connectors without exposure to the open air.
[0056] Below is a detailed description of several embodiments of the invention, accompanied by examples and with reference to the drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0057] In the example illustrated in FIGS. 1 to 4 , a first flexible pipe 11 is connected to a second flexible pipe 11 ′ in a biopharmaceutical assembly, by means of a fluid connection device 10 which comprises a first genderless connector 1 and a second genderless connector 1 ′ which can be coupled.
[0058] The first flexible pipe 11 can be generally defined as a first wall 11 defining a first fluid space 71 . Similarly, the second flexible pipe 11 ′ can be generally defined as a second wall 11 ′ defining a second fluid space 72 .
[0059] The first connector 1 is made of synthetic material, more specifically it can be obtained by molding a plastic material, for example polypropylene, polyethylene, polycarbonate, polysulfone.
[0060] The first connector 1 comprises a tubular nozzle 9 at one end 1 a , and a coupling interface with the second connector at the other end. The tubular nozzle 9 is symmetrical about the axis A. The coupling interface is a genderless interface that is intended to be inserted into an identical or similar interface that is also genderless. There is thus no male or female entity in such a genderless connection.
[0061] The first connector further comprises an intermediate portion which is in the form of a cylindrical body 18 centered on the axis A. A collar 16 extends radially outward from the cylindrical body 18 . In this collar are formed a plurality of slots 17 evenly distributed around the circumference of the cylindrical body 18 . In the illustrated example, there are four slots, each in the form of an arc of about 45°, these arcs allowing the passage of an element through the collar in an axial direction as will be seen below.
[0062] Inside the cylindrical body 18 there is a compressible seal 13 ; this seal is in the form of a ring centered on A and having a generally rectangular cross-section in the example illustrated. It comprises in particular a bearing face 13 a intended to cooperate with another bearing face that is part of the seal of another opposing connector to which the first connector can be coupled. The seal 13 is preferably made of elastomeric material or silicone.
[0063] The front face 16 a of the collar 16 , in other words the face which is opposite the position of the tubular nozzle, and near or adjacent to a mating plane P, said mating plane defining a reference position for the mating of the bearing faces 13 a of the seals of the two connectors in the coupled position.
[0064] Projecting beyond the mating plane, opposite the position of the tubular nozzle, are snap-fitting tabs 6 which in the illustrated example are in the form of a stirrup having a square cross-section. The snap-fitting tab has two longitudinal portions 6 b extending from the collar, parallel to the axis A, and a transverse arcuate portion 6 a connecting the ends of the two longitudinal portions 6 b.
[0065] In the example illustrated, there are four snap-fitting tabs 6 which alternate with slots 17 , previously described, and occupying the same diameter length as the slots 17 previously described, each snap-fitting tab defining an arc of approximately 45°.
[0066] Each snap-fitting tab 6 is intended to pass through the corresponding slot of the opposing connector, knowing that to couple a first connector to a second similar or identical connector 1 ′, these must exhibit an angular offset so that the snap-fitting tab of the first is facing a slot of the second and vice versa (see FIGS. 1 and 4 ).
[0067] In addition, provided on the cylindrical body 18 of the connector, and set back relative to the mating plane and the collar, are stop surfaces 8 which may be provided as shoulders, said stop surfaces each being configured to cooperate with a transverse arm 6 a of a snap-fitting tab, in the coupling position, thereby obtaining a clip-on effect, in other works locking the coupled position, as is apparent in FIG. 4 .
[0068] One will note that the snap-fitting tabs 6 are adjacent to the cylindrical body 18 of the opposing connector 6 ; the snap-fitting tabs 6 are arranged outside the cylindrical body 18 of the opposing connector, and substantially mate with the outer contours of the cylindrical body.
[0069] Each stop surface 8 may be formed in a projection of the cylindrical body, comprising a slight anterior ramp to move apart the snap-fitting tabs during insertion of the connector and a posterior radial surface forming the stop surface 8 against which the transverse portion 6 a of the snap-fitting tab comes to bear.
[0070] In FIG. 4 , in the coupling position, the collars 16 , 16 ′ are more or less adjacent to one another when the transverse portion 6 a of the tabs abuts against the stop surfaces 8 under the reactive effect of the seal. It will be seen below that the space between the collars in the coupling position, which can be more or less significant, can be reduced to increase pressure between the seals.
[0071] Note that the snap-fitting tabs 6 are spread apart radially outward during the coupling movement so that each transverse portion 6 a travels beyond the facing stop surface 8 , which forms in the illustrated example a ramp for this purpose.
[0072] The second connector 1 ′, to which the first connector can be coupled, is strictly identical to the first connector in form and material in the example illustrated in FIGS. 1 to 4 . In particular, it comprises a tubular nozzle 9 ′ to which the second flexible pipe 11 ′ can be attached, a cylindrical body 18 with a collar 16 ′, a seal 13 ′, snap-fitting tabs 6 , slots 17 A, and stop surfaces 8 , all of which are identical to those already described for the first connector.
[0073] However, the second connector may present more or less substantial differences provided that the coupling interface with the first connector remains compatible, in particular the position of the transverse arms of the snap-fitting tabs and the position of the stop surfaces, and to a lesser extent the passage provided by the slots.
[0074] In particular, the two connectors may be of different colors, which facilitates visual verification of proper coupling.
[0075] The tubular nozzle 9 comprises an annular bead 19 , which in the illustrated example has a slight ramp 19 a on the side of the flexible pipe 11 to be inserted and a shoulder 19 b on the opposite side. The tubular nozzle may comprise a greater number of beads, for example successive catches as are known per se.
[0076] One will note that the inside diameter D 1 of the tubular nozzle 9 is substantially similar to the inside diameter of the flexible pipe 11 at rest.
[0077] When the flexible pipe 11 is slid onto the tubular nozzle 9 , the pipe is deformed radially outward by the shape of the ramp 19 a , then as the insertion proceeds it returns to a narrower diameter 9 a at the cylindrical bearing surface 9 a.
[0078] The insertion can continue until the front end 11 a of the pipe comes to bear against the rear part 18 b of the cylindrical body 18 (see FIGS. 2 and 4 ).
[0079] Once the flexible pipe is inserted onto the tubular nozzle 9 , a pipe clamp 3 is placed around the pipe at the abovementioned bearing surface 9 a . It should be noted here that the pipe clamp 3 may be placed on standby around a rear portion of the pipe beforehand, prior to the insertion process. Once the clamp is in an appropriate position relative to the bearing surface of the tubular nozzle, the clamp is tightened.
[0080] The pipe clamp shown in the figures is a metal clamp with only one ear 31 provided for tightening. There could be more than one ear, however.
[0081] Pliers are used, for example, to flatten the ear shape 31 so as to reduce the diameter of the ring 30 formed by the pipe clamp 3 . As a result, the pipe clamp then has a smaller diameter than that of the outer surface of the flexible pipe at rest, and therefore exerts a radial force directed inward.
[0082] This radial pressure has two objectives: the first is to ensure a sufficiently effective seal between the pipe 11 and the tubular nozzle 9 , and the second is to mechanically retain the pipe around the nozzle to prevent the pipe from detaching from the tubular nozzle when pulled, due to the aforementioned shoulder 19 b.
[0083] In addition, an optional protective cover 5 is advantageously provided which at least partially covers the first and second collars 16 , 16 ′ that are part of the first and second connectors 1 , 1 ′ respectively, as is apparent in FIG. 2 .
[0084] The protective cover 5 is formed by two parts 5 a , 5 b forming two half-portions of similar size joined by a flexible hinge portion 50 , all obtained in a single molding operation. Specifically, each part may be in the form of a semi-cylindrical portion with a protruding ring 56 in the central area, although other shapes are possible. The two portions are intended to be clipped together in an area diametrically opposite the hinge area, for example by means of hooks 58 , 59 that clip together, which are simply and symbolically represented in FIG. 1 .
[0085] Once the protective cover is installed around the collars of the first and second connectors 1 , 1 ′, the cover 5 thus forms an indicator of proper coupling of the connectors: if the collars 16 , 16 ′ are too far apart, the protective cover cannot be closed around them.
[0086] Advantageously, the cover comprises an annular inner groove 55 adapted to form, in the coupling position, a lock that immobilizes the adjacent collars 16 , 16 ′ against one another as is apparent in FIG. 2 .
[0087] In addition, the inner groove may comprise at least one tapering portion 53 , 54 (of trapezoidal cross-section) so as to exert axial pressure on the collars, which urges the two connectors closer together and increases the mutual contact pressure between the seals 13 , 13 ′.
[0088] In addition, to facilitate the movement of closing the two half-portions of the cover on the collars, the radially external rear portion of the collars 16 b may comprise a chamfer 16 b which facilitates sliding along the tapering portions 53 , 54 .
[0089] In addition, the protective cover 5 may be such that it forms protective elements for the first pipe clamp 3 on the first connector 1 and/or for the pipe clamp 3 ′ of the second connector 1 ′.
[0090] More specifically, the protective cover comprises a first axial extension 51 in the first connector direction and a second axial extension 52 in the second connector direction. In the example shown, the protective cover is thus symmetrical relative to the mating plane P of the coupling. Its installation can therefore be oriented in one direction or the opposite direction.
[0091] The first axial extension 51 forms such “protective elements” for the first pipe clamp 3 : in effect the pipe clamp, in the coupling position, is positioned within the inner region defined by this axial extension 51 . In this manner, if during handling or movement of the connection device, the device comes into contact with external elements 90 , then it is not the pipe clamp which will be in contact with said external elements 90 but instead it will be the protective cover 5 , here the axial extension 51 , which will come into contact with the external element(s) 90 (see FIG. 2 ). Thus, damage from contact with a potentially damaging portion of the clamp 3 can be advantageously avoided.
[0092] The same arrangements and advantages are obtained, mutatis mutandis, for the second connector and its pipe clamp 3 ″.
[0093] It should be noted that the axial extensions may have different shapes: they may be a plurality of separate tabs distributed around the circumference, or a plurality of separate cylindrical wall portions distributed around the circumference.
[0094] Note that the first connector 1 defines a first hollow passage intended to be placed in fluid communication with the first space 71 . Similarly, the second connector defines a second hollow passage intended to be placed in fluid communication with the second space 72 (the inside of the second pipe in the example shown).
[0095] In another embodiment shown in FIG. 5 , the second connector 2 is not intended to receive a flexible pipe, but rather to be secured to a container 12 intended to hold biopharmaceutical fluid. The container can be generally defined as a flexible enclosure 12 formed by a second wall defining a second fluid space 72 .
[0096] A wide disc 28 equipped with a central hole is fixed by welding 29 to the wall 12 of the flexible enclosure. A tubular portion 20 extends from the wide disc 28 to the cylindrical body 18 comprising the stop surfaces 8 , collar 16 ′, and seal 13 ′.
[0097] In this embodiment, there is no second pipe clamp, and furthermore the axial length of the second connector 2 is shorter than the axial length of the first connector 1 . As a result, the protective cover 5 suitable for this application is asymmetrical relative to the mating plane P, the second tubular extension 52 being shorter than the first tubular extension 51 . However, the shape of the annular inner groove 55 is quite similar to what has been described above, as are the protection means for the pipe clamp 3 .
[0098] Note that FIG. 5 illustrates that it is possible to provide several different diameters of nozzles 9 , 9 ′ for one genderless coupling interface, which facilitates modularity and the creation of biopharmaceutical assemblies using various pipe diameters.
[0099] In a variant shown in FIG. 6 , the snap-fitting tabs 6 each comprise an axial extension 61 which extends the tab frontward, thereby forming an extra length projecting beyond the body of the opposing connector in the coupling position. All other characteristics are similar or identical to what has been described above. There is not necessarily a protective cover in this mode.
[0100] In the illustrated example, the axial longitudinal extension 61 of the snap-fitting tabs of the second connector 1 ′ extends significantly beyond the body 18 of the first connector, and therefore the end 62 of this extension is at a distance from the pipe, allowing the operator to manipulate the tab or tabs with his fingers.
[0101] In addition, these frontward axial extensions form protective elements for the pipe clamp 3 of the first connector, preventing a damaging edge of the clamp from coming into direct contact with an external element 90 .
[0102] As is apparent from FIG. 6 , in a symmetrical manner, the first connector 1 also comprises axial longitudinal extensions of the snap-fitting tabs so as to protect the second pipe clamp 3 ′. However, symmetry is not required because the axial extensions of the tabs are not directly implicated in the coupling compatibility of the genderless connectors.
[0103] In a variant shown in FIG. 7A , each of the first and second connectors is equipped with an aseptic sealing membrane prior to its coupling. A first membrane 73 is arranged on the front face of seal 13 , and similarly a second membrane 74 is arranged on the front face of seal 13 ′ of the second connector.
[0104] Note that in this embodiment, each of the connectors comprises only two snap-fitting tabs in order to leave enough room for installation and removal of the aseptic sealing membrane.
[0105] A primary clip-on position is defined, which can be considered an intermediate position in the present embodiment. In this primary clip-on position, the transverse portion 6 a of the snap-fitting tabs 6 is placed in abutment against the stop surfaces 8 , but the collars 16 , 16 ′ are not in contact with one another and are separated by a free space, each collar being, in this position, set slightly back from the interface plane P.
[0106] All other elements not described again here are assumed to be identical or similar to what was presented for the first embodiment.
[0107] In the initial connecting stage, the connectors 1 , 1 ′ are apart from each other and the fluid spaces 71 , 72 are isolated from each other and from the ambient air.
[0108] To perform the connection, first a primary coupling is made between the first and second connectors 1 , 1 ′, as described above, in a maneuver similar to that described for the first embodiment. FIG. 7B illustrates this primary coupling position where the aseptic membranes are sandwiched between the seals 13 , 13 ′ of the two connectors, which are exerting a certain axial pressure against one another.
[0109] Next, the aseptic sealing membranes 73 , 74 are removed by pulling them radially as illustrated by arrow R of FIG. 7B .
[0110] The two fluid spaces 71 , 72 have now been placed in communication without having been in contact with the ambient air.
[0111] For some applications, this represents a sufficient solution for a connection satisfying conditions of isolation and sterility with respect to ambient air.
[0112] Advantageously, when using a protective cover 5 such as the one presented above and as illustrated in FIG. 7C , the movement of closing the cover is utilized to exert an axial pressure. As the tapered shapes of the annular inner groove have a trapezoidal cross-section, closing the cover causes additional axial travel in the coupling to bring the collars 16 , 16 ′ closer together and thus increase the contact pressure between the two seals.
[0113] When a protective cover is used in this manner, the axial pressure of the primary coupling may be substantially reduced to facilitate removal of the aseptic sealing membranes.
[0114] In addition, an optional feature is provided that is compatible with all variants mentioned above: this is the integration of at least one identifier 60 , such as a barcode or electronic tag (for example RFID). Preferably, this identifier is provided on the first connector, and/or on the second connector, and/or on the protective cover as illustrated in FIG. 1 . The identifier could also be a colored dot or a color coding of the part itself.
[0115] Note that according to the invention, the number N of snap-fitting tabs may be any positive integer from 1 to ten. | Fluid-connection device for connecting a flexible pipe defining a first fluid space to a second flexible pipe or a flexible fluid enclosure in a biopharmaceutical assembly, includes a first connector and a second connector equivalent thereto, the first connector and second connector adapted to be coupled together in a genderless manner, by an insertion movement that is essentially an axial translation, into a relative coupling position, which defines a mating plane, each of the connectors including, in an alternating manner along the circumferential direction, N flexible snap-fitting tabs and N stop surfaces, the flexible snap-fitting tabs projecting axially forwards relative to the mating plane, and the stop surfaces being set back from the mating plane so that, in the coupling position, the snap-fitting tabs of one connector clip into place on the stop surfaces of the other connector, such that the resulting position is locked by the snap-fitting tabs. | 5 |
FIELD OF THE INVENTION
This application is a Continuation-In-Part application of U.S. patent application Ser. No. 08/002,785 filed on Jan. 8, 1993 and allowed May 15, 1994.
This invention relates to elastomeric flexible articles (e.g., film articles) that exhibit enhanced lubricity ("slip") with respect to both dry and damp surfaces, particularly skin or other tissue of the wearer, as compared to similar articles or films that are not treated as described herein. This invention also relates to processes for making such articles or films.
BACKGROUND OF THE INVENTION
Elastomeric surfaces of articles, in general, exhibit poor lubricity with respect to a dry surface, such as dry skin or other mammalian tissue. These properties are due to surface friction. Additionally, many elastomeric articles or surfaces display poor lubricity with respect to damp surfaces.
A high surface friction coefficient is useful for many applications such as tire treads, flooring and footwear. However, these same properties are a distinct disadvantage in many other applications and especially in those applications wherein an elastomeric surface must slide on another surface, such as in the donning of gloves over dry or damp skin. This is particularly important in the use of medical gloves, such as examination gloves and surgeon's gloves. These gloves are relatively close- fitting in order to provide sensitivity. Furthermore, most surgeons don their gloves after scrubbing up and without having fully dried their hands, so that areas of their hands may be dry while other areas may be distinctly damp. Consequently, the elastomeric materials useful in such applications must exhibit concurrently enhanced lubricity with respect to dry surfaces (dry slip), enhanced lubricity with respect to damp surfaces (damp slip), as well as the requisite mechanical properties (flexibility, strength, etc.).
Conventionally, dry slip is achieved by the use of powder lubricants such as magnesium carbonate, starch and talc. However, if the hands are damp, the use of a powder is counter-productive and may actually inhibit donning. Furthermore, in surgery, there is a risk of loose powder contaminating the surgical field. These materials can also cause irritation and may be allergenic.
Chlorination of rubber has also been proposed for the purpose of reducing tackiness and decreasing the coefficient of friction of rubber. (See Romberg, "Aqueous Chlorination of Natural Rubber Surfaces", A.C.S. Rubber Division, Spring Meeting (1986); T.C.Q. Noakes, Proc. Int. Rubb. Technol. Conf., Penang, Malaysia (1988); Natural Rubber Technical Information Sheet No. 17, The Malaysian Rubber Producers' Research Association, Latex Series (1977); D.C. Blackley, "High Polymer Lattices", Palmerton Publishing Company (1966), p. 548, and PCT/GB92/00171, published as WO 92 13497. However, chlorination can adversely affect the mechanical properties of flexible elastomeric articles such as rubber gloves and is better avoided for this reason. In addition, chlorination produces surfaces which have very poor damp slip.
Polymeric lubricant coatings which are bonded to the tissue-contacting glove surface or are embedded in the rubber itself have been proposed for the purpose of reducing surface friction of rubber in, for example, U.S. Pat. Nos. 3,813,695; 3,856,561; 4,070,713; 4,143,109; and 4,302,852. U.S. Pat. No. 3,813,695, in particular, describes a laminated surgical glove having a flexible outer layer and a hydrophilic plastic (hydrogel polymer) inner layer. Other articles such as catheters and bathing caps coated with hydrophilic polymers are described in U.S. Pat. Nos. 3,326,742; 3,585,103; 3,607,433; 3,745,042; 3,901,755; 3,925,138; 3,930,076; 3,940,533; 3,966,530; 4,024,317; 4,110,495; and 4,125,477 as well as British Patent Publication Nos. 1028446 and 859297.
James et al., U.S. Pat. Nos. 4,499,154 and 4,575,476, describe treating a rubber article having a coating of a lubricated hydrogel polymer (inherently providing dry slip) bonded layer, with a surfactant material, such as a quaternary ammonium cationic surfactant, or a long chain fatty amine material to improve the lubricity of the coating with respect to damp skin.
U.S. Pat. Nos. 4,143,109 and 4,070,713, and British Patent 1,541,155, propose the use on the skin-contacting surface of an elastomeric medical glove of a second layer of elastomeric material bearing partially-embedded particulate matter (cross-linked starch particles or polyethylene, or ethylene-vinyl acetate copolymer particles 5-40 microns in size). The elastomeric material forming the second layer is said to adhere to both the particles and the elastomeric glove substrate. Carboxylated styrene-butadiene latex, brominated butyl rubber and styrene-polyethylene/butylene-styrene block copolymer are disclosed as specific elastomeric materials suitable for use in forming the particle-bearing layer. The patents state that (i) the elastomeric substrate can be 125-175 microns thick; (ii) the inner layer can be 5-30 microns thick; and (iii) the particle size should be greater than the thickness of the second layer. In all the examples, however, the layer is 15 microns thick, i.e. 10% of the thickness of the laminated glove and 37.5-300% of the thickness of the particles. The resulting gloves are said to be donned easily without the use of additional lubricants, such as dusting powder. The particles described all appear to be organic, solid, essentially nonporous particles. Moreover, as far as the present inventors know, the gloves described in these patents have never been commercialized despite a felt need in the art for powder-free gloves.
European Patent Application EP 543,657 published May 26, 1993 discloses powder-free elastomeric medical gloves comprising a layer of an antiblocking composition (serving as a binder) with particles distributed throughout. The majority of the particles must have a size greater than the thickness of the antiblocking composition in the layer. The antiblocking composition should have mechanical properties comparable to those of the elastomer substrate. Polyurethane aqueous dispersion is said to be preferred as the binder. The particles can be cross-linked corn starch, nylon, polyurethane or mixtures and should be of a size range between 5 and 50 μm with an average size between 30 and 40 μm. This EP application does not disclose nor suggest the requirement that specific properties of the particles or the binder be present or have values within specified ranges that would result in good dry and wet slip as well as good adhesion to the substrate.
It has now been discovered that the dry slip and the damp slip properties of elastomeric articles can be improved substantially by providing on the wearer-contacting surface of these articles a thin layer of an adhering binder material bearing porous, absorbent microparticles and subsequently applying a surfactant or a long chain fatty amine. Under a scanning electron microscope the microparticles appear to be coated by the binder even though they are partially protruding therefrom to give a microroughened (globular reticulated) appearance to the coating, as depicted for example in FIG. 1.
SUMMARY OF THE INVENTION
Disclosed are flexible elastomeric articles displaying slip properties with respect to damp and dry mammalian tissue comprising on their wearer-contacting surface a thin coating of an adherent binder material compatible with the elastomer, the binder being bonded to said surface and appearing to envelop preferably substantially nonaggregated microparticles. The particles are randomly distributed on the wearer-contacting surface and appear coated with the binder, preferably they protrude partially from the binder surface and give the coating a substantially microroughened appearance. The coated article is then treated with a surfactant or a long-chain fatty amine.
Suitable particles include those having a mean size within the range of 4-20 (and preferably 5-13) microns, an oil absorption higher than about 80 g of oil per 100 g of microparticles and preferably a binder:particle weight ratio greater than 1:1. The coating constitutes preferably no more than about 5% of the thickness of the article.
Preferred materials include polyurethane or natural rubber as the substrate elastomer for the article. Suitable binders have a glass-transition temperature within the range from about -60° to about +30° C. Preferred binders comprise at least one of a vinyl acetate-ethylene copolymer, a vinyl acetate-ethylene acrylate copolymer, a vinyl acetate-ethylene-vinyl chloride terpolymer or a polyurethane (which may be the same as or different from the substrate). Preferred microparticles are silica, polyamide or cellulose triacetate particles having a size within the range of about 5 to about 13 microns and a relatively narrow size distribution. Preferably, the particles have a substantially regular shape without sharp angles or edges and are in substantially nonaggregated form (e.g., are primary particles of a near-spherical shape). Preferred surfactants are amphoteric and cationic surfactants.
The elastomeric flexible articles include, without limitation, surgical and examination gloves.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is further described by the following figures, which are intended to illustrate it without limiting its scope:
FIG. 1 is a photomicrograph taken through a scanning electron microscope (SEM) showing the microparticle-bearing binder layer of a preferred embodiment of the present invention. Noteworthy is that the coating has a substantially smooth yet microroughened appearance essentially free of sharp angles, cracks and craters.
FIG. 2 is the same type of photomicrograph as FIG. 1 wherein the binder layer contains microparticles of a different type and presents sharp angles.
FIG. 3 is the same type of photomicrograph as FIG. 1 containing microparticles of yet a different type and presenting a "cratered" surface.
FIG. 4 is the same type of photomicrograph as FIG. 1 showing a coating containing another type of microparticles and also presenting a cratered surface.
FIG. 5 is the same type of photomicrograph as FIG. 1 showing a binder layer containing corn starch microparticles according to the prior art. Noteworthy is the presence of cracks and disruptions throughout the surface.
FIG. 6 is the same type of photomicrograph as FIG. 1 showing a coating finish similar to that of FIG. 1 on a natural rubber substrate.
FIGS. 7 and 8 are the same type of photomicrograph as FIG. 1 and depict the substantially aggregated nature of precipitated silica particles FK 383 and HK125, respectively.
DETAILED DESCRIPTION OF TEE INVENTION
The invention envisages flexible elastomeric articles including those adapted for use in partial or total contact with mammalian tissue, such as surgical, examination and dental gloves, condoms, bandages, catheters, ureters, sheaths, and sheath-type incontinence devices and other film articles. Furthermore, the damp/dry slip-conferring materials may be provided on one or more surfaces of the article including, but not limited to, an inner and/or an outer surface relative to the wearer, as appropriate under the circumstances of the use of each article.
For purposes of this description, the outer surface of an article and, in particular, a glove, is defined as that surface which becomes an external surface of the glove in the position of actual use when worn. The inner surface is defined as that surface which is adjacent to the skin of the wearer when worn. The reverse is true in the case of a catheter or ureter: the outer surface is the surface in contact with the wearer's tissue. To avoid ambiguity, the term "wearer-contacting" surface will be used herein. "Tissue" includes skin or epithelia without limitation.
In the present invention, the substrate elastomer of the elastomeric flexible articles may be a natural or synthetic rubber. Without limitation, examples of synthetic rubbers are polyurethane, polyacrylate, polybutylene, and silicone rubbers and block copolymers of monomers such as styrene and butadiene. Polyurethane and natural rubber are preferred, with polyurethane being most preferred. Typical thicknesses of the elastomer substrate for surgical gloves are within the range 30 to 200 microns, without limitation, with 100-150 microns being preferred.
The material used for the binder should have good adhesion to both the elastomeric substrate and to the microparticles and should preferably not adversely affect the mechanical properties of the article. Moreover, the binder layer should be resistant to the conditions of article manufacture and use. Clearly, the choice of the binder will depend, in substantial measure, on the nature of the substrate elastomer and of the microparticles. We have found, however, that by limiting the thickness of the coating relative to the thickness of the substrate and using correspondingly small, porous, absorbent microparticles, a variety of binder materials can be used. Although it is possible to obtain adequate dry-slip properties using a thicker coating and/or one that shows poor adhesion to the substrate (as deduced, for example, by the presence of a multitude of microscopic cracks in the surface--see FIG. 5), this is not desirable because such a coating shows a tendency to break up to some extent on deformation of the article (such as is incident to normal use, e.g., during donning in the case of a glove) and therefore suffers from the same disadvantages as use of powder lubricants.
When the substrate is a polyurethane and the microparticles are silica (which are preferred), the glass transition temperature of the binder polymer should be in the range of about -60° to about +30° C., preferably between about -5° and about +15° C. Preferred binder materials for a polyurethane substrate include polyurethanes, as well as copolymers and terpolymers of vinyl acetate (e.g., with ethylene, with ethylene acrylate, with ethylene and vinyl chloride, etc.).
When the substrate is natural rubber and the microparticles are silica, the glass transition temperature of the binder polymer should be in the range of about -60° to about +30° C., preferably between about -15° and about +5° C. Preferred binder materials for a natural rubber substrate include copolymers and terpolymers of vinyl acetate (e.g., with ethylene, with ethylene acrylate, with ethylene and vinyl chloride, etc.).
Preferably, the microparticles are absorbent, substantially nonaggregated microspheres, preferably made of silica (or alternatively of polyamide or cellulose triacetate) having a mean size within the range from about 4 to about 20 microns (preferably with at least about 55% and most preferably at least about 60% of the particles being within the above size range). Particle size was measured on a weight percent basis (Coulter Counter, Industrial D Model) and/or on a volume percent basis (Malvern Master Sizer Model E, Malvern Ltd.).
It is further preferred that at least about 30% of the particles are within the 5-13 micron range. (Percentage distribution in the foregoing sentence is on a volume percent basis.) Obviously, the narrower the size distribution the better. Also, a unimodal distribution is preferred.
As revealed by scanning electron micrographs, the particles appear to be enveloped by the binder and the binder-plus-particle (i.e. the coating) thickness should preferably not exceed about 5% of the substrate thickness, and most preferably should not exceed about 2-3% of the substrate thickness.
Microparticle porosity can be conveniently measured in terms of oil absorption (e.g., DIN ISO 787/V). Microparticles having oil absorption values higher than about 80 g/100 g (and preferably higher than about 180 g/100 g) and being substantially smooth (e.g., approximately spherical), in shape and substantially nonaggregated are suitable for the purpose of the invention, but those having oil absorption values higher than about 280 g/100 g are most preferred. Examples of preferred silicas are Syloid ED5 and Syloid ED80, supplied by W. R. Grace & Co. The pore volume should be preferably in the range 1 to 2 ml/g. By "substantially nonaggregated" we mean that at least a substantial majority of the particles are primary particles, not aggregates of smaller particles.
A binder:microparticle ratio sufficient to confer dry slip properties to a glove (or other article according to the invention) is for example within the range of greater than about 1:1 (preferably about 2:1) to about 5:1 by weight based on the binder composition. For medical gloves, a ratio of 3:1 is most preferred. It will be appreciated by those skilled in the art that this amount is subject to optimization for a particular article according to the invention. In other words, minimum and maximum binder:particle ratio is expected to vary somewhat (and the optimum binder:particle ratio is also expected to vary), depending on (i) the application to which the flexible elastomeric article is adapted and (ii) the composition of the elastomeric article. In light of the present disclosure, however, this is within the skill of the art.
The surfactant used to endow the wearer-contacting surface with damp slip may be any surfactant which is suitable for use on skin or other tissue and does not cause an allergic, irritant, or other undesirable reaction in said skin or other tissue. Thus, in principle, amphoteric, anionic, cationic, and nonionic surfactants, and long-chain fatty amines can be used, as taught for example in various patents and patent applications recited herein, the disclosure of which is incorporated by reference in its entirety as if it were physically present in the present specification. However, in general, nonionic surfactants are found to be less effective than the other types and are not recommended as a class (although individual members of this class may be quite effective). Anionic surfactants, namely, those comprising at least one lipophilic moiety such as an alkyl, aralkyl, aryl, or cycloalkyl group containing 8 to 18 carbon atoms, and a hydrophilic moiety such as a carboxylic, phosphoric, sulfonic, sulfuric, or other acid group or salt thereof, generally provide adequate damp slip properties but such surfactants are not preferred as a class because they show a marked tendency to cause irritation to skin and tissue at concentrations effective to provide damp slip.
Suitable cationic surfactants include those comprising at least one lipophilic moiety such as an alkyl, aralkyl, aryl, or cycloalkyl group containing 6 to 18 carbon atoms, and a hydrophilic moiety such as a substituted ammonium group (for example, a tetra-alkylammonium, pyridinium, or like group). The counter-ion present should be compatible with the tissue of the wearer; it could be, for example, chloride or other halide.
Preferred cationic surfactants are quaternary ammonium compounds having at least one C 8 -C 18 hydrocarbyl (alkyl, aryl, aralkyl or cycloalkyl) group; a preferred hydrocarbyl group is a hexadecyl group. The hydrocarbyl group may be attached to a quaternary nitrogen atom which is part of a heterocyclic ring (such as a pyridine, morpholine, or imidazoline ring).
Most preferred cationic surfactants are benzalkonium chlorides, hexadecyltrimethylammonium chloride, hexadecylpyridinium chloride, dodecylpyridinium chloride, the corresponding bromides, and a hydroxyethylheptadecylimidazolium halide.
Suitable amphoteric surfactants include: betaines and sulteines containing at least one C 6 -C 8 hydrocarbyl group. Other types of suitable surfactants are amine oxides, sulfosuccinates and isothionates containing at least one C 6 -C 18 hydrocarbyl group. Amphoteric surfactants are preferred because they generally have a low skin irritancy potential.
Mixtures of surfactants may also be used.
A particularly preferred surfactant is hexadecyl pyridinium chloride, other particularly preferred surfactants are coconut alkyldimethylammonium betaine and coco aminopropyl betaine, all of which are commercially available.
In a preferred embodiment, the surfactant is bacteriocidal or bacteriostatic. The use of such a surfactant serves to inhibit bacterial growth when the layer formed on the coating is in contact with the skin or tissue of the wearer. This is especially an advantage for surgeon's gloves because they are sometimes punctured during surgical procedures, and any bacteria which may have grown on a surgeon's skin since commencement of the operation may be released into the surgical field.
When a neutral fatty amine is used, a C 6 -C 18 hydrocarbyl group, such as a hexadecyl group, is preferably attached to the nitrogen atom. Such an amine is N-N-dimethylhexadecylamine.
The coating of surfactant or long chain fatty amine need not coat the wearer-contacting surface completely. It is only necessary that enough surfactant or long-chain amine is applied to enhance damp slip. It is preferred, to the extent that it is practicable, to keep the surfactant on the wearer-contacting surface, in the case of medical or dental gloves, in order to ensure that maximum grip is maintained on the outer surface. The surfactant can be applied as an aqueous solution containing from about 0.2 to about 2% surfactant. The article can be dipped in such solution or the solution can be sprayed or painted on it, preferably before it is removed from the former. Alternatively, the surfactant can be applied after the article is stripped from the former.
The process for applying the particle-containing coating to the wearer-contacting surface of the elastomeric substrate depends, in part, on the nature of the substrate and on whether the glove or other article is formed by dipping a former into a elastomeric polymer latex or into a solution of the elastomeric polymer in a suitable solvent. Methods for making the elastomeric substrate articles of the present invention are well-known in the art.
Where the article is formed from compounded natural rubber latex, the deposit on the former is beaded and leached in the normal way and may then be partially or fully dried but not fully vulcanized. It is envisaged that the coating will normally be applied by subsequently dipping the deposit on the former into an aqueous suspension of the coating material, i.e., the binder and microparticles. The deposit and coating may then be heated to dry them and to complete vulcanization of the rubber.
In some cases, it may be advantageous to spray or paint a suspension or solution of the coating material on to the deposit on the former. Where spraying is used, it may be convenient to spray the rubber deposit first with a suspension or solution of the binder, dry the deposit, spray with a suspension of the microparticles, dry again, and spray once more with the binder and carrier, followed by final drying and vulcanization.
Other substrate polymers in dispersed, e.g. latex, form, including polyurethanes, may be treated similarly, although a vulcanizing step will not be needed in every case, as can be readily appreciated by those skilled in the art.
When the article is formed by dipping from a polymer in solution, for example, a polyurethane in tetrahydrofuran, the deposit on the former is partially freed from solvent by heating and is then dipped into an aqueous suspension of the coating material and dried in the manner already described. In this case, also, the coating may be applied by spraying or painting, rather than dipping.
It is understood that various optional ingredients may be incorporated in these articles as apparent to those skilled in the art. For example, where the article is a glove an antiblock agent may be used which would facilitate donning and use. The antiblock agent is preferably a low-melting wax (mp. from about 100° C. to about 150° C.) such as polyethylene wax added as an aqueous emulsion (e.g., 1-2%) to the coating mixture. The particle size of the wax should be preferably less than 1 μm to avoid interference with the surface morphology.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following examples, which illustrate the invention without limiting its scope, the following product designations are used:
FK383 precipitated silica (Trade Mark of Degussa Ltd.)
Sipernat 50S precipitated silica (Trade Mark of Degussa Ltd.)
Silosiv A10 zeolite (Trade Mark of W. R. Grace & Co.)
Syloid AL1 silica (Trade Mark of W. R. Grace & Co.)
Syloid ED2 silica (Trade Mark of W. R. Grace & Co.)
Syloid ED5 silica (Trade Mark of W. R. Grace a Co.)
Syloid ED80 silica (Trade Mark of W. R. Grace & Co.)
Syloid 622 silica (Trade Mark of W. R. Grace & Co.)
Vinamul 3692 vinyl acetate/ethylene acrylate copolymer (Trade Mark of Vinamul Ltd. Carshalton, Surrey, England).
Vinamul 3231 vinyl acetate/ethylene copolymer (Trade Mark of Vinamul Ltd.)
Vinamul 3452 vinyl acetate/ethylene/vinyl chloride terpolymer (Trade Mark of Vinamul Ltd.)
Vinamul 3459 vinyl acetate/ethylene/vinyl chloride terpolymer (Trade Mark of Vinamul Ltd.)
Estane 5707 polyurethane (Trademark of B. F. Goodrich Inc.)
Witcobond 787 polyurethane aqueous emulsion (Trademark of Witco Chemical Corporation, New York, N.Y.)
21P40 carboxylated styrene butadiene rubber (Trademark of Doverstrand Ltd., Harlow, Essex, England)
Dehyton AB30 amphoteric surfactant (coconut alkyldimethylammonium betaine, Trade Mark of Henkel Ltd.)
Cross-linked corn starch was from Tunnel Refineries, Greenwich, London, U.K.
Non Cross-linked corn starch was from Biosorb, Arbrook/Ethicon, U.K.
Aquaslip 655 or 671 polyethylene emulsion (Capricorn Chemicals, Ely, Cambridgeshire, U.K.)
HK 125/400 (Degussa)
Dehydol TA 20, nonionic surfactant (Henkel Ltd.)
Witcobond 769 Aqueous Polyurethane (Witco)
Doverstrand 76D41, self-crosslinked styrene butadiene latex (Doverstrand)
Kraton D1117 styrene-isoprene-styrene block co-polymer (Shell Chemicals, U.K.)
0.5% Solid wax (A671)
DC 193 silicone surfactants (Dow Corning, Reading, U.K.)
Microthene FN510 Polyethylene powder (Croxton and Garry, Dorking U.K.)
Microthene FE 532 ethylenevinylacetate powder (Croxton and Garry, Dorking U.K.)
Orgasol 2002 UD Polyamide powder (Atochem, Newbury, U.K.)
Orgasol 2002 EXD Polyamide powder (Atochem, Newbury, U.K.)
TA25 Cellulose triacetate (Presperse Inc., South Plainfield, N.J., U.S.A.)
Beetle 9040 aqueous polyurethane (BIP Chemicals Ltd., Oldbury, U.K.)
Laurapal X1207 non-ionic Surfactant (Witco)
Antioxidant 2246 (2,2'-Methylenebis (4- methyl-6-t-butylphenol) (Anchor Chemical (U.K.) Ltd., Clayton, Manchester, U.K.)
The characteristics of finished films or articles were determined as follows:
Tensile strength, breaking elongation (EB), and stress at 100% strain (S100) were measured according to ASTMD412. Tear strength was measured on angle test pieces (ASTMD624).
Adhesion of the binder to the substrate and adhesion of the particles to the binder were assessed visually using a scanning electron microscope (magnification 1.5×10 2 to 2.5×10 3 ). The samples were evaluated visually based, respectively, on the presence and frequency of cracks in the coating and on "crater" formation in the coating (the latter indicating that particles had been dislodged and therefore did not adhere to the binder). They were then rated on an arbitrary scale from 1 to 5 with 1 signifying "excellent" and 3 signifying "barely acceptable."
Dry slip and damp slip were evaluated subjectively on a scale of 1 (excellent slip) to 5 (no slip--undonnable in the case of a glove) with 3 being "barely acceptable".
EXAMPLE 1
A film article (glove) was made by dipping a handshaped former into an 18% solution of a polyurethane in tetrahydrofuran (single dip process). While in the wet gel state (partially dried), and still on the former, the article was dipped into an aqueous coating solution containing 2.0% silica microparticles (Syloid ED5), 6.0% vinyl acetate/ethylene acrylate copolymer (Vinamul 3692; Tg +13° .), 0.1% xanthan gum, and 91.9% deionized water (all percentages being by weight). It was dried for 20 minutes at 100° C. While still on the former, the dried glove was dipped into a 0.75% aqueous solution of an amphoteric surfactant (Dehyton AB30) for 10 minutes. It was then stripped from the former and air-dried. The thickness of the coating in this Example was about 5 microns; the thickness of the binder alone was 4-5 microns.
The finished glove had tensile strength 60.3MPa and tear strength 60.1N/mm, compared with 62.9MPa and 59.6N/mm respectively, for a similarly prepared but uncoated glove. Its dry slip rating was 1 and its damp slip rating 2.5. Excellent adhesion of the coating to the polyurethane (as well as of the particles to the binder) was demonstrated by scanning electron microscopy which showed a microroughened surface containing no cracks of the coating, no free fragments, and no craters (FIG. 1).
EXAMPLES 2-6
Coated polyurethane gloves were prepared as in Example 1 except that the Vinamul 3692 was substituted by one of the binders shown in Table 1, which shows the dry slip rating and degree of adhesion achieved in each case.
TABLE 1______________________________________ADHESION OF VARIOUS BINDERS TO THEPOLYURETHANE SUBSTRATEExample TgNo. Binder (°C.) Adhesion______________________________________2 Vinamul 3231 0 13 Vinamul 3459 21 24 Vinamul 3452 30 35 Witcobond 787 -50 16 Estane 5707 about -40 1______________________________________
EXAMPLES 7-13
Coated polyurethane gloves were prepared as in Example 1 except that the Syloid ED5 was substituted by one of the microparticles listed in Table 2below. The dry slip ratings and degrees of adhesion achieved in each case are set forth in Table 2. The mean diameters in Table 2 were measured by Coulter counter and are based on weight percent; the oil absorption values were as specified by the manufacturer (except for Example 13). Compare Table 2A where mean diameters were also measured by Malvern (based on volume percent) and oil absorption values were determined by the inventor.
TABLE 2______________________________________EFFECT OF VARIOUS MICROPARTICLESON PROPERTIES OF POLYURETHANE GLOVES Oil Pore Adsorp-Ex. Particle Mean Volume tion DryNo. Type Diameter ml/g g/100 g Slip SEM______________________________________ 1 Syloid 5 μm 1.8 320 1 FIG. 1ED5 7 Syloid 8 μm 1.8 300 1ED80 8 Syloid 12 μm 1.2 180 1.5622 9 Syloid 2 μm 1.8 320 2.5ED210 FK383 1-2 μm N/A 220 3 FIG. 211 Syloid 8 μm 0.4 80 3 FIG. 3AL112 Sipernat 8 μm N/A 330 3.550S13 Corn 5-40 μm N/A 58 2-3 FIG. 4Starch(Cross-linked)______________________________________
As can be seen from Table 2, the particles in Examples 1, 7 and 8 performed most satisfactorily. Particles of Example 9 were too small. Particles of Example 10 were aggregated as seen in FIG. 7 (and consequently not of substantially smooth shape) and this may account for the highly angular appearance of the resulting coating (FIG. 2). In Example 11 the particles had insufficient oil absorption and yielded a coating with craters indicating dislodging of particles (FIG. 3). In Example 12, particle size range and distribution were broad (for example, particles as large as 50μm and as small as 1 μm were routinely seen on SEM and the proportion of 8μm particles was relatively small), and this accounts for the poor slip properties of the coating (see also Example 12A).
The corn starch particles in Example 13 also yielded a coating with craters indicating that the particles had become dislodged (FIG. 4). Their oil absorption was also poor.
EXAMPLE 14
Comparison Example
Coated polyurethane gloves were prepared as in Example 1 except that the aqueous coating dispersion contained 1.5% crosslinked corn starch, 7.5% 21P40, 0.005% xanthan gum, 0.6% casein, 0.4% zinc oxide, and 90.0% deionized water, (according to U.S. Pat. No. 4,143,109) and the dried glove was dipped into deionized water (no surfactant) for 10 minutes prior to stripping. The finished glove had satisfactory physical properties but its dry slip rating was 2-3. Adhesion of the coating to the substrate was poor, judged by its extensively cracked appearance (FIG. 5) and the fact that much of the coating had become detached during the water treatment prior to stripping. The finished glove had the appearance and feel of a powdered glove.
EXAMPLES 15-16
A glove was made from high-ammonia natural rubber latex by a procedure known to those skilled in the art and involving the steps of dipping a hand-shaped former into an aqueous coagulant, air-drying, and dipping into the latex. The wet gel deposit was then dipped into one of the coating dispersions described in Examples 1 and 2. It was then dried and vulcanized by heating for 1/2 hour at 120° C. The properties of the finished gloves are described in Table 3.
TABLE 3______________________________________EFFECT OF VARIOUS COATINGS ONTHE PROPERTIES OF NATURAL RUBBER GLOVES Coating ofExample No. Example No. Dry Slip Adhesion______________________________________15 1 2 316 2 2 1______________________________________
As can be seen from the above Table, softer binders (i.e. binders with lower Tg) are needed to accomplish the same adhesion when a natural rubber substrate is used. FIG. 6 illustrates the adhesion and appearance of a glove according to Ex. 16. It can be seen that the finish is equivalent to that of Example 1. However, much harder binders are perfectly acceptable on polyurethane substrates: see below. Adhesion was measured as described above with 1 being excellent and 5 being the worst.
EXAMPLE 17
Comparison Example
A glove was made from natural rubber latex by the method described in Examples 15-16 except that the coating was that of Example 14 (U.S. Pat. No. 4,143,109). The adhesion of this coating in the finished glove was marginally better (rated 4.5) than that of Example 14 but the slip properties and appearance were the same.
EXAMPLE 18
Aqueous Phase
A glove was made from a polyurethane emulsion (Witcobond 787) by the general method described in Examples 15 and 16, dipping the wet gel into the coating dispersion described in Example 1. The adhesion of the coating was rated 1 and dry slip was rated 1.
EXAMPLES 1A, 7A, 8A-13A AND 19
The procedures of Examples 1 and 8-13 were repeated except as specified below:
Mean diameter was measured both as a weight percentage basis and on a volume percentage basis. In addition, the particle distribution was measured, using the Malvern apparatus. Finally, precipitated silica particles HK 125/400 were added to the materials tested. This material was tested by the procedure of Example 1 except that the coating contained 1.5% HK 125/400; 2.0% Aquaslip 671 polyethylene emulsion containing 40% solids 4.5% V3692 (50% solids), 0.2% xanthan gum; about 1% Dehydol TA 20 (20% solids) in 8 liters of deionized water. This material gave good adhesion (2) to the polyurethane substrate.
The results are set forth in Table 2A. The mean diameters (weight basis) are reproduced from Table 2. The mean diameters (volume basis) are the values preferred by the inventor and are consistent with the results obtained.
In a separate experiment, Syloid 622 produced good adhesion and a dry slip of "1" on a natural rubber substrate. The foregoing results yield the following conclusions:
Oil absorption should be fairly high (at least over 80/100 and preferably over 100/100). A narrow particle size distribution is preferred, the narrower the better. More important than the distribution is the use of nonaggregated particles which is a preferred feature of the invention: FK 383 and HK 125/400 are both aggregated particles made up of smaller (10-30 nm) primary particles as shown in FIGS. 7 and 8 respectively (compare with FIG. 1 which shows Syloid ED5 in the coating).
Stability of the dispersion in the binder is also a factor, as illustrated in Example 21 below.
TABLE 2A__________________________________________________________________________EFFECT OF VARIOUS MICROPARTICLES ON PROPERTIES OF POLYURETHANE GLOVES Mean Particle Diameter (microns) and Distribution (Volume %) Dry Measured Measured in in SlipParticle by by 4-20 5-13 Oil Pore onExampleDesigna- Manufac- Coulter Malvern micron micron Absorp- Volume Poly-Numbertion turer (wt. %) (vol. %) range range tion (ml/g) urethane__________________________________________________________________________ 1A Syloid ED5 Grace 5μ 8.8μ 87% 61% 308 1.8 1 7A Syloid Grace 8 11.1 75 45 300 1.8 1ED80 8A Syloid 622 Grace 12 12.8 59 33 180 1.2 1.5 9A Syloid ED2 Grace 2 4.2 54 26 320 1.8 2.510A FK 383 Degussa 1-2 7.6 57 37 230 N/A 311A Syloid AL1 Grace 8 N/A N/A N/A 80 0.4 312A Sipernat Degussa 8 19.8 47 26 326 N/A 3.550S13A Corn Biosorb 5-40 14.4 75 28 58 N/A 2-3Starch(non-cross-linked)19 HK 125/400 Degussa N/A 9.6 85 55 220 N/A 2__________________________________________________________________________
EXAMPLE 20
EFFECT OF DIFFERENT SUBSTRATES
Three alternative substrates to natural rubber and polyurethane were tested with a particularly preferred coating for adhesion and dry slip: Witcobond 769 Aqueous Polyurethane; Doverstrand 76D41 self cross-linking styrene-butadiene latex; and Shell Kraton D1117 styrene-isoprene-styrene block co-polymer in tetrahydrofuran.
These materials were cast onto glass plates using a K bar and partially dried (15-30 mins at 70° C.). The films, whilst still firmly adhered to the glass plate, were then dipped into the following coating formulation:
0.5% Solid wax (A671)
1.5% Silica (EDS)
4.0% Solid binder (V3692)
0.25% Xanthan Gum
1.0% Solid Dehydol TA 20
0.9% DC 193 silicone surfactants
The coated films were then dried for 30 min at 100° C. The films were stripped from the plate with the aid of water and coating quality/adhesion was assessed visually. The results are in Table 4.
TABLE 4______________________________________EFFECT OF DIFFERING SUBSTRATESON COATING ADHESION/SLIP Adhesion Dry Slip______________________________________Witcobond 769 Good 1Doverstrand 76D41 Good 1Kraton D1117 Good 1______________________________________
As can be seen all performed well and would be suitable as alternative substrates. Adhesion testing was visual and a "good" rating roughly corresponds to 2 in Table 1. Coating quality and dry slip properties were similar to those obtained on polyurethane.
EXAMPLE 21
FURTHER PARTICLE EVALUATION
The following additional particles were tested for oil absorption as described. The results are summarized in Table 5:
TABLE 5______________________________________OIL ABSORPTION OF VARIOUS PARTICLESParticle Oil Absorption g/100 g______________________________________Non-crosslinked Corn Starch 40Microthene (FN510) 50Microthene FE 532 51Magnesium oxide 140Aluminum oxide 34Orgasol 2002 UD 120Orgasol 2002 EXD 100Celluflow TA25 115______________________________________
The particles with high oil absorption values were then assessed for mean size (% volume) and proportion (% volume) between 3 and 20 μm, and between 4 and 12 μm. The results are in Table 6.
TABLE 6______________________________________Particle Size Distribution Data AsMeasured by Malvern Instruments Mean Proportion Particle between Proportion Size 3 and between SpanParticle μm 20 μm (%) 4-12 μm (%) *______________________________________Magnesium 4.9 76 55 1.68oxideAluminum 4.6 69 50 2.04oxidePolyamide 4.8 74 50 1.68powder(Orgasol2002 UD)Polyamide 10.2 78 58 1.86powder(Orgasol2002 EXD)Cellulose 12.2 78 38 1.53triacetate(TA25)______________________________________ *Span is an arbitrary measure shown on the Malvern printouts which gives an indication to the breadth of particle size distribution. For wide distributions the number is large and conversely for small distributions the number is small.
The particles with appropriate mean size and oil absorption were further evaluated as follows:
a)
13 g Magnesium oxide dispersed in 400 g deionized water using a paddle stirrer.
2 g Xanthan gum dispersed in 400 g deionized water using a Silverson mixer.
These mixtures were then blended together by gentle stirring. To this dispersion was added 78 g of Vinamul V3692 (binder) and this dispersion was stirred thoroughly. The formulation was made up to 1L using deionized water. This dispersion was then consigned to a measuring cylinder ready for dipping. Dispersion stability was checked visually immediately after formulation and then again 24 hrs later.
This formulation process was repeated with the following powders and with the following exceptions:
Magnesium Oxide. Ammoniated water and Beetle 9040 (binder) were used to increase pH to match the pH of MgO in dispersion.
Aluminum Oxide
Cellulose triacetate (TA25) 2 g of Laurapal X1207 added to aid with dispersion of powder in deionized water. Silverson mixer used.
Polyamide (Orgasol 2002 UD): 2 g of Laurapal X1207 added to aid dispersion of powder in deionized water. V3231 binder used since the dispersion was intended for use with natural rubber latex. Silverson mixer used.
All of these dispersions were dipped on to `wet gel` thermoplastic polyurethane as in Example 1. However, condom formers were used and for the final example (Orgasol 2002 EXD) the substrate used was natural rubber latex--again in a wet gel state. The condoms were then processed as per the gloves in Example 1.
The resultant condoms were assessed visually for adhesion of coating to substrate, surface-to-surface dry slip, and dry slip against the skin.
The results are described in Table 7:
TABLE 7__________________________________________________________________________STABILITY OF DISPERSIONS AND COATING CHARACTERISTICS STABILITY ADHESION TO SLIPFORMULATION 0 HRS 24 HRS SUBSTRATE PROPERTIES `FEEL`__________________________________________________________________________Magnesium oxide Flocculated Flocculated Generally good but Acceptable (2.5) VeryMagnesium oxide Flocculated Flocculated poorer in granular,(high ph) aggregated areas grainyAluminum O.K. Settling Poor Inconsistent: Feelsoxide wetting some drag. powdery Barely acceptable (3)Orgasol O.K. O.K. Excellent Excellent (1) Similar to2002 UD ED5 system but slightly smoother2002 EXD/V3231 O.K. O.K. Excellent Excellent (1) As 2002 UDon naturalrubberTA25 O.K. O.K. Good/ Excellent (1) Slightly excellent paperyEx. 22 (1) O.K. Settled Coverage very Poor and Very granular patchy. Flakes off, `draggy` (4) and distinct- particularly ly rough when wetEx. 22 (2) O.K. Settled Better coverage Poor (3-4) very than Ex. 22 (2) but granular can be easily and rough abraded.__________________________________________________________________________
The best performances in terms of adhesion and slip properties were those of polyamide powders and cellulose triacetate. Magnesium and aluminum oxide showed poor dispersion stability which probably accounts for the poor properties of coatings containing them.
EXAMPLE 22
COMPARATIVE EXAMPLE
In addition, as comparative examples the following glove coating formulations and gloves were made:
______________________________________(1) First Comparative Formulation (U.S. Pat. No. 4,143,109)______________________________________300 g Kraton G 1650 (SEBS) 30 g Pale crepe grade of natural rubber300 g White mineral oil6600 g Toluene300 g Crosslinked corn starch7530 g Total (represents approx 1:1 particle:binder ratio)______________________________________
The Kraton G was dispersed in 2200 g of Toluene using a paddle stirrer. This process was repeated with the crepe rubber and the starch. The three mixtures were then blended together in a 8-L dipping pot. The dispersion was covered and left to stand overnight before dipping commenced. The dispersion was stirred vigorously immediately before dipping.
______________________________________(2) Second Comparative Formulation (U.S. Pat. No. 4,143,109)______________________________________300 g Brominated butyl rubber (solid)10.5 g Stearic acid3.75 g Antioxidant 2246 (2,2'-Methylene bis (-4 methyl-6-t-butyl phenol)15.0 g Paraffin wax75.0 g Finely divided talc6.0 g Petroleum jelly6.0 Titanium dioxide15.0 g Zinc oxide3.0 g Zinc dimethyldithiocarbamate375 g Microthene FN 510 polyethylene7500 g Hexane8309.25 g Total (represents approx. 1:1 particle:binder ratio)______________________________________
The brominated butyl rubber latex was dried down to form brominated butyl rubber and subsequently cut into very small pieces before dissolution in 2000 g of hexane. To this solution were added petroleum jelly and paraffin wax. A clear solution without lumps or gels was formed. The remaining ingredients (except the Microthene) were dispersed in 200 g of hexane then blended into the solution. After further stirring Microthene beads were dispersed into the remaining hexane before being blended with the bulk solution. After a further period of stirring the dispersion was placed in an appropriate dip pot and covered. The dispersion was left to stand before dipping commenced; however the dispersion was stirred immediately prior to dipping.
Both comparative materials were examined for dispersion stability immediately and 24 hrs after mixing. These dispersions were applied to glove formers coated with a thermoplastic polyester polyurethane. The polyester polyurethane had been dried for 30 mins at ambient temperature after dipping from an approximate 18% solution in tetrahydrofuran. The gloves were subsequently dried at 100° C. for 30 mins before hydration and stripping. The gloves were then visually examined and donned to assess the slip qualities.
The results are also shown in Table 7.
Neither of the examples taken from U.S. Pat. No. 4,143,109 provided an acceptable slip coating. The particles were not well bonded to the substrate, probably because they did not absorb the binder adequately (low oil absorption). The surfaces they provided were granular and showed poor slip. This is ascribed to the relatively large size of the particles (described by the manufacture as having a mean diameter of about 20 micron). | This invention relates to elastomeric flexible articles (e.g., film articles) that exhibit enhanced lubricity ("slip") with respect to both dry and damp surfaces, particularly skin or other tissue of the wearer, as compared to similar articles or films that are not treated as described herein. This invention also relates to processes for making such articles or films. | 2 |
TECHNICAL FIELD
The disclosure relates to programmable graphics hardware. In particular, the disclosure relates to techniques for efficient debugging of software that runs on programmable graphics hardware.
BACKGROUND
A recent trend in the manipulating and displaying of real-time 3D graphics is the increasing use of programmable graphics hardware. Such hardware is characterized by the presence of multiple programmable hardware stages, known as “shaders,” arranged in a pipeline. In contrast with “fixed,” or non-programmable hardware, each hardware stage in a programmable hardware pipeline can be programmed to perform a desired computational function, allowing for increased flexibility in the design of graphics algorithms. Examples of shaders include geometry shaders, vertex shaders, and pixel shaders.
When designing and debugging shader programs, a programmer may find it useful to access and view the runtime values of a shader's internal register and ALU (arithmetic logic unit) variables. This may be difficult, however, as there is usually no mechanism by which a shader's internal values can be transferred to an external location accessible to the programmer, such as an external memory module.
One possible approach is to purposefully assign the value of an internal variable of interest to the color of an outgoing pixel, send this pixel to the pixel blender block, wait until the pixel is drawn on a screen, and then inspect the color of the drawn pixel. While this approach takes advantage of an already existing pathway inside the shader, it has several disadvantages. First, it would be easier for the programmer if the value of the internal variable were displayed in its native format (e.g., floating point, integer, etc.), rather than as the color of a pixel on a screen. Second, the internal graphics pipeline might not be able to deliver the value of the pixel color unmodified to the screen buffer, leading to a problem with precision. For example, the pixel color could be 32-bit floating point, while the screen buffer for a particular monitor might only support 8-bit integer precision. In this case, it may be impossible to ascertain the actual value of an internal shader variable based solely on pixel color. Third, the above technique may be very cumbersome for a vertex shader, since the vertex shader is usually followed by a fragment shader. In this case, the fragment shader would need to be replaced by a “dummy” pass-through shader so that the values generated within the vertex shader can be passed unmodified to a screen buffer.
What is needed is a debugging tool having a simple user interface that allows programmers to easily and reliably ascertain the values of internal shader variables during runtime in programmable graphics hardware.
SUMMARY
One aspect of the present disclosure provides a method for transferring graphics processor unit (GPU) data to a memory buffer, the method comprising determining a base address and a number of sleep cycles; counting a number of vertices or pixels processed to derive an offset; deriving a memory address based on the base address and said offset; checking if the entry corresponding to said memory address has been read; if the entry has been read, writing data to said memory address; and if the entry has not been read, waiting said number of sleep cycles before performing said checking again.
Another aspect of the present disclosure provides an apparatus comprising a counter for counting a number of vertices or pixels processed to derive an offset; and a processor configurable to determine a memory address based on a base address and said offset, the processor further configurable to verify that an entry corresponding to said memory address has been read before writing data to said memory address, the processor further configurable to wait a number of sleep cycles if it is determined that the entry has not been read.
Another aspect of the present disclosure provides a computer program product, comprising computer-readable medium comprising code for causing a computer to determine a base address and a number of sleep cycles; code for causing a computer to count a number of vertices or pixels processed to derive an offset; code for causing a computer to derive a memory address based on the base address and said offset; code for causing a computer to check if the entry corresponding to said memory address has been read; code for causing a computer to write data to said memory address if the entry has been read; and code for causing a computer to wait said number of sleep cycles if the entry has not been read.
Another aspect of the present disclosure provides a method for transferring a runtime variable of a graphics processing unit to a user, the method comprising compiling software code into instructions for the graphics processing unit, the software code comprising a log command specifying a variable name; transferring the value of a variable corresponding to said variable name from the graphics processing unit to an external memory according to a memory flow control protocol; retrieving the value of said variable from said external memory; formatting said retrieved value of said variable; displaying said formatted value of said variable to the user.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an embodiment of a programmable graphics hardware system.
FIG. 2 shows an embodiment in which a shader ALU, running hardware instructions derived from the software code written by user 112 in FIG. 1 , transfers values from internal ALU variables to an externally accessible memory buffer.
FIG. 3 shows an embodiment in which a software driver accesses the memory buffer entries written to by the shader ALUs.
DETAILED DESCRIPTION
Disclosed herein are tools and techniques for allowing programmers easier access to internal shader variables during runtime. These include techniques for transferring data from internal shader variables to an externally accessible memory buffer. Disclosed also are a structure and a protocol for handling the memory buffer to allow reliable buffered delivery of data from the shader ALU to a software driver.
FIG. 1 shows an embodiment of a programmable graphics hardware system. A programmable graphics hardware unit 100 can have several shaders 102 , 104 . In one embodiment, there can be a pixel shader and a fragment shader. In other embodiments, there may be more than two shaders. Each shader may include multiple internal ALUs 102 . 1 through 102 . n , each ALU processing multiple internal variables. For example, ALU 102 . 1 processes internal variables 102 . 1 a and 102 . 1 b . The ALU 102 . 1 may interface to an off-chip memory 106 via a bus 114 . The ALU 102 . 1 may be configured to read and write data to the memory 106 via the bus 114 .
Via the bus 114 , off-chip memory 106 is also accessible by a software driver 108 , which can read the data stored in memory 106 . The software driver 108 communicates with a user interface 110 , which is provided to a programmer or user 112 . The software driver 108 also communicates directly with programmable hardware 100 via the bus 114 .
In an embodiment, the user 112 programs software code through user interface 110 . The code defines the functionality to be performed by the shader 102 , and is written using commands as specified in a high-level shader language specification such as Open GL ES Shading Language. A compiler (not shown) compiles the code into low-level hardware instructions that can be supplied to the shader 102 via software driver 108 .
In an embodiment, the user 112 can embed special log commands into the software code which instruct the shader to output the values of specified internal shader variables during runtime to an externally accessible location for access by the user 112 . In an embodiment, the log command allows the user 112 to specify the name of the internal shader variable to be logged, the data type of the variable (e.g., whether the variable is 32-bit floating point or 8-bit integer), as well as a character string that can be used to attach descriptive information to the logged variable.
In an embodiment, the log command is called an “shprintf” function, and takes the following format:
void shprintf(char*label, int data_type, variable);
where “label” points to a character string which can be up to 3 characters long in an embodiment, and can describe the variable to be logged;
where “data_type” is an integer specifying one of the following data types: unsigned char (8-bit), signed char (8-bit), unsigned short (16-bit), signed short (16-bit), unsigned int (32-bit), signed int (32-bit), float16, float24, float32, or any other data type(s) that might be supported by the architecture;
and where “variable” refers to any attribute, varying or temporary, that exists in the shader.
FIG. 2 shows an embodiment in which a shader ALU, running hardware instructions derived from the software code written by user 112 in FIG. 1 , transfers values from internal ALU variables to an externally accessible memory buffer.
In step 200 , the ALU is initially provided with certain parameters relating to memory buffer access. In one embodiment, these parameters include the address of the buffer (BUF_ADDR), the length of a block (BLK_LEN) as measured in number of buffer entries, the total length of the buffer (BUF_LEN) as measured in buffer entries, and the number of cycles to sleep between attempts to write to the buffer (SLEEP_CYCLE_CNT). In one embodiment, these parameters may be automatically generated uniforms, i.e., run-time objects with the same global state, provided from the software driver to the shader. In one embodiment, the compiler automatically generates these uniforms when it detects the presence of the special log commands in the software code.
In an embodiment, each entry of the memory buffer array can hold a 64-bit word. In other embodiments, each entry can be 128 bits, 256 bits, or any other size. In one embodiment, the number of 64-bit words in the array is a power of two to simplify bit handling in the shader. In an embodiment, the software driver initializes the buffer to all zeroes. The buffer may be subdivided into equally-sized blocks. The size of the buffer and the size of blocks may be controlled at run-time by the software driver as described earlier. The collection of blocks can treated in a circular manner, i.e. the last block may be followed by the first block.
In an embodiment, each entry of the memory buffer array contains information on a dirty bit, a carriage return, a data type, a string label, and data contents. The dirty bit of an entry can indicate whether the contents of the entry have already been read out. The carriage return can indicate whether the corresponding variable is to be displayed in the same line as a subsequent variable. The data type can indicate the data type of the corresponding data contents for display formatting. The string label can identify the data contents. The data contents contain the actual value of the variable of interest.
In an embodiment, the bits of an entry can be allocated as follows:
Carriage
Dirty Bit
Return
Data Type
String label
Data Contents
1 bit
1 bit
6 bits
24 bits
32 bits
Subsequent to being provided the memory buffer access parameters in step 200 , the shader ALU can proceed to implement a flow control algorithm to make sure the shader memory accesses do not overtake the software driver memory accesses, as illustrated in steps 202 - 208 .
In step 202 , the ALU determines an address in the memory buffer to which data will be written. The address may be determined as an offset value from the parameter BUF_ADDR, and may be calculated by simply adding the offset to BUF_ADDR. The offset may be derived from a special counter register in the ALU 102 . 1 that tracks the number of vertices (or pixels, depending on the function of the shader) for which data has already been written to the memory buffer. This may be useful because a single ALU may process multiple vertices (or pixels) in parallel threads, and thus a call to shprintf for one variable may generate multiple instances of data corresponding to the multiple instances of that variable in the parallel threads. The vertex or pixel counter can provide a way to separate each instance of a variable within the memory buffer.
In an embodiment, the programmer can then determine which data in the memory corresponds to which vertex or pixel according to the following. For the vertex shader, the programmer can readily determine the order in which the vertices are processed by the shader, since the order in which vertices are sent to the shader is generally pre-determined by the application. For a pixel shader, however, the programmer might not know the order of pixels processed. In this case, if the programmer needs to know which pixel corresponds to which value stored in memory, the programmer can simply use the aforementioned log command to display the pixel data along with a field identifying the pixel, such as pixel position. For instance, in Open GL ES Shading Language, there are special variables that hold pixel position such as glFragCoord.x and glFragCoord.y.
The vertex or pixel counter could, for instance, be a 32-bit number that is initialized to zero at power up. In an embodiment, the value held by the counter is referred to as pixelCnt. In one embodiment, the offset value is calculated as pixelCnt & (BUF_LEN−1), where pixelCnt is the counter value referred to earlier, & is a logical AND operation, and BUF_LEN is the total length of the buffer in entries. Note that performing a logical AND operation on the value of BUF_LEN−1 allows circular addressing of the memory buffer up to BUF_LEN−1.
In step 204 , the shader ALU checks the dirty bit of the entry corresponding to the memory address to be written to. If the dirty bit is set, this means that the entry has not been processed, and so the shader ALU stalls. In an embodiment, the shader ALU stalls by entering a sleep state, during which execution of the shader program is halted for a period of time. At the end of SLEEP_CYCLE_CNT number of cycles, the shader ALU wakes up and checks the dirty bit again. If the dirty bit is cleared, this means that the entry has been processed, and the shader ALU can proceed to step 208 , where the shader ALU writes new data to that memory address.
In an embodiment, the steps depicted in FIG. 2 can be implemented using the following pseudo-code, wherein BUF_LEN and BLK_LEN are assumed to be powers of two:
offset = pixelCnt & (BUF_LEN−1);
if ( (offset & (BLK_LEN−1)) == 0) {
Dirty = LOAD ( BUF_ADDR + offset);
While (Dirty & 1) {
Sleep SLEEP_CYCLE_CNT;
Dirty = LOAD (BUF_ADDR + offset);
}
}
STORE (BUF_ADDR+offset, value)
In the pseudo-code, the function LOAD returns the bits of the entry corresponding to the memory address specified, and the function STORE writes a specified value to the corresponding memory address. The line “if ((offset & (BLK_LEN−1))===0)” in the pseudocode instructs the shader to perform the dirty-bit check on a per-block basis rather than on a per-entry basis, which may be useful as the LOAD operation for the check may tend to slow the process down. In an alternative embodiment, however, the check can also be performed on a per-entry basis.
FIG. 3 shows an embodiment in which a software driver accesses the memory buffer entries written to by a shader ALU in FIG. 2 .
In step 300 , the software driver initializes the memory buffer to all zeroes. In step 302 , the software driver instructs the ALU to log the desired data. In step 304 , the software driver checks the entry corresponding to the memory address written to determine if the dirty bit is set. If the bit is not set, this indicates that the memory address has not yet been written to, and the software driver will perform some other tasks 310 , and check back at a later time.
If the bit is set, then the algorithm proceeds to step 306 , where the software driver accesses the contents of the memory and streams the data to a user-accessible file. In an embodiment, the facility that saves the log file can be an on-board file system, network communication layer for transmitting the information to a server, etc. In one embodiment, the software driver also converts the data into an appropriate format based on the data type of the value. In step 308 , the software driver clears the dirty bit of the first entry of the block, indicating to the shader that that block of the memory buffer can be stored with new data.
The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
In one or more exemplary embodiments, the functions described may be implemented in hardware, software, firmware, or any combination thereof. If implemented in software, the functions may be stored on or transmitted over as one or more instructions or code on a computer-readable medium. Computer-readable media includes both computer storage media and communication media including any medium that facilitates transfer of a computer program from one place to another. A storage media may be any available media that can be accessed by a computer. By way of example, and not limitation, such computer-readable media can comprise RAM, ROM, EEPROM, CD-ROM or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other medium that can be used to carry or store desired program code in the form of instructions or data structures and that can be accessed by a computer. Also, any connection is properly termed a computer-readable medium. For example, if the software is transmitted from a website, server, or other remote source using a coaxial cable, fiber optic cable, twisted pair, digital subscriber line (DSL), or wireless technologies such as infrared, radio, and microwave, then the coaxial cable, fiber optic cable, twisted pair, DSL, or wireless technologies such as infrared, radio, and microwave are included in the definition of medium. Disk and disc, as used herein, includes compact disc (CD), laser disc, optical disc, digital versatile disc (DVD), floppy disk and blu-ray disc where disks usually reproduce data magnetically, while discs reproduce data optically with lasers. Combinations of the above should also be included within the scope of computer-readable media. | Methods and apparatuses for accessing data within programmable graphics hardware are provided. According to one aspect, a user inserts special log commands into a software program, which is compiled into instructions for the programmable graphics hardware to execute. The hardware writes data to an external memory during runtime according to a flow control protocol, and the software driver reads the data from the memory to display to the user. | 6 |
This application claims the benefit of U.S. Provisional Application Ser. No. 60/023,062, filed Jul. 30, 1996.
BACKGROUND OF THE INVENTION
The present invention relates to an improvement in the efficacy of herbicidal 2,6-substituted pyridines by combination with a selected second herbicidal compound. The term "2,6-substituted pyridines" is being used herein for such pyridine derivatives which may or may not contain further substituents.
The herbicidal 2,6-disubstituted pyridines to be used according to the present invention are a group of compounds, disclosed in European Patent Applications EP 0 572 093 A, EP 0 692 474 A, EP 0 693 490 and International Application WO 94/22833, which display excellent herbicidal performance, in particular against broad-leaved weeds in cereal crops. However, the 2,6-disubstituted pyridines, when used as the sole active ingredient, do not always achieve effective control of the full spectrum of weed species encountered in commercial agronomic applications, in conjunction with reliable selectivity for the crop species. Such gaps in the spectrum of control can be overcome by co-treatment with another herbicide known to be effective against the relevant weed species. The combined use of certain herbicidal pyridines and in addition other herbicides has been described in International Patent Application WO 94/07368.
Surprisingly, it has now been found, that the combined herbicidal activity of compounds from the above mentioned 2,6-disubstituted pyridines with various partners against many broad-leaved weeds and annual grasses is much greater than expected when applied pre- or post-emergence and that this activity cannot be ascribed to an additive effect, but to a remarkable degree of synergism on many broad-leaved weed species and annual grasses, for example on Setaria viridis, Alopecurus myosuroides, Poa annua, Stellaria media, Lamium purpureum, Galium aparine, Veronica hederaefolia, Papaver rhoeas or Matricaria inodora (i.e. these combinations show a much higher level of activity than predicted from that of the individual compounds) which enables also a greater selectivity for the crop species.
A mixture of herbicides shows synergistic effect if the herbicidal activity of the mixture is larger than the sum of activities of the seperately applied compounds. The expected herbicidal activity for a given mixture of two herbicides can be calculated as follows (See Colby, S. R., "Calculating synergistic and antagonistic response of herbicide combinations", Weeds 15, pp 20-22 (1967): ##EQU1## wherein X is the percentage of growth inhibition upon treatment with a herbicide 1 at a dose of p kg/ha compared with an untreated control (X=0%)
Y is the percentage of growth inhibition treatment with a herbicide 2 at a dose of q kg/ha compared with an untreated control
WE is the herbicidal effect to be expected upon treatment (% of growth inhibition compared with untreated control) with a combination of herbicide 1 and 2 at a dose of p+q g/ha, respectively.
If the actual weed control (W) exceeds the expected (calculated) weed control (WE), the mixture displays a synergistic effect.
SUMMARY OF THE INVENTION
The present invention incudes a herbicidal composition comprising a herbicidally acceptable carrier and/or surface active agent together with, as active ingredient, a mixture of:
(1) at least one herbicidal component selected from
a) urea-type herbicide, such as chlortoluron, isoproturon, linuron or neburon,
b) a triazine-type herbicide, such as atrazine, cyanazine or simazine,
c) a hydroxybenzonitrile herbicide, such as bromoxynil or ioxynil,
d) an aryloxyalkanoic acid herbicide, such as dichlorprop, 4-chloro-2-methylphenoxyacetic acid ("MCPA") or mecoprop,
e) a dinitroaniline herbicide, such as pendimethalin,
f) a sulfonylurea herbicide, such as amidosulfuron,
g) a pyridazine herbicide, such as pyridate,
h) a fluorene carboxylic acid herbicide, such as flurenol,
i) a pyridyloxyacetic acid herbicide, such as fluroxypyr,
j) a fenoxyfenoxypropionie acid herbicide, such as fenoxaprop, and
k) an oxyacetamide herbicide, and
(2) at least one compound selected from the compounds of general formulae I and II ##STR2## wherein A 1 and A 2 independently represent an aryl group, at least one of A 1 and A 2 being substituted by one or more of the same or different substituents selected from halogen atoms, alkyl groups, alkoxy groups, haloalkyl groups and haloalkoxy groups;
R 1 represents a hydrogen atom, or a cyano group, or an alkyl, alkoxy, alkylthio or haloalkyl group having from 1 to 4 carbon atoms, and
R 2 represents a hydrogen or halogen atom, provided that at least one of R 1 and R 2 represents a hydrogen atom;
n and m independently represent 0 or 1;
A 3 represents an optionally substituted 5 or 6 membered nitrogen containing heteroaromatic group;
A 4 represents an optionally substituted 5 or 6 membered cyclic hydrocarbon, alkyl, alkenyl, alkynyl, aryl or aralkyl group or independently one of the meanings for A 3 ;
R 3 represents a halogen atom or an alkyl, haloalkyl, alkoxy, alkylthio or dialkylamino group;
X represents an oxygen or sulfur atom;
p represents 0, 1 or 2.
The present invention also includes a method for controlling undesirable plant species comprising application of at least one compound of group (1) and at least one compound of group (2), as defined above. In the method of this invention, these compounds may be applied separately or together, in herbicidally effective amounts.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preferred embodiments of the composition and method of the present invention include those in which A 1 and/or A 2 are preferably phenyl, thienyl or pyrazol groups, independently substituted by one or more substituents selected from fluorine or chlorine atoms, or methyl, methoxy, trifluoromethyl or trifluoromethoxy groups.
Preferably, R 1 represents trifluoromethyl, methylthio or methyl and R 2 a hydrogen atom, or R 1 represents a hydrogen atom and R 2 is a hydrogen or chlorine atom.
Further preferred embodiments include those in which A 3 is suitably pyridyl or pyrazolyl, and A 4 pyridyl, pyrazolyl, phenyl or benzyl. A 3 and A 4 may be the same or different, and are preferably substituted, e.g. by halogen atoms, nitro, cyano, alkyl, alkoxy, alkylthio, aryl or haloalkyl groups wherein the alkyl moiety in each case preferably contains 1 to 6 carbon atoms.
Preferred compounds for use as 2,6-disubstituted pyridines according to the invention include the compounds of formulae III and IV: ##STR3## wherein A 2 represents an aryl, preferably a phenyl group which may be substituted by one or more of the same or different substituents selected from halogen atoms, C 1 -C 4 -alkyl, -alkoxy, -haloalkyl, -haloalkoxy groups, R 1 represents a hydrogen atom or a C 1 -C 4 -alkyl, -alkoxy, -alkylthio or -haloalkyl group, and m is 0, 1 or 2.
Particularly preferred are those compounds of formula III wherein R 1 is methyl, m is 1 and A 2 is phenyl or 4-fluorophenyl, and compounds of formula IV wherein R 1 is a hydrogen atom or a methyl group.
The pattern of persistence of the 2,6-substituted pyridine (abbreviated herein as "BAP") is such that the combined treatment according to the present invention can be attained either by the application of a prepared mixture as defined above, or by time separated application of separate formulations. Hence, in another preferred embodiment, the present invention provides a method for controlling the growth of weeds at a cereal crop locus which comprises applying to the locus a BAP as defined above and a second component which is selected from those listed above as group (1).
The treatment according to the invention may be used to control a broad spectrum of weed species in cereal crops, e.g., in wheat, barley, rice and maize, by pre- or post-emergence treatment, including both early and late post-emergence. The combined use decribed above offers both foliar and residual activity.
By the term "pre-emergence application" is meant application to the soil in which the weed seeds or seedlings are present before emergence of the weeds above the surface of the soil. By the term "post-emergence application" is meant application to the aerial or exposed portions of the weeds which have emerged above the surface of the soil. It will be appreciated that application according to the method may be from pre- to post-weed emergence, and from pre-crop emergence to post-crop emergence. By the term "foliar activity" is meant herbicidal activity obtained by application to the aerial or exposed portions of the weeds which have emerged above the surface of the soil. By the term "residual activity" is meant herbicidal activity obtained some time after application to the soil whereby seedlings present at the time of application or which germinate subsequent to application are controlled.
Weeds that may be controlled by the practice of the present invention include:
______________________________________Veronica persica Veronica hederaefolia Stellaria media Lamium purpureum Lamium amplexicaule Aphanes arvensis Galium aparine Alopecurus myosuroides Matricaria inodora Matricaria matricoides Anthemis arvensis Papaver rhoeas Poa annua Apera spica-venti Phalaris paradoxa Phalaris minor Avena fatua Lolium perenne Bromus sterilis Poa trivialis Spergula arvensis Cerastes holosteoides Arenaria seryllifolia Silene vulgaris Legousia hybrida Geranium dissectum Montia perfoliata Myosotis arvensis Chenopodium alba Polygonum aviculare Polygonum Polygonum convolvulus Galeopsis tetrahit lapathifolium Chrysantemum Centaurea cyanus Viola arvensis segetum Senecia vulgaris Cirsium arvense Fumaria officinalis Raphanus Agrostis stolonifera Atriplex patula raphanistrum Capsella Thlaspi arvense Portulaca oleracea bursa-pastoris Setaria viridis Eleusine indica Euphorbia helioscopia______________________________________
The application rate of the BAP component of this invention is usually in the range of 7.5 to 150 grams of active ingredient (g a.i.) per hectare, with rates between 7.5-100 g a.i./ha often achieving satisfactory control and selectivity. The optimal rate for a specific application will depend on the crop(s) under cultivation and the predominant species of infesting weed, and readily may be determined by established biological tests known to those skilled in the art.
The selection of the non-BAP active ingredient will likewise be dependent on the crop/weed situation to be treated, and will be readily identifiable by those skilled in this area. The application rate this active component is determined primarily by the chemical type of the component, since the intrinsic activity of different types of herbicide varies widely. For example, the activity of a triazine herbicide, such as cyanazine or simazine, can be almost tenfold greater than that of an urea herbicide such as chlortoluron or isoproturon. In general, the preferred application rate of this active ingredient is in the range of 100 to 2500 g a.i./ha, preferably 100-1500 g a.i./ha, for an urea herbicide; in the range of 7.5 to 100 g/ha, for a sulfonylurea herbicide; in the range of 75-400 g/ha for a hydroxybenzonitrile herbicide; in the range of 100-1200 g a.i./ha, for an aryloxyalkanoic acid herbicide; in the range of 250 to 2500 g/ha, for a dinitroaniline herbicide such as pendimethalin; in the range of 40 to 200 g/ha, for a pyridyloxyacetic acid herbicide such as fluroxypyr; in the range of 25 to 250 g/ha, for a fenoxyfenoxypropion acid herbicide; and in the range of 25 to 500 g/ha, for an oxyacetamide herbicide. The optimal rate for the chosen non-BAP component will, however, depend on the crop(s) under cultivation and the level of weed infestation, and can readily be determined by established biological tests. Naturally, with such a wide variation in application rate for the non-BAP component, the ratio of a BAP to a non-BAP component in the present invention will be determinded predominantly by the choice of the non-BAP component. Thus, the preferred ratio BAP:non-BAP may vary, e.g., from about 1:1 (Bromoxynil) to about 64:1 (Isoproturon).
The active compounds can be used in the form of a mixture of separate formulations, typically mixed with water prior to application (tank-mixtures), or as separate formulations applied individually within a certain time interval. Both active compounds can also be formulated together in a suitable ratio according to the present invention, together with usual carriers and/or additives known in the art.
A typical formulation containing one compound of group (1) and one compound of group (2) above may be composed as follows:
______________________________________Wettable Powder______________________________________Compound C 25 g Isoproturon 500 g ligninsulfonate.sup.1) 80 g alkylnaphthalene sulphonate.sup.2) 20 g kaolin.sup.3) to 1000 g______________________________________ .sup.1) e.g. Borresperse N (dispersing agent) .sup.2) e.g. Nekal BX (dispersing agent) .sup.3) e.g. China Clay GTY (filler/carrier)
Formulations of the present invention may be in any form known in the art, e.g., powders, granules, solutions, emulsions, suspensions, and the like.
The following examples illustrate specific embodiments of the present invention; however, the invention is not limited to the embodiments so illustrated, but includes the entire scope of the appended claims.
EXAMPLES
General Method:
The trials are carried out under greenhouse conditions in pre- and post-emergence applications. The plant seeds are sown in pots containing a loamy sand soil (0.5 I). The herbicides are applied as single treatments, or in a combination comprising a BAP compound and a non-BAP compound as designated, before or after emergence of weeds and crop. The herbicidal performance is assessed as percent damage in comparison to the untreated control plants. The assessment is done 21 days after the treatment. Wheat and barley are treated at the 34 leaf stage, the broad-leaf weeds at the 24 leaf stage and annual grasses at the 2-3 leaf stage.
For the BAP component, compounds A to D are employed: ##STR4##
The non-BAP component is identified in each example with application rates (and hence component ratios) chosen to be appropriate to the established activity level of that component.
In the tables, "CCPP-P" means (R)-2-(4-chloro-2-methylphenoxy) proprionic acid.
The results of these experiments are tabulated as Examples 1 to 10, wherein all the results from a chosen "non-BAP component" are collected under the same Example number, different dosage rates/test species being recorded in the examples. From these results, it is clear that synergism exists between the BAP and the non-BAP compounds. Crop tolerance (wheat and barley) is excellent in all treatments.
Example 1a
Herbicidal performance of the mixture Compound A+loxynilsalt (30 g a.i./ha+60 g a.i./ha=mixture 1:2) against broad-leaved weeds in post-emergence application
______________________________________ Compound A Ioxynil Compound A + Ioxynil 30 g a.i./ha 60 g a.i./ha 30 g a.i./ha + 60 g a.i./haweed species % Control WE W______________________________________Galium 80 40 88 100 aparine (1.whorl) Galium 57 5 59 94 aparine (2.whorl) Matricaria 1 89 89 100 inodora______________________________________ WE = expected response by means of the Colby formula W = observed response
Expected control of Galium aparine (1.whorl), Galium aparine (2.whorl) and Matricaria inodora was 88, 59 and 89%, resp., clearly demonstrating that the combination is synergistic.
Example 1b
Herbicidal performance of the mixture Compound A+loxynilsalt (15 g a.i./ha+60 g a.i./ha=mixture 1:4) against broad-leaved weeds in post-emergence application
______________________________________ Compound A Ioxynil Compound A + Ioxynil 15 g a.i./ha 60 g a.i./ha 15 g a.i./ha + 60 g a.i./haweed species % Control WE W______________________________________Matricaria 1 89 89 100 inodora Papaver rhoeas 79 0 79 97 Myosotis 72 37 82 100 arvensis______________________________________ WE = expected response by means of the Colby formula W = observed response
Expected control of Matricaria inodora, Papaver rhoes and Myosotis arvensis was 89, 79 and 82% resp., clearly demonstrating that the combination is synergistic.
Example 1c
Herbicidal performance of the mixture Compound B+loxynilsalt (30 g a.i./ha+60 g a.i./ha=mixture 1:2) against broad-leaved weeds in post-emergence application
______________________________________ Compound B Ioxynil Compound B + Ioxynil 30 g a.i./ha 60 g a.i./ha 30 g a.i./ha + 60 g a.i./haweed species % Control WE W______________________________________Galium 83 40 90 100 aparine (1.whorl) Galium 67 5 69 85 aparine (2.whorl)______________________________________ WE = expected response by means of the Colby formula W = observed response
Expected control of Galium aparine (1.whorl) and Galium aparine (2.whorl) was 90 and 69%, resp., clearly demonstrating that the combination is synergistic.
Example 1d
Herbicidal performance of the mixture Compound B+loxynilsalt (15 g a.i./ha+60 g a.i./ha=mixture 1:4) against broad-leaved weeds in post-emergence application
______________________________________ Compound B Ioxynil Compound B + Ioxynil 15 g a.i./ha 60 g a.i./ha 15 g a.i./ha + 60 g a.i./haweed species % Control WE W______________________________________Galium 80 40 88 100 aparine (1.whorl) Galium 60 5 62 82 aparine (2.whorl) Matricaria 7 89 90 100 inodora______________________________________ WE = expected response by means of the Colby formula W = observed response
Expected control of Galium aparine (1.whorl), Galium aparine (2.whorl) and Matricaria inodora was 88, 62 and 90%, resp., clearly demonstrating that the combination is synergistic.
Example 2a
Herbicidal performance of the mixture Compound A+Bromoxynil Octanoate (60 g a.i./ha+60 g a.i./ha=mixture 1:1) against broad-leaved weeds in post-emergence application
______________________________________ Compound Compound A + A Bromoxynil Bromoxynil 60 g a.i./ha 60 g a.i./ha 60 g a.i./ha + 60 g a.i./haweed species % Control WE W______________________________________Galium 67 70 90 100 aparine (1.whorl) Galium 42 57 75 90 aparine (2.whorl) Papaver rhoeas 10 79 81 100______________________________________ WE = expected response by means of the Colby formula W = observed response
Expected control of Galium aparine (1.whorl), Galium aparine (2.whorl), Stellaria media and Papaver rhoeas was 90, 75 and 81%, resp., clearly demonstrating that the combination is synergistic.
Example 2b
Herbicidal performance of the mixture Compound A+Bromoxynil Octanoate (30 g a.i./ha+60 g a.i./ha=mixture 1:2) against broad-leaved weeds in post-emergence application
______________________________________ Compound Compound A + A Bromoxynil Bromoxynil 30 g a.i./ha 60 g a.i./ha 30 g a.i./ha + 60 g a.i./haweed species % Control WE W______________________________________Galium 57 70 87 92 aparine (1.whorl) Galium 32 57 71 82 aparine (2.whorl) Lamium 65 17 71 85 purpureum Stellaria media 45 0 45 69 Papaver rhoeas 9 79 81 100______________________________________ WE = expected response by means of the Colby formula W = observed response
Expected control of Galium aparine (1.whorl), Galium aparine (2.whorl), Lamium purpureum, Stellaria media and Papaver rhoeas was 87, 71, 71, 45 and 81%, resp., clearly demonstrating that the combination is synergistic.
Example 2c
Herbicidal performance of the mixture Compound A+Bromoxynil Octanoate (30 g a.i./ha+120 g a.i./ha=mixture 1:4) against broad-leaved weeds in post-emergence application
______________________________________ Compound Compound A + A Bromoxynil Bromoxynil 30 g a.i./ha 120 g a.i./ha 30 g a.i./ha + 120 g a.i./haweed species % Control WE W______________________________________Galium 57 75 89 100 aparine (1.whorl) Galium 32 77 84 99 aparine (2.whorl) Stellaria media 65 57 85 90______________________________________ WE = expected response by means of the Colby formula W = observed response
Expected control of Galium aparine (1.whorl), Galium aparine (2.whorl) and Stellaria media was 89, 84 and 85%, resp., clearly demonstrating that the combination is synergistic.
Example 2d
Herbicidal performance of the mixture Compound B+Bromoxynil Octanoate (30 g a.i./ha+60 g a.i./ha=mixture 1:2) against broad-leaved weeds in post-emergence application
______________________________________ Compound B Bromoxynil Compound B + Bromoxynil 30 g a.i./ha 60 g a.i./ha 30 g a.i./ha + 60 g a.i./haweed species % Control WE W______________________________________Galium 65 57 85 100 aparine (2.whorl) Stellaria 62 0 62 84 media Papaver rhoeas 17 79 83 100______________________________________ WE = expected response by means of the Colby formula W = observed response
Expected control of Galium aparine (2.whorl), Stellaria media and Papaver rhoeas was 85, 62 and 83%, resp., clearly demonstrating that the combination is synergistic.
Example 2e
Herbicidal performance of the mixture Compound B+Bromoxynil Octanoate (15 g a.i./ha+60 g a.i./ha=mixture 1:4) against broad-leaved weeds in post-emergence application
______________________________________ Compound B Bromoxynil Compound B + Bromoxynil 15 g a.i./ha 60 g a.i./ha 15 g a.i./ha + 60 g a.i./haweed species % Control WE W______________________________________Galium 67 70 90 100 aparine (1.whorl) Stellaria 47 0 47 83 media Papaver rhoeas 2 79 79 100______________________________________ WE = expected response by means of the Colby formula W = observed response
Expected control of Galium aparine (1.whorl), Stellaria media and Papaver rhoeas was 90, 47 and 79%, resp., clearly demonstrating that the combination is synergistic.
Example 2f
Herbicidal performance of the mixture Compound B+Bromoxynil Octanoate (15 g a.i./ha+120 g a.i./ha=mixture 1:8) against broad-leaved weeds in post-emergence application
______________________________________ Compound B Bromoxynil Compound B + Bromoxynil 15 g a.i./ha 120 g a.i./ha 15 g a.i./ha + 120 g a.i./haweed species % Control WE W______________________________________Galium 67 75 92 100 aparine (1.whorl) Galium 45 77 87 98 aparine (2.whorl) Stellaria 47 0 47 75 media______________________________________ WE = expected response by means of the Colby formula W = observed response
Expected control of Galium aparine (1.whorl), Galium aparine (2.whorl) and Stellaria media was 92, 87 and 47%, resp., clearly demonstrating that the combination is synergistic.
Example 3a
Herbicidal performance of the mixture Compound A+CMPP-P (30 g a.i./ha+480 g a.i./ha=mixture 1:16) against broad-leaved weeds in post-emergence application
______________________________________ Compound A CMPP-P Compound A + CMPP-P 30 g a.i./ha 480 g a.i./ha 30 g a.i./ha + 480 g a.i./haweed species % Control WE W______________________________________Papaver 32 47 64 87 rhoeas Lamium 62 67 87 99 purpureum Polygonum 60 40 76 99 convolvulus______________________________________ WE = expected response by means of the Colby formula W = observed response
Expected control of Papaver rhoeas, Lamium purpureum and Polygonum convolvulus was 64, 87 and 76%, resp., clearly demonstrating that the combination is synergistic.
Example 4a
Herbicidal performance of the mixture Compound A+Amidosulfuron (50 g a.i./ha+15 g a.i./ha=mixture 3.3:1) against broad-leaved weeds in post-emergence application
______________________________________ Compound Amido- Compound A + Amido- A sulfuron sulfuron 50 g a.i./ha 15 g a.i./ha 50 g a.i./ha + 15 g a.i./haweed species % Control WE W______________________________________Galium 50 40 70 82 aparine (1.whorl) Galium 30 20 44 97 aparine (2.whorl)______________________________________ WE = expected response by means of the Colby formula W = observed response
Expected control of Galium aparine (1.whorl) and Galium aparine (2.whorl) was 70 and 44%, resp., clearly demonstrating that the combination is synergistic.
Example 4b
Herbicidal performance of the mixture Compound B+Amidosulfuron (7.5 g a.i./ha+30 g a.i./ha=mixture 1:4) against broad-leaved weeds in post-emergence application
______________________________________ Compound B + Amido- Compound Amido- sulfuron B sulfuron 7.5 g a.i./ha + 30 g 7.5 g a.i./ha 30 g a.i./ha a.i./haweed species % Control WE W______________________________________Veronica 65 0 65 96 persica Stellaria 25 50 63 87 media Papaver rhoeas 7 15 21 65 Lamium 70 0 70 96 purpureum______________________________________ WE = expected response by means of the Colby formula W = observed response
Expected control of Veronica persica, Stellaria media, Papaver rhoeas and Lamium purpureum was 65, 63, 21 and 70%, resp., clearly demonstrating that the combination is synergistic.
Example 5a
Herbicidal performance of the mixture Compound B+Fluroxypyr (30 g a.i./ha+90 g a.i./ha=mixture 1:3) against broad-leaved weeds in post-emergence application
______________________________________ Compound Compound B + B Fluroxypyr Fluroxypyr 30 g a.i./ha 90 g a.i./ha 30 g a.i./ha + 90 g a.i./haweed species % Control WE W______________________________________Matricaria 22 45 57 95 inodora Papaver rhoeas 80 0 80 92 Polygonum 15 45 53 80 convolvulus______________________________________ WE = expected response by means of the Colby formula W = observed response
Expected control of Matricaria inodora, Papaver rhoeas and Polygonum convolvulus was 57, 80 and 53%, resp., clearly demonstrating that the combination is synergistic.
Example 5b
Herbicidal performance of the mixture Compound B+Fluroxypyr (15 g a.i./ha+120 g a.i./ha=mixture 1:8) against broad-leaved weeds in post-emergence application
______________________________________ Compound B Fluroxypyr Compound B + Fluroxypyr 15 g a.i./ha 120 g a.i./ha 15 g a.i./ha + 120 g a.i./haweed species % Control WE W______________________________________Stellaria 45 67 82 100 media Veronica 77 52 89 97 persica Polygonum 17 80 83 98 lapathifolium______________________________________ WE = expected response by means of the Colby formula W = observed response
Expected control of Stellaria media, Veronica persica and Polygonum lapathifolium was 82, 89 and 83%, resp., clearly demonstrating that the combination is synergistic.
Example 6a
Herbicidal performance of the mixture Compound B+Cyanazine (30 g a.i./ha+120 g a.i./ha=mixture 1:4) against broad-leaved weeds in post-emergence application
______________________________________ Compound B Cyanazine Compound B + Cyanazine 30 g a.i./ha 120 g a.i./ha 30 g a.i./ha + 120 g a.i./haweed species % Control WE W______________________________________Galium 52 5 54 86 aparine (1.whorl) Galium 45 0 45 72 aparine (2.whorl) Galium 40 0 40 75 aparine (3.whorl) Stellaria 42 61 77 100 media Matricaria 22 52 63 100 inodora Papaver rhoeas 80 0 86 100 Polygonum 7 60 63 100 convolvulus______________________________________ WE = expected response by means of the Colby formula W = observed response
Expected control of Galium aparine (1.whorl), Galium aparine (2.whorl), Galium aparine (3.whorl), Stellaria media, Matricaria inodora, Papaver rhoeas and Polygonum convolvulus was 54, 45, 40, 77, 63, 80 and 63%, resp., clearly demonstrating that the combination is synergistic.
Example 6b
Herbicidal performance of the mixture Compound B+Cyanazine (15 g a.i./ha+120 g a.i./ha=mixture 1:8) against broad-leaved weeds in post-emergence application
______________________________________ Compound B Cyanazine Compound B + Cyanazine 15 g a.i./ha 120 g a.i./ha 15 g a.i./ha + 120 g a.i./haweed species % Control WE W______________________________________Stellaria 27 61 72 100 media Matricaria 20 52 62 100 inodora Polygonum 7 60 63 97 convolvulus______________________________________ WE = expected response by means of the Colby formula W = observed response
Expected control of Stellaria media, Matricaria inodora and Polygonum convolvulus was 72, 62 and 63%, resp., clearly demonstrated that the combination is synergstic.
Example 6c
Herbicidal performance of the mixture Compound B+Cyanazine (30 g a.i./ha+240 g a.i./ha=mixture 1:8) against broad-leaved weeds in post-emergence application
______________________________________ Compound B Cyanazine Compound B + Cyanazine 30 g a.i./ha 240 g a.i./ha 30 g a.i./ha + 240 g a.i./haweed species % Control WE W______________________________________Galium 52 10 57 92 aparine (1.whorl) Galium 45 10 51 95 aparine (2.whorl) Galium 40 5 43 81 aparine (3.whorl) Stellaria 42 72 84 100 media Matricaria 22 85 88 100 inodora Papaver rhoeas 80 0 80 100______________________________________ WE = expected response by means of the Colby formula W = observed response
Expected control of Galium aparine (1.whorl), Galium aparine (2.whorl), Galium aparine (3.whorl), Stellaria media, Matricaria inodora and Papaver rhoeas was 57, 51, 43, 84, 88 and 80%, resp., clearly demonstrating that the combination is synergistic.
Example 6d
Herbicidal performance of the mixture Compound B+Cyanazine (15 g a.i./ha+240 g a.i./ha=mixture 1:16) against broad-leaved weeds in post-emergence application
______________________________________ Compound B Cyanazine Compound B + Cyanazine 15 g a.i./ha 240 g a.i./ha 15 g a.i./ha + 240 g a.i./haweed species % Control WE W______________________________________Galium 40 10 46 85 aparine (1.whorl) Galium 37 10 43 77 aparine (2.whorl) Galium 40 5 43 60 aparine (3.whorl) Stellaria 27 72 80 100 media Matricaria 20 85 88 100 inodora Papaver rhoeas 60 0 60 87______________________________________ WE = expected response by means of the Colby formula W = observed response
Expected control of Galium aparine (1.whorl), Galium aparine (2.whorl), Galium aparine (3.whorl), Stellaria media, Matricaria inodora and Papaver rhoeas was 46, 43, 43, 80, 88 and 60%, resp., clearly demonstrating that the combination is synergistic.
Example 7a
Herbicidal performance of the mixture Compound C+Isoproturon (50 g a.i./ha+150 g a.i./ha=mixture 1:3) against grasses in post-emergence application
______________________________________ Compound C + Compound Isoproturon C Isoproturon 50 g a.i./ha + 150 g 50 g a.i./ha 150 g a.i./ha a.i./hagrass % control WE W______________________________________Alopecurus 88 30 91 100 myosuroides Setaria viridis 75 58 89 100 Lolium perenne 78 10 80 100______________________________________ WE = expected response by means of the Colby formula W = observed response
Expected control of Alopecurus myosuroides, Setaria viridis and Lolium perenne was 91, 89 and 80%, resp., clearly demonstrated that the combination is synergistic.
Example 7b
Herbicidal performance of the mixture Compound C+Isoproturon (25 g a.i./ha+150 g a.i./ha=mixture 1:6) against grasses in post-emergence application
______________________________________ Compound C + Compound Isoproturon C Isoproturon 25 g a.i./ha + 150 g 25 g a.i./ha 150 g a.i./ha a.i./hagrass % control WE W______________________________________Alopecurus 83 30 88 100 myosuroides Setaria viridis 55 58 81 100 Lolium perenne 65 10 69 94______________________________________ WE = expected response by means of the Colby formula W = observed response
Expected control of Alopecurus myosuroides, Setaria viridis and Lolium perenne was 88, 81 and 69%, resp., clearly demonstrating that the combination is synergistic.
Example 7c
Herbicidal performance of the mixture Compound C+Isoproturon (12.5 g a.i./ha+150 g a.i./ha=mixture 1:12) against grasses in post-emergence application
______________________________________ Com- Compound C + pound C Isoproturon 12.5 g Isoproturon 12.5 g a.i./ha + 150 g a.i./ha 150 g a.i./ha a.i./hagrass % control WE W______________________________________Alopecurus 65 30 76 88 myosuroides Setaria viridis 30 58 70 94 Lolium perenne 38 10 44 91 Poa annua 75 65 91 99______________________________________ WE = expected response by means of the Colby formula W = observed response
Expected control of Alopecurus myosuroides, Setaria viridis, Lolium perenne and Poa annua was 76, 70, 44 and 91%, resp., clearly demonstrating that the combination is synergistic.
Example 7d
Herbicidal performance of the mixture Compound C+Isoproturon (25 g a.i./ha+300 g a.i./ha=mixture 1:12) against grasses in post-emergence application
______________________________________ Compound C + Compound Isoproturon C Isoproturon 25 g a.i./ha + 300 g 25 g a.i./ha 300 g a.i./ha a.i./hagrass % control WE W______________________________________Alopecurus 83 73 95 100 myosuroides Lolium perenne 65 40 79 98______________________________________ WE = expected response by means of the Colby formula W = observed response
Expected control of Alopecurus mysuroides and Lolium perenne was 95 and 79%, reps., clearly demonstrated that he combination is synergistic.
Example 7e
Herbicidal performance of the mixture Compound C+Isoproturon (12.5 g a.i./ha+300 g a.i./ha=mixture 1:24) against grasses in post-emergence application
______________________________________ Compound Compound C + C Isoproturon 12.5 g Isoproturon 12.5 g a.i./ha + 300 g a.i./ha 300 g a.i./ha a.i./hagrass % control WE W______________________________________Alopecurus 65 73 90 99 myosuroides Lolium perenne 38 40 63 91 Poa annua 75 83 96 100______________________________________ WE = expected response by means of the Colby formula W = observed response
Expected control of Alopecurus myosuroides, Lolium perenne and Poa annua was 90, 63 and 96%, resp., clearly demonstrating that the combination is synergistic.
Example 7f
Herbicidal performance of the mixture Compound A+Isoproturon (30 g a.i./ha+1920 g a.i./ha=mixture 1:64) against broad-leaved weeds in post-emergence application
______________________________________ Compound A + Compound Isoproturon A Isoproturon 30 g a.i./ha + 1920 g 30 g a.i./ha 1920 g a.i./ha a.i./haweed species % Control WE W______________________________________Veronica 81 0 81 97 persica Lamium 35 3 37 97 purpureum Myosotis 57 25 68 99 arvensis Viola 75 65 91 100 arvensis Polygonum 5 4 9 80 convolvulus Galium 75 0 75 90 aparine (2.whorl)______________________________________ WE = expected response by means of the Colby formula W = observed response
Expected control of Veronica persica, Lamium purpureum, Myosotis arvensis, Viola arvensis, Polygonum convolvulus and Galium aparine (2.whorl) was 81, 37, 68, 91, 9 and 75% resp., clearly demonstrating that the combination is synergistic.
Example 7g
Herbicidal performance of the mixture Compound D+Isoproturon (15 g a.i./ha+300 g a.i./ha=mixture 1:20) against Alopecurus myosuroides in pre-emergence application
______________________________________ Compound D + Compound Isoproturon D Isoproturon 15 g a.i./ha + 120g 15 g a.i./ha 120 g a.i./ha a.i./haweed species % Control WE W______________________________________Alopecurus 60 75 90 99 myosuroides______________________________________ WE = expected response by means of the Colby formula W = observed response
Expected control of Alopecurus myosuroides was 90%, resp., clearly demonstrating that the combination is synergistic.
Example 8a
Herbicidal performance of the mixture Compound D+Pendimethalin (15 g a.i./ha+450 g a.i./ha=mixture 1:30) against Alopecurus myosuroides in pre-emergence application
______________________________________ Compound D + Compound Pendimethalin D Pendimethalin 15 g a.i./ha + 450 g 15 g a.i./ha 450 g a.i./ha a.i./haweed species % Control WE W______________________________________Alopecurus 57 35 72 90 myosuroides______________________________________ WE = expected response by means of the Colby formula W = observed response
Expected control of Alopecurus myosuroides was 72%, resp., clearly demonstrating that the combination is synergistic.
Example 8b
Herbicidal performance of the mixture Compound D+Pendimethalin (15 g a.i./ha+900 g a.i./ha=mixture 1:60) against Alopecurus myosuroides in pre-emergence application
______________________________________ Compound D + Compound Pendimethalin D Pendimethalin 15 g a.i./ha + 900 g 15 g a.i./ha 900 g a.i./ha a.i./haweed species % Control WE W______________________________________Alopecurus 57 55 81 96 myosuroides______________________________________ WE = expected response by means of the Colby formula W = observed response
Expected control of Alopecurus myosuroides was 81%, resp., clearly demonstrating that the combination is synergistic
Example 9a
Herbicidal performance of the mixture Compound C+Fenoxaprop (12.5 g a.i./ha+15 g a.i./ha=mixture 1:1,2) against Setaria viridis in post-emergence application
______________________________________ Compound C + Compound Fenoxaprop C Fenoxaprop 12.5 g a.i./ha + 15 g a.i./ha 12.5 g 15 g a.i./ha a.i./haweed species % Control WE W______________________________________Setaria viridis 30 62 73 94______________________________________ WE = expected response by means of the Colby formula W = observed response
Expected control of Setaria viridis was 73%, resp., clearly demonstrating that the combination is synergistic.
Example 9b
Herbicidal performance of the mixture Compound C+Fenoxaprop (12.5 g a.i./ha+30 g a.i./ha=mixture 1:2.4) against Setaria viridis in post-emergence application
______________________________________ Compound C 12.5 g Fenoxaprop Compound C + Fenoxaprop a.i./ha 30 g a.i./ha 12.5 g a.i./ha + 30 g a.i./haweed species % Control WE W______________________________________Setaria viridis 30 72 80 93______________________________________ WE = expected response by means of the Colby formula W = observed response
Expected control of Setaria viridis was 80%, resp., clearly demonstrating that the combination is synergistic.
Example 9c
Herbicidal performance of the mixture Compound C+Fenoxaprop (12.5 g a.i./ha+60 g a.i./ha=mixture 1:4.8) against Setaria viridis in post-emergence application
______________________________________ Compound C 12.5 g Fenoxaprop Compound C + Fenoxaprop a.i./ha 60 g a.i./ha 12.5 g a.i./ha + 60 g a.i./haweed species % Control WE W______________________________________Setaria viridis 30 77 84 100______________________________________ WE = expected response by means of the Colby formula W = observed response
Expected control of Setaria viridis was 84%, resp., clearly demonstrating that the combination is synergistic. | A herbicidal composition containing
(1) a substituted pyridine of general formulae I or II ##STR1## as defined herein, and
(2) at least one herbicidal component selected from
a) an urea-type herbicide, such as chlortoluron, isoproturon, linuron or neburon,
b) a triazine-type herbicide, such as atrazine, cyanazine or simazine
c) a hydroxybenzonitrile herbicide, such as bromoxynil or ioxynil,
d) an aryloxyalkanoic acid herbicide, such as dichlorprop, MCPA or mecoprop,
e) a dinitroaniline herbicide, such as pendimethalin,
f) a sulfonylurea herbicide, such as amidosulfuron,
g) a pyridazine herbicide, such as pyridate,
h) a fluorene carboxylic acid herbicide, such as flurenol,
i) a pyridyloxyacetic acid herbicide, such as fluroxypyr,
j) a fenoxyfenoxypropion acid herbicide, such as fenoxaprop, and
k) an oxyacetamide herbicide,
which provides a synergistic effect against a broad spectrum of weed species, e.g., in cereal crops. The invention also provides a method for controlling weeds by applying both a compound (1) and a compound (2) to a locus. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. patent application Ser. No. 12/063,976 filed on Oct. 3, 2008, now U.S. Pat. No. 7,914,149, which is a United States national phase application of international patent application number PCT/EP2006/007895, filed Aug. 9, 2006, which claims priority to European Application Number 05018062.9, filed Aug. 19, 2005, each of which is hereby incorporated by reference in its entirety.
BACKGROUND
[0002] The present invention is concerned with a method of generating a computer program for control of an apparatus capable to ablate corneal tissue or a contact lens for treatment of presbyopia.
[0003] Presbyopia is the lack of capability of the eye lens to accommodate for far distance and near distance.
[0004] The prior art knows many optical approaches to presbyopia including reading glasses, monovision, multifocal contact lenses, intraocular implants, and accommodative intraocular lenses. None of these attempts can restore accommodation but all represent compromises to establish a more or less fair near vision at the costs of far vision. Some methods were designed to restore accommodation by means of scleral expansion near the ciliary body, however, have so far failed to prove efficacy.
[0005] In refractive laser surgery, first “presbyopia corrections” have been reported in the early nineties (Moreira H, Garbus J J, Fasano A, Clapham L M, Mc Donnell P J; Multiffical Corneal Topographic Changes with Excimer Laser photorefractive Keratectomy; Arch Ophthalmol 1992; 100: 994-999; Anschütz T, Laser Correction for Hyperopia and Presbyopia, Int Ophthalmol Clin 1994; 34: 105-135). However, such techniques have not gained wide clinical acceptance. More sophisticated presbyopia correction profiles have been proposed including an induced central steep island (CSI), U.S. Pat. No. 5,533,997 (Ruiz) and WO93/25166 (King, Klopotek). The present invention partially refers to the concept of CSI disclosed in the afore-mentioned patents. Also decentered steep areas have been proposed, see U.S. Pat. No. 5,314,422 to Nizzola, and Bauerberg J M, Centered vs. Inferior off-center Ablation to Correct Hyperopia and Presbyopia, J Refract Surg 1999. The prior art also suggests a near vision zone in the mid-periphery of the cornea, see Telandro A, Pseudo-accommodative Cornea: a new Concept for Correction of Presbyopia, J Refract Surg 2004; 20:S714-S717; and Cantu R, Rosales M A, Tepichin E, Curioca A, Montes V, Bonilla J; Advanced Surface Ablation for Presbyopia using the Nick EC-5000 Laser, J Refract Surg 2004, 20: S711-S713.
SUMMARY
[0006] The present invention aims at an effective method for presbyopia correction and provides a method of generating a computer program for control of a laser system for photorefractive treatment of presbyopia by ablation of tissue from or in the cornea or from a contact lens.
[0007] To this end, the method of generating a computer program for control of an apparatus for photorefractive surgery comprises the following steps:
[0000] (a) selecting an eye model,
(b) measuring the pupil diameter of the patient at far distance mesopically and at short distance photopically,
(c) selecting wanted short and far distances regarding optimum sight,
(d) calculating a global optimum regarding curvature (1/R) and asphericity (Q) of the cornea on the basis of the results obtained in steps (a) (b) and (c) by means of optical ray tracing and minimal spot diameter at the retina and
(e) deriving the computer program in accordance with the results of step (d).
[0008] This method of determining global optimum for curvature and asphericity creates a purely aspheric shape including a small amount of myopia with increased depths of focus. A stronger refractive power is obtained for near in the central area surrounded by a mid-periphery with less power. The aspheric global optimum includes an even naturally occurring corneal asphericity that provides a variable pseudoaccommodation depending on the asphericity constant Q and the pupil diameter change amplitude during the near reflex.
[0009] According to an alternative embodiment of the invention a computer program for control of an apparatus for photorefractive surgery is generated by the following steps:
[0000] (a) selecting an eye model,
(b) measuring the pupil diameter of the patient at far distance mesopically and at short distance photopically,
(c) selecting wanted short and far distances regarding optimum sight,
(d) determining a central steep island with diameter in the range of 2 to 4 millimeter and a refractive height of 1 to 4 diopters at the cornea and calculating a curvature and asphericity in the rest of the cornea depending on the central island selected, and
(e) deriving the computer program in accordance with the results of step (d).
[0010] This technique results in a multifocal cornea with two main foci. Again a stronger refractive power is obtained for near in the central area surrounded by a mid-periphery of less power. The two main driving forces for this multifocal CSI are, on the one hand, the pupil size that decreases during focusing near objects (pupillary near reflex) and, on the other hand, also the depths of focus is increased.
[0011] This CSI-configuration is a corneal analogon to the artificial bifocal, intraocular lens (IOL). Due to its increased depths of focus, the advantage of the CSI-technology is a twice better retinal image of near objects as compared to the globally optimized shape and a four times better image compared to the non-accommodated emmetropic eye.
[0012] According to a preferred embodiment of the present invention, the optimal configuration (computer program) is tested for patient satisfaction prior to surgery using contact lenses. When applying one of the two afore-mentioned ablation techniques, first contact lenses can be formed in accordance with the generated computer program and the so formed lenses are tested by the patient for a few days. Therefore the present invention also provides a method of generating a computer program product for control of an apparatus capable of ablating contact lenses.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a pair of charts mapping spot diameter in the retina for far and near objects in the context of an emmetropic eye (no accommodation).
[0014] FIG. 2 is a pair of charts mapping spot diameter in the retina for far and near objects in the context of a global optimum.
[0015] FIG. 3 is a pair of charts mapping spot diameter in the retina for far and near objects in the context of a central steep island.
[0016] FIG. 4 is a graph mapping spot diameter in the retina between a central steep island and an off-center steep island.
DETAILED DESCRIPTION
[0017] In the following the invention is described in more detail with regard to specific embodiment.
1. Theoretical Eye Model
[0018] The eye model used here is based on the model of Liou and Brennan (Liou H L, Brennan N A, Anatomically accurate, finite Model Eye for optical Modeling; J Opt Soc Am A Opt Image Sci Vis 1997; 14: 1684-1695). This model is characterized by aspheric anterior and posterior corneal and lenticular surfaces. In addition, it includes a linear refractive index gradient of Δn=0.2 inside the lens. The parameters for the emmmetropic eye are listed in Table 1. The anterior cornea was approximated by a biconoid surface
[0000] z =( x 2 /Rx+y 2 /Ry )/(1+(1−(1+ Qx ) x 2/ Rx 2−(1+ Qy ) y 2/ Ry 2)1/2) 1.
[0000] where 1/Rx,y arc the curvatures and Qx,y are the asphericity constants in the corresponding main meridians, the positive z-direction points into the eye, the positive y-direction upwards. The reference wavelength is 555 nm. In order to include the Stiles-Crawford effect a transmission filter is introduced (Moon P, Spencer D E, On the Stiles-Crawford Effect, J Opt Soc Am 1944; 34: 319-32)
[0000] T ( r )=exp(− ar 2) 2.
[0000] with the apodization constant a=0.105 and r the radial distance from the center of the pupil.
[0019] To model central or decentered steep islands, cubic spline functions are introduced with steps of 0.5 mm radial distance from the apex of the cornea. All optical surfaces are centered on the optical axis. A pupil diameter of 5 mm is used for simulation of the far distant (object distance 5 m) and 2.5 mm for near (object distance 0.4 m) vision configuration. The object is a point light source located 1° up. Additional (reading) glasses have a distance of 12 mm from the vertex of the cornea.
[0020] The quality of the retinal image is described either by the “rms spot diameter” or the “rms wavefront error” similar to the technique published earlier (Seiler, T Reckmann W, Maloney R K, Effective spherical Aberration of the Cornea as a quantitative Descriptor of the Cornea, J Cataract Refract Surg. 1993; 19 Suppl: 155-65).
[0021] All calculations can be performed with a commercially available optical design program such as, e.g., the optical design program ZEMAX EE, version March 2004 (Zemax Development Cooperation, San Diego, Calif.). Useful is an optimization process aiming on a minimal spot diameter in the retina (circle of least confusion), but depending on the problem also modulation transfer function, wavefront error and point spread function can be used as optimization operands.
[0022] The quality of the retinal image is determined in near and far distant configuration for the following scenaria (Table 2): (1) the emmetropic eye optimized regarding asphericity and eye length, (2) the global optimum for simultaneous near and far distant vision optimized regarding R and Q, (3) central steep island with a diameter of 3 mm and a refractive height of 3 D optimized regarding R and Q, (4) scenario (3) but the central steep island is decentered towards inferior in 0.5 mm-steps up to 3 mm.
2. Results
[0023] Optimization of eye length and asphericity in the emmetropic eye for far distance vision yielded approximately physiologic values (Table 1): an eye length of 24.01 mm and a corneal asphericity constant of −0.158. The minimal spot diameter in the retina d=1.396 microns as well as the wavefront error of 0.034 waves are close to the diffraction limit. Introducing a corneal astigmatism of 0.75 D increases the minimal spot diameter to 29.662 microns and the wavefront error to 1.338 waves, a value that is clinically observed.
[0024] Comparing the spot diameter in the retina for the far and near distant object reveals in the emmetropic eye (no accommodation) a shift of the focus of 890 microns behind the retina ( FIG. 1 ) which can be shifted back into the retina by a reading glass of 2.32 diopters with a vertex distance of 12 mm.
[0025] FIG. 2 demonstrates the spot diameter through the retina for the global optimum regarding R and Q (GO) in the far and near object configuration. It is worth mentioning that the two configurations differ not only by the distance of the object but also by the pupil diameter. The spot diameter in the retina increases to 37.61 microns for the far distant object and decreases to 34.22 microns for the near object (Table 2). Comparing the optimized emmetropic eye (scenario 1 ) with the global optimum (scenario 2 ) the difference in a case of a CSI with 3 mm in diameter and 3 diopters in height consists in an increase in central corneal power of 1.4 diopters (myopia) and a more prolate corneal shape QGO=−0.68. Again, by using a reading glass of 1.01 diopters the focus can be shifted into the retina yielding a spot diameter of 3.56 microns. The other CSI configurations yield different values for curvature 1/R and asphericity constant Q.
[0026] The spot diameter through the retina for the central steep island with optimized R and Q for simultaneous far and near vision is depicted in FIG. 3 . Whereas for the far distant object the spot diameter is comparable to that in the global optimum (GO) it is better by a factor of approximately 2 for near vision. However, reading glasses cannot improve this result any more.
[0027] Decentration of the steep island degradates the quality of the retinal image which is shown in FIG. 4 . Compared to the central steep island a decentration of for example 1 mm results in a 1.6-fold worsening for far and 4.7-fold worsening for near vision. Again, reading glasses can only marginally improve near vision.
3. Discussion
[0028] The major finding of this study is that there are configurations of the corneal shape that represent a clinically meaningful compromise of minor losses in far distance vision with improvement of near vision. The two most attractive approaches are (1) the central steep island combined with appropriate curvature and asphericity in the rest of the cornea and (2) the global optimum for curvature and asphericity. Whereas the first proposal means a multifocal cornea with two main foci, the second one is a purely aspheric shape creating a small amount of myopia with increased depth of focus. Both corneal shapes provide a stonger refractive power for near in the central area surrounded by a mid-periphery with less power. The two main driving forces of the multifocal CSI- as well as the aspheric GO-shape are, on one hand, the pupil size that decreases during focusing near objects (pupillary near reflex) and, on the other hand, also the depth of focus is increased in both optical scenaria.
[0029] The CSI-configuration is a corneal analogon to the artificial bifocal IOL (Jacobi K W, Nowak M R, Strobel J, Special Intraocular Lenses, Fortschr Ophthalmol 1990; 87: S29-S32) with all its known advantages and disadvantages such as loss in contrast sensitivity, halos, glare, and reduced visual satisfaction (Leyland M D, Langan L, Goolfee F, Lee N, Bloom P A, Prospective Randomized Double-Masked Trial of Bilateral Multifocal, Bifocal or Monofocal Intraocular Lenses, Eye 2002; 16: 481-490); (Pieh S, Lackner B, Hanselmayer G, Zohrer R, et al., Halo Size under Distance and Near Conditions in Refractive Multifocal Intraocular Lenses, Br J. Ophthalmol. 2001; 85: 816-821); (Lesueur L, Gajan B, Nardin M, Chapotot E, Arne J L, Comparison of visual Results and Quality of Vision between Two Multifocal Intraocular Lenses. Multifocal Silicone and Bifocal PMMA, J Fr Ophthalmol, 2000; 23: 355-359); (Knorz M C, Seiberth V, Ruf M, Lorger C V, Liesenhoff H, Contrast Sensitivity with monofocal and biofocal Intraocular Lenses, Ophthalmologica 1996; 210: 155-159); (Haaskjold E, Allen E D, Burton R L, et al., Contrast Sensivity after Implantation of Diffractive Bifocal and Monofocal Intraocular Lenses, J Cataract Refract Surg 1998; 24: 653-658).
[0030] In contrast, the aspheric GO includes an even naturally occurring corneal asphericity that provides a variable pseudoaccomodation depending on the asphericity constant Q and the pupil diameter change amplitude during the near reflex.
[0031] Due to its increased depth of focus the advantage of the CSI is a twice better retinal image of near objects compared to the GO-shape and four times better compared to the non-accommodated emmetropic eye, but also due to the increased depth of focus one of its disadvantages is the inability to improve both near and far vision by means of spectacles. In addition, the effect of the CSI is critically dependent on centration: already at a decentration of 0.1 mm the advantage of the CSI compared with GO is gone and a degradation of the retinal image for distance vision by a factor of 1.3 happens. Using modern eye-trackers centration is achieved reliably, however, there is a principal problem because the CSI should be centered regarding the visual axis and the crossing point of the visual axis through the cornea is uncertain and hard to determine. Reasonable centration is much easier obtained using the GO-approach because it does not contain such a localized optical inhomogeneity. A major disadvantage of a multifocal optics of the eye is the loss in mesopic vision as measured in low contrast visual acuity and contrast sensitivity that has been repeatedly reported after multifocal intraocular implants satisfaction (Leyland M D, Langan L, Goolfee F, Lee N, Bloom P A, Prospective randomized double-masked Trial of Bilateral Multifocal, Bifocal or Monofocal Intraocular Lenses, Eye 2002; 16: 481-490); (Lesueur L, Gajan B, Nardin M, Chapotot E, Arne J L, Comparison of visual Results and Quality of Vision between Two Multifocal Intraocular Lenses. Multifocal Silicone and Bifocal PMMA, J Fr Ophthalmol. 2000; 23: 355-359); (Knorz M C, Seiberth V, Ruf M, Lorger C V, Liesenhoff H, Contrast Sensitivity with monofocal and biofocal Intraocular Lenses, Ophthalmologica 1996; 210: 155-159); (Haaskjold E, Allen E D, Burton R L, et al., Contrast Sensivity after Implantation of Diffractive bifocal and monofocal Intraocular Lenses, J Cataract Refract Surg 1998; 24: 653-658).
[0032] Many patients complain about an increase of halos (Pieh S, Lackner B, Hanselmayer G, Zohrer R, et al., Halo Size under distance and near Conditions in Refractive Multifocal Intraocular Lenses, Br J. Ophthalmol. 2001; 85: 816-821). Regarding these optical side effects we would like to cite a recent statement of Georges Baikoff (Baikoff G, Matach G, Fontaine A, Ferraz C, Spera C, Correction of Presbyopia with refractive multifocal Phakic Intraocular Lenses, J Cataract Refract Surg. 2004; 30: 1454-1460): “Optical defects are inevitable with multifocal IOLs; . . . ”. Although this argument holds mainly for the clearly multifocal CSI-shape of the cornea a similar loss in contrast sensitivity is expected to occur also with strongly aspheric corneas. However, an asphericity constant Q of −0.7 as intended in the global optimum (GO) is only −0.5 away from the average (Kiely P M, Smith G, Carney L G, The Mean Shape of the human Cornea, Optica Acta 1982; 29: 1027-1040) and compares favorably with the up to three times larger changes in the asphericity constant after standard myopic LASIK of up to +1.5 (Holladay J T, Dudeja D R, Chang J. Functional Vision and conical Changes after Laser in Situ Keratomileusis determined by Contrast Sensitivity, Glare Testing, and Corneal Topography. J Cataract Refract Surg. 1999; 25: 663-669); (Koller T, Iseli H P, Hafezi F, Mrochen M, Seiler T, Q-Factor customized Ablation Profile for the Correction of Myopic Astigmatism, J Cataract Refract Surg. (2005 submitted). Also, emmetropic or hyperopic eyes receiving a hyperopia correction for attempted slight myopia for monovision experience a shift in asphericity towards prolate that is in the order of −0.5 (Chen C C, Izadshenas A, Rana M A, Azar D T, Conical Asphericity after hyperotic Laser in Situ Keratomileusis. J Cataract Refract Surg, 2002; 28: 1539-1545).
[0033] The currently most frequently used concept of presbyopia correction is the monovision approach where the dominant eye is corrected for emmetropia and the non-dominant for minor myopia ranging from −0.5 D to −2.0 D (Miranda D, Krueger R R, Monovision Laser in Situ Keratomileusis for pre-presbyopic and prescbiopic Patients, J Refract Surg. 2004; 20: 325-328); (Mc Donnell P J, Lee P, Spritzer K, Lindblad A S, Hays R D, Assiocations of Presbyopia with vision-targeted health-related Quality of Life, Arch Ophthalmol. 2003; 121: 1577-1581); (Johannsdottir K R, Stelmach L B, Monovision: A Review of the scientific Literature, Optom Vis Sci. 2001; 78: 646-651); Greenbaum S, Monovision Pseudophakia, J Cataract Refract Surg. 2002; 28: 1439-1443); (Jain S, Ou R, Azar D T, Monovision Outcomes in presbyopic Individuals after refractive Surgery, Ophtalmology. 2001; 108: 1430-1433). In clinical surgery practice the optimal configuration is tested for patient satisfaction prior to surgery using contact lenses. A similar strategy may be appropriate when applying one of the two presented ablation profiles including binocular versus monocular multifocal/aspheric treatment. Assuming that in the future we will have access to such a set of contacts and the patient may decide for surgery after a few days of simulation of his future optics we are still at risk of dissatisfaction. In a study testing monovision in presbyopic patients by means of contact lenses the immediate response was nota good predictor for satisfaction after two weeks (Du Toit R, Ferreira J T, Nel Z J, Visual and nonvisual Variables implicated in Monovision Wear, Optom Vis Sci. 1998; 75: 119-125).
[0034] To facilitate understanding the correlation of minimal spot diameter and visual acuity the spot diameters in the retina for various degrees of low myopia are considered. With a myopia of −0.5 diopters an uncorrected vision of approximately 20/30 may be obtained under scotopic lightning conditions which corresponds to a spot diameter in the retina of 40 microns. This may serve as a gross reference for the two configurations CSI and GO. With CSI a near visual acuity of 20/25 and a far distant VA of 20/30 seems to be obtainable, good lightning conditions and appropriate pupil diameters provided. With the GO approach both near and far VA arc at approximately 20/30 with the option to improve near VA to 20/20 with reading glasses, an option that we do not have in CSI-treated eyes. It is clear that only prospective controlled studies will give us better information about the visual acuities achieved after presbyopia corrections.
[0035] The last and most critical point that needs to be discussed is that any presbyopia “correction” necessarily is a kind of compromise. Whatever one wins in the near domain must be lost in far distance vision and vice versa. Having this in mind and considering the dependence of the optical result on pupil sizes under various conditions and its centration it is obvious that any ablative presbyopic correction should be handled as a customized treatment and simulated preoperatively by means of contact lenses. One of the strongest predictors of a satisfying outcome of refractive surgery is the patient's expectation. Especially with presbyopia correction the balance of the optically possible and the individually desirable has to be made preoperatively. Also important in this context is the reversibility of the operation: simple monovision and GO is easy to correct by means of a reoperation, whereas the CSI profile is more difficult to reverse although recently progress has been reported using advanced customized ablation by means of Zernike and Fourier algorithms (Hafezi F, Iseli H P, Mrochen M, Wüllner C, Seiler T, A New Ablation Algorithm for the Treatment of Central Steep Islands after Refractive Laser Surgery, J Cataract Refract Surg. (2005 submitted).
4. The Method
[0036] Resulting from the above findings, the present invention proposes the following method:
[0037] The shape of the cornea, represented by its curvature (1/R), the asphericity (Q) and a central steep island (CSI) are formed individually (i.e. for a particular patient) such that the optical quality (sharpness) of the image at the retina is optimal simultaneously at the following two configurations: (a) far object (e.g. the distance to the eye is 5 m or more), the pupil diameter is large (e.g. 5 mm, generally speaking larger than 3.5 or 4 mm) and (b) near object (e.g. the object is 0.4 m from the eye, generally speaking nearer than 0.6 m), the pupil diameter is small (e.g. smaller than 3 mm).
[0038] Such an individually adapted configuration can be simulated by contact lenses used by the patient. This includes the option of monovision, e.g. the dominant eye for far sight and the non-dominant eye for presbyopia correction.
[0039] The method can be summarized as follows:
[0040] (1) Measuring the pupil diameter for a far distance mesopically and a short distance photopically,
[0041] (2) Defining the distances with intended optimum sight for far distance and near distance,
[0042] (3) Calculating the global optimum for R and Q by means of optical designer software (for example ZEMAX) on the basis of a selected eye model (e.g. Liou-Brannen), using, optionally, the refinement disclosed in (Seiler T, Reckmann W, Maloney R K, Effective spherical Aberration of the Cornea as a quantitative Descriptor of the Cornea, J Cataract Refract Surg. 1993; 19 Suppl: 155-65). This may or may not include a CSI,
[0043] (4) Manufacturing a corresponding contact lens (if not available on stock) that is stabilised on the eye regarding the optical axis,
[0044] (5) If the patient is satisfied with the result the cornea can be treated accordingly.
[0045] The CSI typically has a diameter of 3 mm at the cornea (the range is 2 to 4 millimetre) and a refractive power of 3 dpt (a range of 2 to 4 dpt). The parameters are entered into the above-stated software by means of cubic spline functions, for example.
[0046] For an average eye (R=7.77 mm Q=−0.15) a myopia, without CSI, of −1.5 dpt and Q-factor of −0.7 is obtained. Including CSI a small hyperopia of +0.9 dpt and a Q-value of +0.22 should be aimed at.
[0047] When determining the global optimum the wanted configurations for near and far are defined (distances, pupil diameters) and the starting values of R and Q (where required including astigmatism) are entered into the program. Thereafter, two runs for optimization are started (one including CSI, the other without CSI). The values of R and Q are entered as operands which are freely variable and the program is iteratively run until the quality of the picture at the retina, defined by the minimum spot radius at the retina or the MTF (Modulation Transfer Function) or the point spread function is optimized. The such optimized optical configuration of the cornea is aimed at when ablating the cornea or the lens respectively.
[0000]
TABLE 1
Parameters of the optimized emmetropic eye model
curvature radius
apex position
refractive
Surface
R (mm)
asphericity Q
(mm)
index
ant. cornea
7.77
−0.158
0.00
1.376
post. cornea
6.4
−0.6
0.52
1.336
pupil
13.0
0
3.68
1.336
ant. lens
12.4
−0.94
3.68
1.453*
post. lens
−8.1
−0.96
7.70
1.336
retina
12.0
0
24.01
—
*The lens includes a linear gradient of refractive index increasing from 1,453 at the surfaces to 1,652 in the center
[0000]
TABLE 2
Quality of the retinal image (point light source, λ = 550 nm)
minimal spot
diameter (microns)
far distance
near distance
optical scenario
(5 m)
(0.4 m)
1.
emmetropic eye optimized (Q = −0.158)
1.40
65.48
2.
corneal astigmatism 0.75D
29.66
76.85
(Q = −0.158).
3.
global optimum for R and Q
37.61
34.22
(R = 7.55; Q = −0.68)
4.
central steep island optimized R and Q
44.47
17.62
(R = 7.92; Q = +0.22)
5.
decentered steep island, decentered
68.84
82.85
by 1 mm, optimized R and Q
(R = 7.68; Q = −0.42)
6.
centered steep annulus optimized
130.1
77.62
R and Q (R = 7.21; Q = −1.72) | Systems and methods for treating presbyopia are provided. In one embodiment, a system for photorefractive treatment of presbyopia includes a laser source configured for ablating corneal tissue and a control system in communication with the laser source and configured to control the laser source to ablate conical tissue of a patient to achieve a desired corneal shape. In some instances, the control system controls the laser source by calculating a global optimum regarding curvature and asphericity of the cornea. In some instances, control system controls the laser source by calculating a central steep island and calculating a curvature and asphericity for the rest of the cornea. In some embodiments, a laser source is controlled to ablate the cornea of the patient in accordance with a calculated shape profile to achieve a desired corneal shape. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority benefit from U.S. provisional patent application 61/508,151 filed 15 Jul. 2011.
FIELD
[0002] The present disclosure relates to shape of the combustion chamber and injector orientation in internal combustion engines.
BACKGROUND
[0003] Thermal efficiency and engine-out emissions from an internal combustion engine are determined by many factors including the combustion system design and the mechanical design. Combustion system design includes combustion chamber shape, the fuel injection nozzle, and the fuel injection pressure, intake manifold and exhaust manifold, etc. All of these together are optimized to achieve mixing quality that leads to effective combustion. Much is known and much has been studied in typical diesel engine combustion systems to determine what chamber shape and fuel injection characteristics lead to the desired output. However, in unconventional engines, less is known about what combustion chamber shape and fuel injection characteristics can provide the desired mixing and engine performance.
[0004] Such an unconventional engine, an opposed-piston, opposed-cylinder (OPOC) engine 10 , is shown isometrically in FIG. 1 . An intake piston 12 and an exhaust piston 14 reciprocate within each of first and second cylinders (cylinders not shown to facilitate viewing pistons). An intake piston 12 ′ and an exhaust piston 14 couple to a journal (not visible) of crankshaft 20 via pushrods 16 . An intake piston 12 and exhaust piston 14 ′ couple to two journals (not visible) of crankshaft 20 via pullrods 18 , with each intake piston 12 having two pullrods 18 . The engine in FIG. 1 has two combustion chambers formed between a piston top 22 of intake piston 12 (or 12 ′) and a piston top 24 of exhaust piston 14 (or 14 ′) and the cylinder wall (not shown). The pistons in both cylinders are shown are at an intermediate position in FIG. 1 . Combustion is initiated when the pistons are proximate each other. The piston tops 22 and 24 in FIG. 1 may not be optimized to provide the desired performance.
SUMMARY
[0005] An internal combustion engine is disclosed which includes a cylinder wall with first and second pistons adapted to reciprocate therein. The two pistons are disposed in the cylinder in an opposed fashion. A crankshaft having first and second eccentric journals couples to the first and second pistons via first and second connecting rods. At a particular angle of rotation of the crankshaft, the pistons are at their closest approach. The piston top of the first piston has three regions: a center, an outer ring near the periphery of the piston, and an inner ring, all of which have a center that is substantially coincident with a central axis of the cylinder. The piston top of the second piston has three regions: a center, outer ring near the periphery of the piston, and inner ring, all of which have a center that is substantially coincident with the central axis of the cylinder. Surfaces of the pistons are a predetermined distance apart in the outer ring and center regions when the crankshaft is at the particular angle. A volume between the first and second pistons proximate the inner ring substantially forms a toroidal volume when the crankshaft is at the particular angle. The predetermined distance is in the range of 0.5 to 3 mm.
[0006] The engine also includes a fuel injector disposed in the cylinder wall with an axis of the fuel injector roughly normal to the cylinder wall. A channel is defined in the outer ring to provide an opening for line-of-sight access from a tip of the injector to the toroidal volume formed between the pistons. The fuel injector has at least one orifice and the orifice is arranged so that a spray exiting the orifice is largely directed into the toroidal volume. The fuel injector may contain a plurality of orifices from which fuel sprays exit. In some embodiments, two fuel injectors are provided and orifices of the injector are aligned with channels cut into the outer ring of the pistons for line-of-sight access from the tips of the injectors to the toroidal volume formed between the pistons. The first and second injectors are located about 180 degrees around the cylinder from each other.
[0007] In one embodiment, the surfaces of the first and second pistons in the center regions are substantially flat. Alternatively, a surface of the first piston is concave in the central region and the second piston is convex in the central region. The engine is a two-stroke engine; the first piston is an intake piston; the second piston is an exhaust piston; intake ports are defined in the cylinder wall proximate the intake piston; and exhaust ports are defined in the cylinder wall proximate the exhaust piston.
[0008] Also disclosed is a method to provide fuel to an opposed-piston, internal-combustion engine including: injecting fuel multiple times into a combustion chamber, which includes: a cylinder wall, an intake piston disposed within the cylinder wall, an exhaust piston disposed within the cylinder wall with a top of the intake piston opposite a top of the exhaust piston. The tops of the intake and exhaust pistons each have three regions: a center, an outer ring near the periphery of the piston, and an inner ring, all of which are have a center substantially coincident with a central axis of the cylinder. Two channels are defined in the inner ring region of the intake piston with the two channels diametrically opposed. A volume between the first and second pistons proximate the inner ring substantially forms a toroidal volume. The combustion chamber further includes first and second fuel injectors disposed in the cylinder wall with the first injector proximate the first channel and the second injector proximate the second channel. The injection can be single event or multiple events based on different operating conditions. The multiple injections are separated in time such that a fuel cloud from a second injection is substantially separate from a fuel cloud from the first injection.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is an isometric drawing of an OPOC engine;
[0010] FIGS. 2 and 3 are cross sections of a combustion chamber according to an embodiment of the disclosure;
[0011] FIG. 4 is a sketch of the regions on the piston top;
[0012] FIGS. 5 and 6 show the combustion chamber of FIGS. 2 and 3 at crank angle positions displaced from that of the closest approach of the pistons;
[0013] FIG. 7 is a cross section of a combustion chamber according to an embodiment of the disclosure;
[0014] FIGS. 8 and 9 illustrate intake and exhaust piston tops, respectively, for the combustion chamber of FIG. 7 ;
[0015] FIG. 10 is an illustration of the piston top of the intake piston associated with the combustion chamber of FIGS. 2 and 3
[0016] FIGS. 11-16 illustrate the location of fuel clouds from multiple injections into a combustion chamber according to an embodiment of the disclosure; and
[0017] FIG. 17 shows a simulation of fuel injection and combustion in a chamber according to an embodiment of the disclosure.
DETAILED DESCRIPTION
[0018] As those of ordinary skill in the art will understand, various features of the embodiments illustrated and described with reference to any one of the Figures may be combined with features illustrated in one or more other Figures to produce alternative embodiments that are not explicitly illustrated or described. The combinations of features illustrated provide representative embodiments for typical applications. However, various combinations and modifications of the features consistent with the teachings of the present disclosure may be desired for particular applications or implementations. Those of ordinary skill in the art may recognize similar applications or implementations whether or not explicitly described or illustrated.
[0019] In FIG. 2 , a cross section of a portion of an OPOC engine is shown illustrating a combustion chamber according to an embodiment of the disclosure. A portion of intake piston 40 and a portion of exhaust piston 42 are shown at their closest position. Piston 40 has grooves 44 and 45 and piston 42 has grooves 46 and 47 to accommodate piston rings (not shown). Pistons 40 and 42 reciprocate within cylinder wall 50 . The combustion chamber is the volume enclosed between the tops of pistons 40 and 42 and the cylinder wall 50 .
[0020] The cross section illustrated in FIG. 3 is a rotated 90 degrees with respect to the cross section illustrated in FIG. 2 . The cross section in FIG. 3 cuts through injectors 60 . It can be seen that proximate injectors 60 , a pocket 62 is provided to accommodate injectors 60 . Sprays emanating from injectors 60 are discussed below.
[0021] A top of intake piston 140 is shown in FIG. 4 . The piston is shown having three regions: outer ring 152 , inner ring 154 , and center 156 . Exhaust piston 142 has three corresponding regions: an outer ring, an inner ring, and a center. The majority of the volume of the combustion chamber, when the pistons are in close proximity, is contained in the volume between the inner ring surface of the intake piston and the inner ring surface of the exhaust piston. Outer ring 152 includes passages 158 defined therein to allow for line-of-sight access between fuel injectors (not shown) and the toroidal volume associated with inner ring 154 . As shown in FIG. 2 , the surfaces of the outer ring of the intake and exhaust pistons are displaced from each other a small distance: at most 2 mm, at least 0.5 mm. Very little of the combustion chamber volume is contained between the pistons in the outer ring region. Similarly, the exhaust piston top and the intake piston top are displaced from each other a very small distance in the center region and thus, very little of the combustion chamber volume is contained between the pistons in the center region.
[0022] The cross section of the combustion chamber volume, as shown in FIGS. 2 and 3 , is two oval areas 64 . The shape of the combustion chamber in the inner ring region is a surface of revolution generated by revolving oval area 64 in space about a central axis 66 of cylinder 50 . Strictly speaking, a torus is the result of rotating a circle around an axis. However, in the present disclosure, the term torus is used to apply to any 2 -dimensional shape rotated about the central axis. In the embodiment in FIGS. 2 and 3 , the shape rotated about the central axis is generally curved, but not a circle. Nevertheless, the term torus is applied to the resulting combustion chamber. Furthermore, the term torus is being used to describe a shape in which the cross-sectional area is not constant as taken along points in the revolution. For example in FIG. 4 , as outer ring 152 is shown as an annulus and is defined by a circle at the interior edge and center 156 is an oval. Dotted lines 160 and 162 are axes of symmetry of center 156 . If the depth of inner ring 154 is substantially constant throughout inner ring 154 , the lesser width near axis 160 indicates that the cross sectional area (taken through the central axis of the cylinder) is less than the cross sectional area near axis 162 . The term toroidal volume is applied to such a situation in which the cross-sectional area varies around the circumference. Also, the smaller cross-sectional area is smaller close to passages 158 because the fuel coming out of the injectors is compact. The cross sectional area is greater in the region of axis 162 , which is farther from the injector tips. At this location, the fuel spray has expanded. With such a configuration, it is easier to avoid fuel droplets from impacting the piston top when the larger cross-sectional area is provided somewhat away from the injector tip.
[0023] The center region of the top of intake piston 40 has a concave shape and the center region of the top of exhaust piston 42 has a convex shape; these nest together. The top of exhaust piston 42 is at a higher temperature than the top of intake piston 40 because the exhaust gases exit through exhaust ports proximate exhaust piston 42 . Thus, it is an advantage for exhaust piston 42 to have a convex shape with no corners that might generate hot spots. Corners 68 on center region 56 of the top of intake piston 40 could be problematic on an exhaust piston, but are less likely to present issues on an intake piston.
[0024] Pistons 40 and 42 are at their closest approach in FIGS. 2 and 3 . The combustion chamber at a position 10 crank angle degrees rotated away from the position of closest approach is shown in FIGS. 5 and 30 crank degrees rotated in FIG. 6 .
[0025] In an alternative embodiment in FIG. 7 , center regions 96 of the intake and exhaust pistons are flat. The bulk of the combustion chamber in this alternative is yielded by revolving region 98 about central axis 66 of cylinder 50 .
[0026] In FIG. 8 , a view of the top of intake piston 80 is shown with orifices on injectors 60 situated so that fuel jets 106 travel through channels in the piston top. The channels are not separately visible in the view in FIG. 8 . Fuel jets 106 are directed into the inner ring region 102 , which is depressed with respect to center region 104 and outer ring region 100 . In the embodiment shown in FIG. 8 , four fuel jets emanate from injector 60 , with one of the fuel jets not visible. There is a very small angle between the individual jets. Alternatively, an injector with a different number of jets may be used. The jets are directed along a tangent of the surface of the toroidal volume to limit the amount of fuel droplets coming in direct contact with the piston top. The rounded surfaces of the torus help to direct the flow toward the center of the toroidal volume.
[0027] In FIG. 9 , the top of exhaust piston 82 has a raised outer ring 120 with the inner ring 122 and 124 being at the same level of depression. Injectors 60 are shown directing fuel through channels (not separately shown) into inner ring region 122 at a direction substantially tangent to an interior edge of outer ring 120 . There is just one pair of injectors 60 , but illustrated in both FIGS. 8 and 9 to show how the fuel jets interact with the piston tops of the pistons.
[0028] In FIG. 10 , a detail of the top of intake piston 40 of FIGS. 2 and 3 is shown. A channel 130 is provided through outer ring 126 of the piston top to allow fuel jets to exit into the inner channel. Fuel jets are not shown in channel 130 . Opposite channel 130 is another channel which is not visible due to the jets 132 a, 132 b, 132 c , and 132 d being illustrated, thereby not allowing a view of the channel. Fuel jets 132 a - d are directed into the depression associated with inner ring 127 . Center region 128 is oval. This allows a wider space in inner ring 127 to accommodate the fuel jets. Edge 136 is the visible edge of outer ring 126 from this view. The dashed line 138 shows that inner ring 127 is slightly re-entrant. There is no such undercut along the 2-2 section.
[0029] A method of distributing fuel into the cylinder is illustrated in FIGS. 11-16 . Piston top 200 has channels 202 through which fuel jets can be sprayed. Piston top 200 has three regions: center 208 , inner ring 206 and outer ring 204 . A swirl flow 210 is developed, as shown in FIG. 11 . In FIG. 12 , fuel jets 212 are first injected. In FIG. 13 , illustrating a snapshot later in time, fuel jets 212 rotate in inner ring 206 due to the momentum of the jets themselves as well as the swirl 200 . Fuel jets 212 become fuel clouds in FIG. 13 . In FIG. 14 , an even later snapshot, a second injection causes fuel jets 214 to enter inner ring 206 . The timing of the second injection is such that the tips of fuel jets 214 substantially do not overlap with fuel jets (now clouds) 212 . In FIG. 15 , fuel jets 212 and 214 are now both fuel clouds and have moved around inner ring 214 further. At a later time, in FIG. 16 , a third injection produces fuel jets 216 with the timing of the third injection so that none of the clouds substantially overlap. Furthermore, the third cloud from the first injector does not overlap with the first cloud from the second injector.
[0030] FIGS. 3 , 4 and 6 show the combustion chamber shape from when the pistons are at their position of closest approach ( FIG. 3 ) as they move away from each other ( FIGS. 5 and 6 ). FIGS. 3 , 4 and 6 can be considered in reverse order to show the combustion chamber shape as the pistons are moving toward each other. By considering the change of the combustion chamber from FIG. 6 to FIG. 5 , the air that is between pistons 40 and 42 in the outer ring portion 52 is squished into the inner ring portion 54 . Similarly, air between pistons 40 and 42 in the center 56 is squished into the inner ring portion 54 . The movement caused by these squish flows is shown by arrows 58 a - d . Because the opening connecting the volume associated with the outer ring region 52 with the volume associated with the inner ring region 54 is tangent to the inner ring region 54 , a tumble flow is induced. Similarly, the opening connecting the volume associated with the center region 56 is tangent to the inner ring region, also promoting a tumble flow. The flow exiting from the squish regions induces flows in the direction of arrows 58 a and 58 b which causes a clockwise tumble, as view in the cross section illustrated in FIG. 5 . The flow exiting from the squish regions induces flows in the direction of arrows 58 c and 58 d which causes a counter clockwise tumble.
[0031] In FIG. 17 , a representation of modeling results is shown. Two injectors 250 inject fuel primarily into inner ring region 254 , which is between center 252 and outer ring 256 . The intake ports (not shown) are angled such that a swirl flow is induced by incoming gases into the cylinder, as shown by clockwise arrow 248 . Injectors 250 inject fuel tangentially into inner ring region 254 in the direction of the swirl, as shown by arrow 248 . Thus, fuel droplets are carried by the swirl flow.
[0032] A limitation in obtaining satisfactory combustion at the highest load condition is utilizing the air in the cylinder. This is accomplished by the fuel droplets being relatively uniformly mixed in the air at the highest torque operating condition in which the most fuel is injected. The representation in FIG. 17 is for a 100 mm bore cylinder with a swirl ratio of 5 at the highest torque condition, i.e., longest fuel pulse width anticipated. The crank angle illustrated in FIG. 17 is about 20 degrees into the expansion stroke, which is also the end of the fuel injection interval. Liquid droplets 260 and 262 are contained mostly in inner ring 254 . Droplets 260 and 262 are shown much larger than in reality so that they can be viewed in FIG. 17 . Much of the fuel has vaporized and combustion is occurring. Surfaces 270 and 272 are isothermal surfaces which are indicative of the surface of the flame. Some of the combustion is occurring in outer ring 256 having spilled out of inner ring 254 . In FIG. 17 , it can be seen that tips 274 and 276 of combustion surfaces 270 and 272 , respectively, do not overlap. Based on hole sizes on the injector tip, injection pressure, the number of orifices on the injector, and the swirl ratio, the air utilization, as illustrated in FIG. 17 in which the combustion surfaces do not overlap but encompass most of inner ring 254 , can be obtained.
[0033] Small orifices in the injector create small droplets that vaporize more readily. Such small droplets are helpful in avoiding soot formation. However, small droplets have low inertia and do not travel far into the chamber, which is harmful for air utilization. By injecting the fuel in the same direction as the swirl flow, small droplets are carried by the flow to access unused air away from the injector, thereby facilitating the injection of smaller droplets than could otherwise be used.
[0034] While the best mode has been described in detail with respect to particular embodiments, those familiar with the art will recognize various alternative designs and embodiments within the scope of the following claims. While various embodiments may have been described as providing advantages or being preferred over other embodiments with respect to one or more desired characteristics, as one skilled in the art is aware, one or more characteristics may be compromised to achieve desired system attributes, which depend on the specific application and implementation. These attributes include, but are not limited to: cost, strength, durability, life cycle cost, marketability, appearance, packaging, size, serviceability, weight, manufacturability, ease of assembly, etc. The embodiments described herein that are characterized as less desirable than other embodiments or prior art implementations with respect to one or more characteristics are not outside the scope of the disclosure and may be desirable for particular applications. | A toroidal combustion chamber shape with a side injector is disclosed for an opposed-piston engine. Fuel is injected into the toroidal volume from a fuel injector in the cylinder wall. In one embodiment, fuel is injected from each injector a plurality of times with the timing between the injections such that fuel clouds from each injection remain substantially isolated from each other. | 5 |
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to an apparatus for supplying gas to inflate a vehicle occupant restraint, such as an airbag, and particularly to an apparatus for supplying generated gas along with stored gas. Description of the Prior Art
Typically, an inflatable vehicle occupant restraint is inflated solely by gas which is generated by ignition of gas generating material. The gas generating material is generally volatile and must be handled carefully. Some have suggested that inflatable restraints be inflated by gas which is stored under pressure and by gas which is generated through ignition of gas generating material. In this way, the amount of gas generating material used can be reduced
U.S. Pat. No. 3,723,205 discloses an apparatus for supplying gas to inflate a vehicle occupant restraint. The apparatus comprises gas generating material in combination with stored pressurized gas. The stored gas can be nitrogen, air, carbon-dioxide or helium. The gas generating material, when ignited, generates a hot gas. The gas generating material comprises a halogen free alkali metal salt, an inorganic oxidizer, and a polyvinyl chloride binder. Suitable inorganic oxidizers include alkali metal chlorates and perchlorates, such as ammonium perchlorate, and alkaline earth metal nitrates. Examples of halogen-free alkali metal salts are alkali metal oxalates, carbonates, bicarbonates, and azides, e.g., KN 3 , The generated gas ruptures a seal and is directed into the pressurized stored gas. This increases the temperature and thus the pressure of the stored gas causing the commingled stored gas and generated gas to rupture a second seal. The commingled gas then flows into an inflatable device.
In U.S. Pat. No. 3,723,205 the ignition of the gas generating material creates relatively small particles which flow with the gas directly into the inflatable device. Removing these relatively small particles apparently was considered unnecessary because the patent does not disclose a technique for removal of these particles.
SUMMARY OF THE INVENTION
The present invention relates to a source of gas for inflating a vehicle occupant restraint such as an airbag. The source of gas comprises a container in which gas generating material is located. The gas generating material comprises an alkali metal azide and a metal oxide. The container also contains a supply of pressurized nitrogen gas which is separated from the gas generating material. The gas generating material when ignited produces heated nitrogen gas. An ignitor ignites the gas generating material to create the heated nitrogen gas. In the event of an emergency situation, such as a vehicle collision, the gas generating material is ignited by the ignitor to produce the heated nitrogen gas. The heated nitrogen gas commingles with the stored nitrogen gas, and commingled gases then flow toward the inflatable vehicle occupant restraint. The flow is constrained to follow a tortuous path whereby the residue produced by combustion of the gas generating material is separated from the commingled gases as the gases flow toward the inflatable vehicle occupant restraint.
Preferably, the tortuous path is defined such that molten metal and other particles in the residue deposit on the walls defining the path. Also, particles of nonmolten residue become trapped and do not flow into the inflatable vehicle occupant restraint. The tortuous path is defined in part by openings in the container which direct the gas transversely of the longitudinal axis of the container and into a diffuser. The diffuser directs the gas parallel to the longitudinal axis of the container and has openings which direct the gas again transversely of the longitudinal axis of the container and toward the airbag.
The tortuous path is also defined in part by the container. The container includes an inner housing containing the gas generating material and an outer housing containing the stored gas. The gas generated by ignition of the gas generating material is directed through an exit passage from the inner container in one direction parallel to the longitudinal axis of the container. The gas then flows in another direction opposite the one direction parallel to the longitudinal axis of the container. The gas then flows through the openings in the container which direct the gas transversely of the longitudinal axis of the container.
Further, during the flow of gas toward the inflatable vehicle occupant restraint, the gas is directed into a helical flow path. Preferably, this occurs when the gas is flowing in a direction parallel to the longitudinal axis of the container and prior to the gas flowing into the diffuser. Gas directing blades are each formed in a helical shape to create the helical flow. The blades are positioned in the gas flow in an axially spaced relation and extend at an angle to the gas flow and thus create the helical flow. The creation of the helical flow results in turbulence and deposit of residue on the blades and on the walls of the container adjacent the blades.
In addition, the container includes a pair of burst disks. One burst disk controls the flow of the gas generated by ignition of the gas generating material. The other burst disk controls the flow of gas from the container toward the inflatable vehicle occupant restraint. The disk which controls the flow of gas from the container toward the inflatable vehicle occupant restraint is heated to weaken the disk and thereby allow the pressure of the stored gas to break the disk. Each of the burst disks is a bulged prescored disk which has areas that pivot open to allow the gas to flow past the disk.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features of the present invention will become apparent to those skilled in the art to which the present invention relates from reading the following specification with reference to the accompanying drawings, in which:
FIG. 1 is a longitudinal sectional view of an apparatus for supplying gas to inflate a vehicle occupant restraint in accordance with the present invention;
FIG. 2 is an enlarged sectional view of a portion of the apparatus of FIG. 1;
FIG. 3 is a view taken approximately along line 3--3 of FIG. 2; and
FIG. 4 is a sectional view taken approximately along line 4--4 of FIG. 1.
DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention is directed to an apparatus for providing gas to inflate an inflatable vehicle occupant restraint such as an airbag. The apparatus may take a variety of forms and may vary in detailed structure. As illustrative of the present invention, the drawings illustrate a preferred embodiment which includes a container 14 for providing gas to inflate an airbag.
Referring to FIG. 1, the container 14 comprises an elongated cylindrical outer housing 16. The outer housing 16 contains stored nitrogen gas under pressure. The stored nitrogen gas housing 16 comprises a thin wall housing closed at one end 20. At its opposite end 26, the outer housing 16 is closed off by an end cap 28. End cap 28 has a diameter corresponding with end 26 of the outer housing 16. The end cap 28 is seated on the end 26 of the outer housing 16 and is welded to the end 26 by a circular weld 30. Weld 30 seals the end cap 28 to outer housing 16. The outer housing 16 is capable of retaining nitrogen gas at high pressures in the range of 3,000 to 3,500 psi.
The container 14 also comprises an outer cylindrical diffuser 40 which surrounds the stored nitrogen gas outer housing 16. The diffuser 40 is spaced from the outer housing 16 so that it defines with the outer housing 16 a diffusion chamber 42. The diffuser 40 is substantially coextensive with the stored nitrogen gas housing 16 and is welded at one end to the outer housing 16 and at its other end to end cap 28 by circular welds 44, 46.
The container 14 also comprises a gas generator 50, which is positioned within the outer housing 16. The gas generator 50 extends longitudinally within the outer housing 16, but its center line 52 is offset slightly to one side of the center line 54 of the housing 16. The gas generator 50 comprises a tubular inner housing 56. The tubular inner housing 56 may be formed in one piece with end cap 28 or welded to end cap 28 as illustrated. The inner housing 56 has a chamber 68 filled with gas generating material 70. The chamber 68 communicates with a passage 62 which is formed in the end cap 28 and which contains a squib 64, or other ignition device. The squib 64 is sealed in the passage 62. The squib is ignitable, for instance, by electric current in a known manner, the current being conveyed to the squib wires 66. Ignition of the squib 64 ignites the gas generating material 70 in chamber 68. The squib 64 is an ignition-type squib which is well known. A typical squib which could be used is marketed by Special Devices, Inc. under Model designation 89295.
The gas generating material 70 comprises shaped grains pressed from a mixture of an alkali metal azide compound and a metal oxide. The metal of the metal oxide is lower in the electromotive series than the alkali metal, so that the alkali metal will completely react with the metal oxide, replacing the metal in the metal oxide. The stoichiometry of the gas generating composition is such that all of the alkali metal will react with the metal oxide and no unreacted free alkali metal remains.
Examples of suitable alkali metals are sodium, potassium and lithium. Examples of suitable metal oxides are iron oxide (Fe 2 O 3 or Fe 3 O 4 ), copper oxide (CuO), aluminum oxide, and silicon dioxide (SiO 2 ).
The gas generating material 70 preferably contains a predetermined amount of fibers, such as graphite fibers, to reinforce the grains mechanically and avoid cracks in the grains. Cracks in a grain produce unwanted grain surface area that can accelerate grain burn rate in an unpredictable manner. The graphite fibers also function to promote burning of the grains and assist in forming a larger, stronger sinter. The use of fibers assists in producing a relatively coarse residue which consists substantially of materials which are non-volatile under the reaction conditions. Fibers other than graphite, such as glass and steel wool, can be used. The graphite fibers can, by way of example, be 3-6 microns in diameter and 40-80 thousandths of an inch in length.
The gas generating material 70 preferably also contains an extrusion aid such as bentonite, a binder such as sodium nitrate, and a sintering aid such as fumed silicon dioxide. One suitable silicon dioxide is sold under the trademark CAB-0-SIL by Cabot Manufacturing Company with the product designation EH5.
A preferred gas generating composition comprises:
______________________________________Component Preferred Range Example______________________________________Sodium Azide 61-68% 63%Iron Oxide 23-28% 26.5%Graphite Fibers 2-5% 4%Bentonite 0-5% 2%Fumed Silicon 1-2% 2%DioxideSodium Nitrate 0-5% 2.5%______________________________________
The iron oxide is doped with about 1% nickle oxide.
The shape of the grains of gas generating material 70 is not critical. A preferred shape comprises "macaroni" shaped pieces, as shown. Each such piece is about a quarter to one-half inch in length, e.g. 0.4 inch, about 0.25 inch in diameter, and has a central longitudinal opening of about 0.09 inch in diameter. To produce the macaroni shaped pieces of the gas generating material, a slurry is formed of the gas generating ingredients, and the slurry is extruded through a die to the desired shape. The extruded material is then cut to desired lengths and the extruded pieces are dried. The gas generating material can have other configurations, for instance a pill-shape In the embodiment of the present invention illustrated in the Figures, the gas generating material 70 is randomly disposed within the chamber 68. By way of example, forty to fifty grams of gas generating material 70 may be used.
Preferably, the inner housing 26 also contains a booster material 72. The booster material 72 is an ignition enhancing material which is ignitable by squib 64 and produces a high temperature flame that enhances the ignition of the gas generating material 70. The booster material 72 preferably comprises a metal fuel such as magnesium, boron, or chromium, and an oxidant such as an alkali or alkaline earth metal nitrate, chlorate, chromate, or perchromate Another known oxidant is a halogen containing hydrocarbon homopolymer or copolymer, such as TEFLON and VITON (Trademarks E.I. Dupont de Nemours & Co.). One suitable booster material is boron potassium nitrate (BKNO 3 ). This booster material ignites with a high caloric output of about 1100-1650 calories per gram. Another suitable booster material comprises a granular mixture of 25% by weight of boron and 75% potassium nitrate, with or without 10% lead azide. This mixture burns with a very high flame suitable for igniting gas generant material and is disclosed in U.S. Pat. No. 4,561,675. The booster material 72 is shown in the drawings as discrete pills positioned adjacent to the squib 64 and interposed between the gas generating material 70 and the squib 64. Alternatively, the booster material can be mixed into the formulation of the gas generating material, or applied as a coating to the gas generating material, or dispersed as discrete grains throughout the chamber 68. Preferably the booster material is present in the chamber 68 in an amount up to about 30%, for instance about 10%, of the weight of the material in the chamber 68.
Referring to FIG. 2, the gas generator inner housing 56 has at its end 80 away from the squib 64 an inwardly projecting rim 82 defining a narrowed opening 84. A particle filter 79 is located in the chamber 68 adjacent opening 84. The filter 79 is a metal disk, preferably a steel disk, having a plurality of openings therein of a suitable size, such as 0.090 inches. The disk functions to trap large particles in the generated gas in the chamber 68.
The rim 82 of the inner housing 56 functions in part to retain the gas generating material 70 within the chamber 68, and in part as a seat for a burst disk 86 which closes opening 84. The burst disk 86 (FIG. 3) comprises a bulged (domed) center portion 88, which extends toward chamber 68, and a peripheral flange 90. The burst disk 86 is preferably welded to the inner housing 56.
The bulged burst disk 86 can be comprised of a number of different materials. One suitable material is stainless steel. The bulged burst disk 86 is preferably scored with crossed score lines 94 in the center portion 88, as shown in FIG. 3. The score lines define areas of the bulged burst disk which are petal shaped and which pivot or move outwardly relative to chamber 68 when the bulged burst disk bursts.
In operation, the squib 64 fires the booster material 72 which, in turn, ignites the gas generating material 70. This generates a high pressure gas which ruptures the burst disk 86 allowing the generated gas to exit at high velocity from the chamber 68 through the filter 79 and passage 84. The gas jet exiting from passage 84 is directed at high velocity generally parallel to the longitudinal axis 54 of the outer housing 16 in the direction of arrow 100, FIG. 1. The gas jet flows towards the closed end 20 of the outer housing 16. The closed end 20 has a domed inner deflection surface 102. The domed surface 102 forces the gas jet to make a 180 degree turn and to flow back along the outer housing 16 towards the housing end 26, as shown by arrows 104 in FIG. 1. This flow is also generally parallel to the longitudinal axis 54 of the outer housing 16 but in a direction opposite the direction of arrow 100.
The gas jet exiting from passage 84 comprises primarily nitrogen gas and solid residue in the form of relatively large particulates and molten metal. Because of the 180 degree turn at the end 20 of the outer housing 16, at least some of the relatively large particulates are inertially removed from the nitrogen gas stream, and impinge and fuse against the domed surface 102. In a preferred embodiment of the present invention, the domed surface 102 is coated with a coating material 106, such as a high temperature silicone grease, which helps capture particles at surface 102 rather than allowing them to rebound into the nitrogen gas jet stream. An example of a suitable coating material is a valve and lubricant sealant marketed by Dow Corporation under the trade designation "Dow Sealant 111".
Gas flowing in the path illustrated by arrows 104 impinges against a pair of helical blades 108, 109 (see FIG. 4) which are interposed in the annular space 110 between the inner housing 56 and outer housing 16. The blades 108, 109 are spaced axially from each other along the housing 16, and each extends about 180° about the inner housing member 56. The axial spacing is illustrated in FIGS. 1 and 2, with blade 108 being shown in phantom lines. The blades are also circumferentially spaced about 180° relative to each other. Thus, about one half of the gas flow engages each blade and is directed into a helical path through which the gas swirls about the inner housing member 56. This causes the stream of gas to adopt a helical path which results in further inertial separation of residual products of combustion from the nitrogen gas stream and fusion of molten products on the surfaces of the blades 108, 109 and housings 16, 56.
The end cap 28 has a passage 120 which is offset to one side of the center of the end cap 28 and is in communication with the annular space 110. The passage 120 contains a squib 122 which is threaded into and sealed in the passage 120. The passage 120 is covered with a burst disk 124 which is similar to the burst disk 86. The burst disk 124 has a center bulged domed portion 126, which extends into the passage 120, and a peripheral flange portion 128, which is welded to a surface 130 of the end cap 28. The burst disk 124 blocks fluid communication between annular space 110 and passage 120.
The passage 120 has a chamber portion 132 interposed between the bulged burst disk 124 and the squib 122. The chamber portion 132 communicates with passages 134 which extend laterally through the end cap 28 and transversely of the axis 54 of the outer housing 16. The passages 134 open to the diffusion chamber 42. The gas exiting into the diffusion chamber 42 from the radial passages 134 is guided in a direction generally parallel to the axis 54 of the outer housing 16. The gas then encounters a pair of radially extending baffles 140, 141 around which the gas must flow. The baffles 140, 141 trap further particles in the gas. The diffuser 40 has radially extending openings 142 which are located downstream of the baffles 140, 141 and which direct gas from the diffusion chamber 42 to a vehicle restraint such as an airbag.
In operation, the squib 122, when fired, produces a high temperature which heats the burst disk 124 to a high temperature. One suitable type of squib is marketed by Dynamit Nobel under the trade designation "AZEL 7, Mod. 3". This reduces the tensile strength of the burst disk 124 and causes the burst disk 124 to rupture due to the pressure within the outer housing 16. On rupture of the burst disk 124, the gas within housing 16 exits through passage 120 into chamber portion 132 and flows through radial passages 134 into the diffusion chamber 42. The gas exits from the diffusion chamber through openings 142.
By the present invention, the amount of gas generating material required can be substantially reduced compared with the amount required in conventional gas generating apparatus. For instance, the apparatus of the present invention may require 1/10th of the gas generating material conventionally required. In addition, the present invention enables substantial flexibility in the inflation of the airbag. For instance, relative amounts of booster material, gas generating material and stored nitrogen gas can be varied. Also, the sequence of firing the squibs 64 and 122 can be varied. For instance, squib 122 can be fired before squib 64 to release stored nitrogen gas to the airbag first, or can be fired after squib 64 to release the commingled gases. The present invention also provides for effective removal of particulate from the nitrogen gas. This is facilitated by the composition of the gas generating material 70 which is such as to produce a particulate having a relatively large particle size. Further the multiple changes of direction for the gas stream as it flows from the inner housing 56 and from the outer housing 16 to the airbag provide a tortuous path which inertially separates particulates from the gas stream. Thus, a minimum amount of particulates are directed into the airbag.
From the above description of a preferred embodiment of the invention, those skilled in the art will perceive improvements, changes and modifications. Such improvements, changes and modifications within the skill of the art are intended to be covered by the appended claims. | A source of gas for inflating a vehicle occupant restraint comprises a container. Gas generating material in said container comprises an alkali metal azide and a metal oxidizer. When ignited, the gas generating material produces heated nitrogen gas. A supply of pressurized nitrogen gas is also in the container. Structure is provided for separating the supply of pressurized nitrogen gas from the gas generating material. The separating structure is releasable to enable the heated nitrogen gas and the stored nitrogen gas to commingle. The source of gas also includes structure for directing the stored nitrogen gas and the heated nitrogen gas through a tortuous path toward the vehicle occupant restraint so as to remove particulates from the gases. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation application of PCT Application No. PCT/CN2015/097852 filed on Dec. 18, 2015 which claims priority to Chinese Application No. 201410796582.9 filed on Dec. 19, 2014, the entire contents of which are hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to two-dimensional (2D) photonic crystal (PhC) optical OR-transformation logic gates.
BACKGROUND OF THE INVENTION
[0003] In 1987, the concept of PhC was proposed separately by E. Yablonovitch from United States Bell Labs who discussed how to suppress spontaneous radiation and by S. John from Princeton University who made discussions about photonic localization. A PhC is a material structure in which dielectric materials are arranged periodically in space, and is usually an artificial crystal consisting of two or more materials having different dielectric constants.
[0004] With the emergence of and in-depth research on PhC, people can control the motion of photons in a PhC material more flexibly and effectively. In combination with traditional semiconductor processes and integrated circuit technologies, design and manufacture of PhCs and devices thereof have continually and rapidly marched towards all-optical processing, and the PhC has become a breakthrough for photonic integration. In December 1999, the PhC was recognized by the American influential magazine Science as one of the top-ten scientific advances in 1999, and therefore has become a hot topic in today's scientific research field.
[0005] An all-optical-logic device mainly includes an optical amplifier-based logic device, a nonlinear loop mirror logic device, a Sagnac interference-type logic device, a ring-cavity logic device, a multi-mode-interference logic device, an optical-waveguide-coupled logic device, a photo isomerized logic device, a polarization-switch optical-logic device, a transmission-grating optical-logic device, etc. These optical-logic devices have the common short coming of large size in developing large-scale integrated optical circuits. With the improvement of science and technology in recent years, people have also done research and developed quantum-optical-logic devices, nanomaterial-optical-logic devices and PhC-optical-logic devices, which all conform to the dimensional requirement of large-scale optical integrated circuits. For modern manufacturing processes, however, the quantum-optical-logic devices and the nanomaterial optical-logic devices are very difficult to be manufactured, whereas the PhC-optical-logic devices have competitive advantages in terms of manufacturing process.
[0006] In recent years, PhC-logic devices have become a hot area of research drawing widespread attentions, and it is highly likely for them to replace the current widely-applied electronic-logic devices in the near future. The PhC-logic device can directly realize all-optical-logical functions, such as “AND”, “OR”, “NOT” and the like, and is a core device for realizing all-optical computing. In the process of realizing all-optical computing, PhC-logical function devices based on “AND”, “OR”, “NOT”, “XOR” and the like have been successfully designed and investigated, and various complex logic components are still needed for achieving the goal of all-optical computing.
SUMMARY OF THE INVENTION
[0007] The present invention is aimed at overcoming the defects of the prior art and providing a PhC all-optical OR-transformation logic gate with compact structure, strong anti-interference capability, and ease of integration with other optical-logic elements.
[0008] The technical proposal adopted by the invention to solve the technical problem is as follows:
[0009] The PhC all-optical OR-transformation logic gate of the present invention comprises an optical switch unit (OSU), a PhC-structure unit, a reference light, a wave-absorbing load (WAL) and a D-type flip-flop (DFF) unit; two system-signal-input ports are respectively connected with a first logic-signal X 1 and a second logic-signal X 2 ; the reference-light source is connected with the reference-light-input port of the OSU; three intermediate-signal-output ports are respectively connected with two intermediate-signal-input ports of the PhC-structure unit and the WAL; a clock-signal CP is input into the input port of a two-branch waveguide which connects with a first clock-signal-CP-input port of the OSU and a second clock-signal-CP-input port of the DFF unit, respectively; the signal-output port of the PhC-structure unit is connected with the D-signal-input port of the DFF unit.
[0010] The OSU is a 3×3 optical-selector switch; the OSU comprises a first clock-signal-CP-input port, two system-signal-input ports, a reference-light-input port and three intermediate-signal-output ports; the two system-signal-input ports are respectively the first logic-signal-input port and the second logic-signal-input port; the three intermediate-signal-output ports are respectively the first intermediate-signal-output port, the second intermediate-signal-output port and the third intermediate-signal-output port.
[0011] The PhC-structure unit is a 2D-PhC cross-waveguide nonlinear cavity; the PhC-structure unit is a 2D-PhC cross-waveguide four-port network formed by high-refractive-index dielectric pillars, a left port of the four-port network is the first intermediate-signal-input port, a lower port is the second intermediate-signal-input port, an upper port is the signal-output port, and a right port is an idle port; two mutually-orthogonal quasi-1D PhC structures are placed in two waveguide directions crossed at a center of a cross waveguide, a dielectric pillar is arranged in the middle of the cross-waveguide, a dielectric pillar is made of a nonlinear material, a cross section of the dielectric pillar is square, polygonal, circular or oval; the dielectric constant of a rectangular linear pillar clinging to the central nonlinear pillar and close to the signal-output port is equal to that of the central nonlinear pillar under low-light-power conditions; and the quasi-1D PhC structures and the dielectric pillar constitute a waveguide defect cavity.
[0012] The DFF unit comprises a clock-signal-input port, a D-signal-input port and a system-output port; the input signal at the D-signal-input port of the DFF unit is equal to the output signal at the output port of the PhC-structure unit.
[0013] The 2D PhC is a (2k+1)×(2k+1) array structure, where k is an integer more than or equal to 3.
[0014] The cross section of the high-refractive-index dielectric pillar of the 2D PhC is circular, oval, triangular or polygonal.
[0015] A background filling material for the 2D PhC is air or a different low-refractive-index medium with the refractive index less than 1.4.
[0016] The refractive index of the dielectric pillar in the quasi-1D PhC of the cross waveguide is 3.4 or a different value more than 2; the cross section of the dielectric pillar is rectangular, polygonal, circular or oval.
[0017] Compared with the prior art, the present invention has the following advantages:
[0018] 1. Compact in structure, and ease of manufacture;
[0019] 2. Strong anti-interference capability, and ease of integration with other optical-logic elements; and
[0020] 3. High contrast of high and low logic outputs, and fast operation.
[0021] These and other objects and advantages of the present invention will become readily apparent to those skilled in the art upon reading the following detailed description and claims and by referring to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a structural schematic diagram of a PhC all-optical OR-transformation logic gate of the present invention;
[0023] In FIG. 1 , the indications are: OSU 01 , first logic-signal-input port 11 , second logic-signal-input port 12 , reference-light-input port 13 , first intermediate-signal-output port 14 , second intermediate-signal-output port 15 , third intermediate-signal-output port 16 , first clock-signal-input port, PhC-structure unit 02 , first intermediate-signal-input port 21 , second intermediate-signal-input port 22 , idle port 23 , signal-output port 24 , circular high-refractive-index linear-dielectric pillar 25 , first rectangular high-refractive-index linear-dielectric pillar 26 , second rectangular high-refractive-index linear-dielectric pillar 27 , nonlinear-dielectric pillar 28 , first logic-signal X 1 , second logic-signal X 2 , reference-light 03 , reference-light E, WAL 04 , DFF unit 05 , second clock-signal-input port 51 , D-signal-input port 52 , and system-output port 53 .
[0024] FIG. 2 is a waveform diagram of the basic logic functions of a PhC-structure unit shown in FIG. 1 for the lattice constant d of 1 μm and the operating wavelength of 2.976 μm;
[0025] FIG. 3 is a waveform diagram of two logic-signal all-optical OR-transformation logic function of the present invention for the lattice constant d of 0.5208 μm and the operating wavelength of 1.55 μm; and
[0026] FIG. 4 is a truth table of the logic functions of a 2D-PhC cross-waveguide nonlinear cavity shown in FIG. 1 .
[0027] The present invention is more specifically described in the following paragraphs by reference to the drawings attached only by way of example.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0028] The terms a or an, as used herein, are defined as one or more than one, the term plurality, as used herein, is defined as two or more than two, and the term another, as used herein, is defined as at least a second or more.
[0029] As shown in FIG. 1 , the PhC all-optical OR-transformation logic gate of the present invention comprises an OSU 01 , a PhC-structure unit 02 , a reference-light source 03 , a WAL 04 and a DFF unit 05 ; the OSU 01 is a 3×3 optical-selector switch controlled by a clock-signal CP, used for controlling and selecting a logic signal for outputting, the clock-signal CP controls three input port signals for selective output as the logic input of next stage of PhC-structure unit 02 ; and the OSU comprises a first clock-signal-CP-input port, two system-signal-input ports, a reference-light-input port and three intermediate-signal-output ports; and two system-signal-input ports are respectively a first logic-signal-input port and a second logic-signal-input port; and three intermediate-signal-output ports are respectively a first intermediate-signal-output port, a second intermediate-signal-output port and a third intermediate-signal-output port; the first logic-signal-input port 11 , the second logic-signal-input port 12 and the reference-light input 13 of the OSU 01 are respectively input from the first logic-signal X 1 , the Second logic-signal X 2 and the reference-light E; first logic-signal X 1 is connected with the first logic-signal-input port 11 of the OSU 01 , and second logic-signal X 2 is connected with the second logic-signal-input port 12 of the OSU 01 ; reference-light E output by the reference-light source 03 is connected with the reference-light-input port 13 of the optical-selector switch, and the reference-light E output by the reference-light is 1; the first intermediate-signal-input port 21 of the PhC-structure unit 02 is connected with the first intermediate-signal-output port 14 of the OSU 01 , the second intermediate-signal-input port 22 of the PhC-structure unit 02 is connected with the second intermediate-signal-output port 15 of the OSU 01 and the three intermediate-signal-output port 16 of the OSU 01 is connected with the WAL 04 . the WAL is used for absorbing light wave entering it; the DFF unit 05 comprises a clock-signal-input port, a D-signal-input port and a system-output port; a clock-signal CP is input through the input port of a two-branch waveguide, one port of the two-branch waveguide is connected with the first clock-signal-CP-input port of the OSU 01 , and another port of the two-branch waveguide is connected with the second clock-signal-input port 51 of the DFF unit 05 ; the D-signal-input port 52 of the DFF unit 05 is connected with the signal-output port 24 of the PhC-structure unit 02 , i.e., the input-signal of the D-signal-input port 52 of the DFF unit 05 is equal to the output signal of the output port of the PhC-structure unit; the DFF unit 05 takes the output signal at the output port of the PhC-structural unit 02 for an input-signal D; the system-signal-output port 53 of the DFF unit 05 is the system-output port of the PhC all-optical OR-transformation logic gate of the present invention; the PhC-structure unit 02 is a 2D-PhC cross-waveguide nonlinear cavity and is arranged behind the OSU, the background filling material for the 2D PhC is air or a different low-refractive-index medium with a refractive index less than 1.4; the cross section of the high-refractive-index dielectric pillar of the 2D PhC is circular, oval, triangular or polygonal, and the cross section of the high-refractive-index dielectric pillar of the 2D PhC is circular, oval, triangular or polygonal; the 2D-PhC cross-waveguide nonlinear cavity is a 2D-PhC cross-waveguide four-port network formed by high-refractive-index dielectric pillars, the four-port network has a four-port PhC structure, the left port is a first intermediate-signal-input port, the lower port is a second intermediate-signal-input port, the upper port is a signal-output port, and the right port is an idle port; two mutually-orthogonal quasi-1D PhC structures are placed in two waveguide directions crossed at the center of a cross-waveguide, the cross section of the dielectric pillar in the quasi-1D PhC is rectangular, polygonal, circular or oval, and the refractive index of the dielectric pillar is 3.4 or a different value more than 2; the dielectric pillar is arranged in the middle of the cross-waveguide, the dielectric pillar is made of a nonlinear material, the cross section of the dielectric pillar is square, polygonal, circular or oval, and the quasi-1D PhC structures and the dielectric pillar constitute a waveguide defect cavity. The lattice constant of the 2D-PhC array is d, and the array number is 11×11; the circular high-refractive-index linear-dielectric pillar 25 is made of a silicon (Si) material, and has a refractive index of 3.4 and a radius of 0.18d; the first rectangular high-refractive-index linear-dielectric pillar 26 has a refractive index of 3.4, long sides of 0.613d and short sides of 0.162d; the second rectangular high-refractive-index linear-dielectric pillar 27 has a dielectric constant being the same as that of a nonlinear dielectric under low-light-power conditions, and has a dimension equal to that of the first rectangular high-refractive-index linear-dielectric pillar 26 ; and the central square nonlinear-dielectric pillar 28 is made of a Kerr type nonlinear material, and has a side length of 1.5d, a dielectric constant of 7.9 under low-light-power conditions and a third-order nonlinear coefficient of 1.33×10 −2 μm 2 /V 2 . Twelve rectangular high-refractive-index linear-dielectric pillars and one square nonlinear-dielectric pillar are arranged in the center of the 2D PhC cross-waveguide nonlinear cavity in the form of a quasi-1D PhC along longitudinal and transverse waveguide directions, the central nonlinear-dielectric pillar clings to the four adjacent rectangular linear-dielectric pillars and the distance there between is 0, every two adjacent rectangular linear-dielectric pillars are spaced 0.2668d from each other, and the dielectric constant of a rectangular linear pillar clinging to the central nonlinear pillar and close to the signal-output port is equal to that of the central nonlinear pillar under low-light-power conditions.
[0030] The present invention can realize an OR-transformation logic gate function of all-optical-logic signals under the cooperation of unit devices such as the optical switch, based on the photonic band gap (PBG) characteristic, quasi-1D PhC defect state, tunneling effect and optical Kerr nonlinear effect of the 2D-PhC cross-waveguide nonlinear cavity shown by PhC-structure unit 02 in FIG. 1 . Introduced first is the basic principle of the PhC nonlinear cavity in the present invention: a 2D PhC provides a PBG with certain bandwidth, a light wave with its wavelength falling into this bandgap can be propagated in an optical path designed inside the PhC, and the operating wavelength of the device is thus set to certain wavelength in the PBG; the quasi-1D PhC structure arranged in the center of the cross-waveguide and the nonlinear effect of the central nonlinear-dielectric pillar together provide a defect state mode, which, as the input light wave reaches a certain light intensity, shifts to the operating frequency of the system, so that the structure produces the tunneling effect and signals are output from the output port 24 .
[0031] For the lattice constant d of 1 μm and the operating wavelength of 2.976 μm, referring to the 2D PhC cross-waveguide nonlinear cavity shown by PhC-structure unit 02 of FIG. 1 , and for a signal A input from the port 21 and a signal B input from the port 22 as shown by the upper two diagrams in FIG. 2 , a logic-output waveform at the signal-output port 24 of the 2D PhC cross-waveguide nonlinear cavity of the present invention can be obtained, as illustrated by the lower diagram of signal waveform in FIG. 2 . A logic operation truth table shown in FIG. 4 can be obtained according to the logic operation characteristic shown in FIG. 2 . In FIG. 4 , C is the output at the output port 24 of the PhC-structure unit 02 current state Q n , and Y is signal output of the output port 24 of the PhC-structure unit 02 —the next state Q n+1 . A logic expression of the PhC structure can be obtained according to the truth table:
[0000] Y=AB+BC (1)
That is
[0032] Q n+1 =AB+BQ n (2)
[0033] According to the basic logic operation characteristic of the above 2D PhC cross-waveguide nonlinear cavity, the logic output at the previous step serves as a logic input to the structure itself to realize logic functions.
[0034] Referring to FIG. 1 , for CP=0, the optical-selector switch turns the input-signal X 1 at the logic-signal-input port 11 to the second intermediate-signal-output port 15 of the optical-selector switch, and the input-signal-X 1 is further projected to the second intermediate-signal-input port 22 of the PhC-structure unit 02 , i.e., the input signal at the second intermediate-signal-input port 22 of the PhC-structure unit 02 is equal to the input-signal-X 1 at the first logic-signal-input port 11 ; simultaneously, the optical-selector switch turns the reference-light E at the reference-light-input port 13 to the first intermediate-signal-output port 14 of the optical-selector switch, and the reference-light E is further projected to the first intermediate-signal-input port 21 of the PhC-structure unit 02 , i.e., the input signal at the first intermediate-signal-input port 21 of the PhC-structure unit 02 is equal to the reference-light E at the reference-light-input port 13 ; and simultaneously, the optical-selector switch turns the logic-signal X 2 at the second logic-signal-input port 12 to the third intermediate-signal-output port 16 of the optical-selector switch, and the logic-signal X 2 is further projected to the WAL 04 .
[0035] For CP=1, the optical-selector switch turns the input-signal X 1 at the first logic-signal-input port 11 to the third intermediate-signal-output port 16 of the optical-selector switch, and the input-signal X 1 is further projected to the WAL 04 ; simultaneously, the optical-selector switch turns the logic-signal X 2 at the second logic-signal-input port 12 to the first intermediate-signal-output port 14 of the optical-selector switch, and the logic-signal X 2 is projected to the first intermediate-signal-input port 21 of the PhC-structure unit 02 , i.e., the input signal at the first intermediate-signal-input port 21 of the PhC-structure unit 02 is equal to the logic-signal X 2 at the second logic-signal-input port 12 ; and simultaneously, the optical-selector switch turns the reference-light E at the reference-light-input port 13 to the second intermediate-signal-output port 15 of the optical-selector switch, and the reference-light E is further projected to the second intermediate-signal-input port 22 of the PhC-structure unit 02 , i.e., the input signal at the second intermediate-signal-input port 22 of the PhC-structure unit 02 is equal to the reference-light E at the reference-light-input port 13 .
[0036] With the cooperation described above, the OR transformation logic function of all-optical-logic signals can be realized.
[0037] The 2D PhC structure of the device in the present invention can be of a (2k+1)×(2k+1) array structure, where k is an integer more than or equal to 3. Design and simulation results will be provided below in an embodiment given in combination with the accompanying drawings, wherein the embodiment is exemplified by an 11×11 array structure and a lattice constant d of 0.5208 μm.
[0000] In formula (5), suppose A=1, leading to:
[0000] Q n+1 =B (3)
[0000] In formula (5), suppose B=1, leading to:
[0000] Q n+1 =A+Q n (4)
[0038] Thus, the first signal X 1 is input to the second intermediate-signal-input port 22 of a PhC-structural unit 02 at the moment t n , i.e., B=X 1 ; simultaneously, supposing that the input-signal A of the port 21 is equal to 1, the logic-input-signal X 1 (t n ) at the moment t n is stored in an optical circuit; then, at the moment t n+1 , the second signal X 2 is input to the first intermediate-signal-input port 21 of the PhC-structural unit 02 , i.e., the logic-input-signal A of the first intermediate-signal-input port 21 at the moment is equal to X 2 (t n+1 ), and simultaneously, supposing that the logic-input-signal B of the second intermediate-signal-input port 22 is equal to 1. The output-signal 24 of the PhC-structural unit 02 is:
[0000] Q n+1 =X 1 ( t n )+ X 2 ( t n+1 ) (5)
[0039] Hence, a CP control signal, an optical switch and a reference-light source need to be introduced into the system; as CP=0, the optical switch 01 projects the first signal X 1 to the second intermediate-signal-input port 22 , and simultaneously projects the signal “1” to the first intermediate-signal-input port 21 ; and for CP=1, the optical switch 01 projects the second signal X 2 to the first intermediate-signal-input port 21 , and simultaneously projects the signal “1” to the second intermediate-signal-input port 22 .
[0040] The optical-selector switch operates as follows under the control of a clock-signal CP:
[0041] At a moment t n , CP is made equal to 0, the optical-selector switch turns the first signal X 1 (t n ) at the first logic-signal-input port 11 to the second intermediate-signal-output port, and the delay signal X 1 (t n ) is further projected to the second intermediate-signal-input port 22 of the PhC-structure unit 02 ; simultaneously, the optical-selector switch turns the second signal X 2 (t n ) at the second logic-signal-input port 12 to the third intermediate-signal-output port 16 , and the second signal X 2 (t n ) is further projected to the WAL 04 , and simultaneously, the optical-selector switch turns the reference-light E of the reference-light-input port 13 to the first intermediate-signal-output port 14 , and the reference-light E is further projected to the first intermediate-signal-input port 21 of the PhC-structure unit 02 ; the output of the port 24 at this moment can be obtained from the expression (2):
[0000] Q n+1 =X 1 ( t n ) (6)
[0042] At a moment t n+1 , CP is made equal to 1, the optical-selector switch turns the signal X 1 (t n+1 ) at the first logic-signal-input port 11 to the third intermediate-signal-output port 16 , and the delay-signal X 1 (t n+1 ) is further projected to the WAL 04 ; simultaneously, the optical-selector switch turns the second signal X 2 (t n+1 ) at the second logic-signal-input port 12 to the first intermediate-signal-output port 14 , and the second signal X 2 (t n+1 ) is further projected to the first intermediate-signal-input port 21 of the PhC-structure unit 02 ; and simultaneously, the optical-selector switch turns the reference-light E at the reference-light-input port 13 to the second intermediate-signal-output port 15 , and the reference-light E is further projected to the second intermediate-signal-input port 22 of the PhC-structure unit 02 ; the output at the port 24 at this moment can be obtained from the expression (2):
[0000] Q n+1 =X 2 ( t n+1 )+ X 1 (t n ) (7)
[0043] The output at the output port 24 of the PhC-structure unit 02 is equal to the input at the D-signal-input port 52 of the DFF unit 05 , and it can be obtained from the expressions (6) and (7) that the input-signal D of the D-signal-input port 52 is X 1 (t n ) for CP=0 and is X 2 (t n+1 )+X 1 (t n ) for CP= 1 .
[0044] It can be known according to the logic characteristic of the DFF that for CP=1, the system output follows with the input-signal D; and for CP=0, the system output keeps the input-signal D at the previous moment. Thus, it can be known that the output Q n+1 at the system-output port 53 of the device in the present invention is Q n+1 =X 2 (t n+1 )+X 1 (t n ) for CP=1; and at a next moment for CP=0, the system output keeps the output of the previous moment, i.e., the system output in a clock cycle is:
[0000] Q n+1 =X 2 ( n+ 1)+ X 1 ( n ) (8)
[0045] Hence, the device in the present invention can realize the OR-transformation logic function of two logic signals.
[0046] For the operating wavelength of 1.55 μm in the device, the lattice constant d is 0.5208 μm for the PhC-structure unit 02 , the radius of the circular high-refractive-index linear-dielectric pillar 25 is 0.093744 μm; the long sides of the first rectangular high-refractive-index linear-dielectric pillar 26 are 0.3192504 μm, and the short sides are 0.0843696 μm; the size of the second rectangular high-refractive-index linear-dielectric pillar 27 is the same as that of the first rectangular high-refractive-index linear-dielectric pillar 26 ; the side length of the central square nonlinear-dielectric pillar 28 is 0.7812 μm, and the third-order nonlinear coefficient is 1.33×10 −2 μm 2 /V 2 ; and the distance between every two adjacent rectangular linear-dielectric pillars is 0.13894944 μm. Based on the above dimensional parameters, as the first logic-signal X 1 and the second logic-signal X 2 are input according to the waveforms shown in FIG. 3 , a system-output waveform diagram at the lower part in FIG. 3 can be obtained under the control of the clock-signal CP. Hence, the system carries out OR-logic operation on the logic-input quantity X 2 (n+1) and the logic-input quantity X 1 (n) at the previous moment. That is, the OR-transformation logic function of two logic signals is realized.
[0047] With reference to FIG. 3 , the device in the present invention can realize the same logic function under different lattice constants and corresponding operating wavelengths by scaling.
[0048] In conclusion, an OR-transformation logic function of two all-optical-logic signals in the present invention can be realized by the control of the clock-signal CP of the clock-signal-input port under the coordination of relevant unit devices.
[0049] In the logic-signal processing in an integrated optical circuit, self-convolution operation of a single logic signal can be defined, and the above-mentioned logic operation of logic signals is a basic operation of the self-convolution operation of two logic signals. The OR-transformation logic function of logic signals realized in the present invention plays an important role in realizing self-correlation transformation or self-convolution operation of logic variables.
[0050] While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims. | A photonic crystal (PhC) all-optical OR-transformation logic gate, which comprises an optical-switch unit (OSU), a PhC-structure unit, a reference light, a wave-absorbing load (WAL) and a D-type flip-flop (DFF) unit; two system-signal-input ports are respectively connected with a first logic-signal X 1 and a second logic-signal X 2 ; the reference light is connected with the reference-light-input port of the OSU; three intermediate-signal-output ports are respectively connected with two intermediate-signal-input ports of the PhC-structure unit and the WAL; a clock-signal CP through the input port of a two-branch waveguide are respectively connected with a first clock-signal CP input port of the OSU and a second clock-signal-CP-input port of the DFF unit; the signal-output port of the PhC-structure unit is connected with the D-signal-input port of the DFF unit. The structure of the present invention is compact in structure, strong in anti-interference capability and ease of integration with other optical-logic elements. | 6 |
PRIORITY CLAIM
[0001] This application is a continuation of U.S. patent application Ser. No. 14/455,103, filed Aug. 8, 2014, which is a continuation-in-part from U.S. patent application Ser. No. 14/184,217, filed Feb. 19, 2014, now U.S. Pat. No. 8,899,973, issued on Dec. 12, 2014, which is a continuation from U.S. patent application Ser. No. 13/544,519, filed on Jul. 20, 2012, now U.S. Pat. No. 8,758,008, issued on Jun. 24, 2014, which claims the benefit of U.S. Provisional Patent Application Ser. No. 61/598,662, filed Feb. 14, 2012; the disclosures of which are incorporated herein by reference in their entireties.
TECHNICAL FIELD
[0002] The subject matter described herein relates to candles with items embedded within and methods for manufacturing and selling same.
BACKGROUND
[0003] People like to give and receive presents. In some cultures it is customary to wrap a gift present in an attractive package which is pleasing to the eye of the recipient and which also prevents the recipient from immediately knowing the nature or value of the present, which peaks the interest of the recipient, increases the recipient's anticipation of the unwrapping of the gift, and increases the recipient's delight and enjoyment of the gift revealed.
[0004] Candles are popular gifts due to their pleasant form, color, and/or scent. A burning candle provides a warm, relaxing atmosphere, and candles are associated with love, romance, or special occasions. Candle bodies are typically made of an opaque or translucent material, such as wax, which is consumed while the candle burns.
[0005] Candle bodies thus make an ideal container within which to hide an item, such as jewelry, gifts traditionally given on romantic or special occasions, or other items, where the presence, nature, or value of the item is slowly revealed as the candle body is consumed, to the delight of the recipient of the candle. In addition, the excitement of anticipation one feels while waiting to find out the nature or value of a gift received may be heightened when the recipient of a candle containing an embedded item knows beforehand that there is a possibility that the value of the embedded item can be larger, and sometimes much larger, than the purchase price of the candle within which the item is embedded.
[0006] Thus, there is a need for candles with items embedded within them where the presence, nature, or value of the embedded item is obscured by the candle body and therefore unknown to the purchaser or user of the candle until the candle body has been consumed sufficiently to reveal the presence, nature, or value of the item.
SUMMARY
[0007] According to one aspect, the subject matter described herein includes a method for manufacturing a candle having an item embedded within. In some embodiments, the method can comprise providing a first set of items, each item having a first value, providing a second set of items, each item having a second value different from the first value, combining the first and second sets of items to create a third set of items, and distributing the items of the third set among a set of candles, wherein each candle of the set of candles comprises an enclosure that forms a periphery of the candle, wax that forms a body of the candle, and a wick. One item from the third set can be enclosed within a first container that is embedded within the wax of the candle body, wherein the first container can be attached to the inside of the enclosure that forms a periphery of the candle such that the presence of the first container is visible through the enclosure but the nature of the embedded item from the third set, the value of the embedded item from the third set, or the value of the embedded item from the third set relative to a purchase price of the candle is not discernable while the item from the third set is embedded in the candle.
[0008] According to another aspect, the subject matter described herein includes a candle with an embedded item. The candle includes a candle body including wax and a wick, where the candle body includes an embedded item such that the presence, nature, and/or value of the item is obscured by the candle body.
[0009] According to another aspect, the subject matter described herein includes a candle with an embedded item. The embedded item can in some embodiments comprise an object that is redeemable for a prize. The embedded item can in some embodiments comprise an object of value such as a ring for example and an object that is redeemable for a prize of greater value. The object that is redeemable for a prize can comprise a token that may be exchanged for the prize. The object that is redeemable for a prize can display a prize identifier for identifying the prize, the type of prize, or the value of the prize. The prize identifier can comprise one or more characters. In some aspects, the object that is redeemable for a prize can be redeemable by submitting the prize identifier to a first party. The first party, in response to receiving the prize identifier, can provide the identified prize. In some aspects, the object that is redeemable for a prize can be redeemable by entering the prize identifier (for example a random code or numerical indicator) into a web page that transmits the prize identifier to the first party. The object that is redeemable for a prize can be redeemable by transmitting the prize identifier to the first party via a letter, an email, a text message, or a telephone call.
[0010] As used herein, the term “wax” refers to substances that can be used to form a candle body and which are consumed, usually as fuel, while the candle burns. Examples include, but are not limited to, animal fats or waxes, such as tallow, insect waxes, such as bee's wax, plant waxes and fats, such as soy-based products, and petroleum-based substances, such as paraffin.
[0011] As used herein, the term “wick” refers to any object which holds the flame of a candle. Examples include, but are not limited to, string, cord, wood, or other objects that draw the liquid fuel to the flame, usually via capillary action.
[0012] According to yet another aspect, the subject matter described herein includes a method for manufacturing a candle that contains an item whose presence, nature, and/or value is obscured from the buyer. The method includes attaching an item to the inside of a container, and filling the container with wax such that the wax obscures the nature or value of the item.
[0013] According to yet another aspect, the subject matter described herein includes another method for manufacturing a candle that contains an item whose presence, nature, or value is obscured from the buyer. The method includes adding a first amount of wax to a container or mold, allowing the first amount wax to harden sufficiently enough to support an item that is placed on the surface of the wax, placing the item on the surface of the wax; and adding into the container a second amount of wax at least sufficient to obscure the presence, nature, or value of the item.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Preferred embodiments of the subject matter described herein will now be explained with reference to the accompanying drawings, wherein like reference numerals represent like parts, of which:
[0015] FIG. 1 shows a method for making a candle that contains an item according to one embodiment of the subject matter described herein;
[0016] FIGS. 2A through 2D show the steps of a method for manufacturing a candle having an item embedded within according to an embodiment of the subject matter described herein; and
[0017] FIGS. 3A through 3C show the steps of an alternative method for manufacturing a candle having an item embedded within according to an embodiment of the subject matter described herein, in which the candle can be partially constructed and the item introduced or placed into the candle before construction of the candle is completed.
DETAILED DESCRIPTION
[0018] The subject matter described herein includes a candle having an embedded item within and methods for manufacturing and selling same. Example embedded items include, but are not limited to, jewelry, such as rings, earrings, and chains, precious or semiprecious stones, pearls, etc. Alternatively, or in addition, in some embodiments example embedded items include, but are not limited to, tokens or redeemable objects that can be redeemed in exchange for jewelry, such as rings, earrings, and chains, precious or semiprecious stones, pearls, etc. As an example, a method for manufacturing a candle having a ring embedded or token for a ring within is disclosed.
[0019] FIG. 1 shows a method for making a candle that contains an item according to one embodiment of the subject matter described herein. At step 100 , a first set of items, each having a first value, is created. For example, a set of rings, each ring worth $10, can be collected and optionally prepared for embedding within the finished product candles. At step 102 , a second set of items, each having a second value, is created. For example, a set of rings, each ring worth $100, can be collected and optionally prepared for use. Other sets of rings can be collected, each additional set having rings each worth another value, such as $1,000 per ring, $5,000 per ring, and so on. The values used above are for illustration only and are not limiting. All items in a set need not be the same. For example, a set of items can include different types of items, such as rings, earrings, pins, etc., but having the same or very similar relative value. Moreover, items in one set need not be the same as items in another set. For example, the first set of items could be rings and earrings while the second set of items could be bracelets and necklaces.
[0020] At step 104 , the sets of rings are combined. At step 106 , the combined set of items is distributed among a set of candles such that each candle includes one item from the combined set embedded within the candle. Optionally, in some embodiments, in step 108 the candles can be sold for a first price, where the value of the embedded item is not known to the purchaser at the time of purchase. In one embodiment, the value of the item cannot be determined by the purchaser of the candle until the candle has been burned or the wax melted to expose the item (or allow the item to be removed and unwrapped if the item has been encased in a pouch, bag, or protective wrapping.) In one embodiment, the purchaser knows that a candle might contain an embedded item but cannot determine at the time of purchase whether the candle does or does not contain the embedded item.
[0021] Referring again to FIG. 1 , in some embodiments at step 100 , a first set of items, each having a first value, is created. For example, a set of rings, each ring worth $10, can be collected and optionally prepared for embedding within the finished product candles. Then, in some embodiments at step 102 , a second set of items, each having a second value, is created. For example, tokens, vouchers or redeemable objects (referred to collectively as redeemable objects) for a set of rings, each ring worth $100, can be collected and optionally prepared for use. Other sets tokens, vouchers or redeemable objects for rings can be collected, each additional set of tokens, vouchers or redeemable objects being redeemable for rings each worth another value, such as $1,000 per ring, $5,000 per ring, and so on. The values used above are for illustration only and are not limiting. All items, tokens, vouchers or redeemable objects in a set need not be the same. For example, a set of items can include different types of items, such as rings, earrings, pins, etc., but having the same or very similar relative value. Moreover, items or redeemable objects in one set need not be the same as items in another set. For example, the first set of items could be rings and earrings while the second set of items could be bracelets and necklaces, or redeemable objects for the same.
[0022] In some embodiments, at step 104 , the sets of rings and redeemable objects are combined. At step 106 , the combined set of items is distributed among a set of candles such that each candle includes one item from the combined set embedded within the candle. Thus, in some aspects a candle can have embedded therein an item from the first set of items, e.g. a ring, having a first value, or an item from the second set of items, e.g. a redeemable object for a ring of a second value. Alternatively, in some embodiments at step 106 the combined set of items is distributed among a set of candles such that each candle includes one item from the first set of items, e.g. a ring of a first value, and one item from the second set of items, e.g. a redeemable object for a ring of a second value.
[0023] Thus, in some embodiments, a candle can have a ring with a first value, or a ring with a second value, or a ring with a first value plus a redeemable object for a ring of a second value, or a ring with a second value plus a redeemable object for a ring of a first value. In some embodiments, a candle can have a ring of a first value, or a redeemable object that is redeemable for a ring of a second value. In some embodiments, the ring of the first value is a value less than the purchase price of the candle, and the redeemable object for a ring of a second value has a value greater than, in some instances significantly greater than, the purchase price of the candle. In some embodiments, a candle can have a redeemable object redeemable for a ring of a first value, or a redeemable object that is redeemable for a ring of a second value. In some embodiments, the ring of the first value is a value less than the purchase price of the candle, and the redeemable object for a ring of a second value has a value greater than, in some instances significantly greater than, the purchase price of the candle.
[0024] Optionally, in some embodiments, in step 108 the candles can be sold for a first price, where the value of the embedded item(s) is not known to the purchaser at the time of purchase. In one embodiment, the value of the item(s) cannot be determined by the purchaser of the candle until the candle has been burned or the wax melted to expose the item (or allow the item to be removed and unwrapped if the item has been encased in a pouch, bag, or protective wrapping.) In one embodiment, the purchaser knows that a candle might contain an embedded item, and/or a redeemable object that is redeemable for an item of value, but cannot determine at the time of purchase whether the candle does or does not contain the embedded item(s).
[0025] FIGS. 2A through 2D show the steps of manufacturing a candle having an item embedded within according to one embodiment of the subject matter described herein. In FIG. 2A , an enclosure or container 200 is provided. In one embodiment, enclosure or container 200 can be intended to contain the finished product, and can be made of glass, plastic, or other material, and can be transparent, translucent, opaque, or some combination. Alternatively, enclosure or container 200 may not be intended to contain the finished product, e.g., the container can be a mold that is used (and possibly reused) during manufacture and is not a part of the finished product.
[0026] An item 202 , such as a ring, jewelry, prize, redeemable object or other item, is placed into a pouch 204 or other item container. In FIG. 2B , adhesive 206 can in some embodiments be applied to the pouch 204 containing item 202 , and pouch 204 can be attached to the inside wall of candle enclosure or container 200 , such that the pouch is affixed to the inside of the candle container, as shown in FIG. 2G . Wax 208 can then be poured into candle enclosure or container 200 , covering the pouch 204 and obscuring the item 202 from view, resulting in the product shown in FIG. 2D . In one embodiment, a wick can be placed or affixed within container 200 prior to adding wax 208 . Alternatively, a wick can be inserted into wax 208 after it has been poured into enclosure or container 200 .
[0027] For example, in one embodiment, rings of different values are placed into small plastic bags, and in some embodiments each small plastic bag can be wrapped in gold foil or the like. Alternatively, in one embodiment, rings and/or redeemable objects of different values are placed into small plastic bags, and in some embodiments each small plastic bag can be wrapped in gold foil or the like. For each ring and/or redeemable object wrapped in plastic and gold foil, a small gold foil indicator is glued to the gold foil that contains the ring and bag. The small gold foil indicator is glued to the inside of the glass container, which allows the customer to see the location of the ring and/or redeemable object within the container. The small gold foil indicator is visible through the glass container. Wax is poured into the glass container and a wick is installed into the wet wax. In one embodiment, the wax is soy wax. The wax cools or is cooled, and labels are applied to the glass container and/or the wax. In one embodiment, the item can be affixed in more than one place to the container prior to filling the container with wax. In one embodiment, the process can include applying labels or decorations to the inside or outside of enclosure or container 200 prior to adding wax 208 . For example, the process can include applying a safety label to the bottom of a glass container that will contain the candle wax.
[0028] FIGS. 3A through 3D show the steps of an alternative method for manufacturing a candle having an item embedded within, in which the candle can be partially constructed and the item introduced or placed into the candle before construction of the candle is completed. In FIG. 3A , for example, a candle mold or container 300 can be partially filled with wax 302 A, which is allowed to harden until it is firm enough to support the item 304 (e.g. ring and/or redeemable object) in the desired location within the candle body. In FIG. 3B , item 304 is placed onto or into the firm wax 302 A at or near the desired location within the candle body, and in FIG. 3C , additional wax 302 B is placed into mold 300 . The amount of additional wax 302 B is sufficient to at least cover and obscure item 304 and can partially or completely fill container 300 . In one embodiment, a wick is then inserted into wax 302 A and 302 B. In an alternative embodiment, the wick is placed within container 300 prior to adding wax 302 A and/or wax 302 B.
[0029] The subject matter described herein also includes a candle with an item embedded within, such as are shown in FIGS. 2D and 3C . In one embodiment, the item can be a ring, other types of jewelry, other types of prizes, a redeemable object that is redeemable for jewelry or other object, or other item. In one embodiment, the candle is designed such that the existence, nature, or value of the embedded item and/or redeemable object cannot be determined without burning the candle or otherwise melting the wax so that the item is exposed to view.
[0030] In one embodiment, a purchaser or recipient is not aware at the time of purchase or receipt that the candle contains an embedded item at all. In one embodiment, the purchaser or recipient is aware at the time of purchase or receipt that the candle does contain an embedded item, but the candle is designed so that at the time of purchase or receipt, a purchaser or recipient of the candle does not know or cannot determine the general nature of the item, the exact nature of the item, the absolute value of the item, the price range of the item, the value of the redeemable object or the value of the object for which it can be redeemed, and/or the value of the item relative to the purchase price of the candle.
[0031] The candle can comprise wax within a shell or container, or wax not contained in a shell or container. The wax and/or container can be transparent, translucent, or opaque. For example, all or part of the container can be transparent allowing the wax to be seen, but the opacity of the wax prevents the buyer from determining the nature or value of the item embedded within. Alternatively, the wax can be translucent but the container is also translucent with the result that the nature or value of the item embedded within the wax is indiscernible. Alternatively, the nature or value of the item can be obscured by an opaque material (other than the wax of the candle) that surrounds or covers the item and where the item and the opaque covering are both embedded within the candle wax. In one embodiment, the wax and container can be transparent or translucent enough to see the item but the opaque material in which the item is wrapped obscures the nature or value of the item. In one embodiment, the item can be covered or wrapped with a material that prevents damage to the item from the heat of the candle flame as the candle wax is burned away to expose the item.
[0032] The subject matter described herein also includes a method for making a candle that contains an item such that the nature and/or value of the item is obscured from the buyer and/or recipient. In one embodiment, the value of the embedded item, or object redeemable for an item, can be less than the sale price of the candle, equal to the sale price of the candle, greater than the sale price of the candle, or much greater than the sale price of the candle. For example, a candle can be sold for $25 that contains within it a ring which can have a value of $10, $100, $1,000, or $5,000, or a redeemable object that can be redeemed for a ring which can have a value of $10, $100, $1,000, or $5,000. | A candle with an embedded item and methods for manufacturing same are disclosed. A method for manufacturing a candle having an embedded item can include providing a first set of items of a first value and a second set of items of a second value different from the first value, combining the two sets to create a third set, and distributing the items of the third set among a set of candles, one item per candle, where the presence, nature, or value of the item within the candle is obscured. The method can further include selling the candles for a first price, wherein, the presence of the embedded item, the nature of the embedded item, the value of the embedded item, or the value of the embedded item relative to the first price is not known to the purchaser. The embedded item can comprise an object redeemable for a prize. | 5 |
FIELD OF THE INVENTION
The present invention relates to the field of locating and tracking devices. In particular, it relates to a system and method for locating a vehicle.
BACKGROUND OF THE INVENTION
One of the difficulties encountered when driving in a large or unfamiliar city is locating and returning to one's vehicle after parking. Particularly in the case of rental vehicles, where both the vehicle and city are unfamiliar to the driver, and with the large size of parking garages in malls, hotels and other venues, it can be very difficult for the driver to not only locate the parked vehicle, but also to determine how to return to the location. However, with the development and increased usage of portable navigation systems, such as GPS tracking and mapping devices, the potential exists to use those systems to assist the driver in locating their vehicle after leaving it parked.
For example, U.S. Pat. Nos. 6,392,592 and 6,694,258 to Johnson et al. (“Johnson”) disclose a hand-held car locator device consisting of two parts, a transmitter/receiver in the vehicle, and a fob which is carried by the user. When the user wants to locate the vehicle, they activate the fob, and a signal is sent to the vehicle, which then gets its current location using GPS or similar means, and sends the location back to the fob for the user to see. Johnson also discloses automatic transmission of location to the fob, such as upon locking of the vehicle doors.
Problems with the above-mentioned Johnson patents include the following: it requires that a GPS or similar location tracking unit be located in the vehicle at all times and it requires that the location tracking unit be powered by the vehicle's battery while the vehicle is off, which can present vehicle battery drainage issues. Johnson also requires a fob with (1) transceiver technology, (2) the ability to interpret a signal from a location tracking unit, (3) the ability to display location and/or directional information, and (4) strong transmission signal capabilities—which necessitates a significant power source—in order to effectively contact the tracking unit in the vehicle (as the signal may be issued from a great distance and can be blocked by concrete walls or other such obstructions).
Another example, U.S. Pat. No. 6,407,698 to Ayed (“Ayed”) discloses a method of locating a parked vehicle using a sensor incorporated into the vehicle and a mobile GPS device where the sensor is activated when the vehicle is parked and sends a signal to the GPS device. The GPS device then retrieves the current coordinates on receiving the signal from the sensor. The Ayed method requires modification of the vehicle to incorporate the sensor, as well as possession of a separate mobile GPS device by the user. In Ayed, as the location coordinates are retrieved by the GPS device once the vehicle is parked, there is also the risk of a failure to connect to the GPS satellites in a timely manner, such that the retrieved coordinates do not correspond to the vehicle's parking location.
As with Johnson, Ayed requires a second device to communicate with the GPS device to determine the location of the parked vehicle. Another problem is the need to modify the vehicle to include sensors to indicate to the locator device that the vehicle is parked, or other devices, such as a cradle, to accommodate the locator device.
Additionally, Ayed requires that the sensors installed in the vehicle have sufficient sophistication and complexity to both accurately and consistently note that the vehicle is parked and to then communicate with the GPS device, creating a risk of failure in that the parking of the vehicle may not be detected by the sensor and, as a result, a failure to communicate the signal to the GPS device.
Yet another example is found in U.S. Pat. No. 6,489,921 issued to Wilkinson (“Wilkinson”). The Wilkinson patent discloses a handheld device (i.e. a keychain fob) which senses when it has been moved out of range of an RF signal tag that is mounted on the vehicle's dashboard near the vehicle's ignition. When the user removes the key (and keychain fob apparatus) from the immediate range of the vehicle's ignition, which is likely indicative of the user being in the process of leaving the vehicle, the RF signal is therefore lost. This signal loss automatically prompts the device to initiate the device's GPS receiver to seek satellite signals and, upon securing said signals, to record the device's coordinates. These coordinates, in turn, are meant to correspond to the location of the user's parked vehicle. When re-activated, the device gets the GPS coordinates for its current location, and calculates the shortest distance to the recorded coordinates. It then displays on-screen an arrow indicating the direction the user should travel to get back to the original coordinates. Once the device is back within range of the RF signal, it disengages and waits for the RF signal to drop below threshold again to resume the process.
Problems with Wilkinson include an issue with apparatus size, as Wilkinson expresses a need for an apparatus with locating technology capabilities that is small enough in size and weight to be placed on a key chain (and thus to be in range of the RF tag that is to be placed by the vehicle's ignition).
Wilkinson and Ayed share a common limitation, in that the coordinates of the vehicle are retrieved after the vehicle is parked. Initiating the locating technology after parking creates a significant risk that the coordinates will not be retrieved in a timely fashion, as the device needs time to secure multiple satellite signals in order to determine its location. By the time the device secures the required satellite signals and calculates its location the user may have walked a significant distance from their vehicle, thus significantly limiting the device's ability to secure an accurate determination of the location of the vehicle. This, in turn, largely undermines the purpose and intent of both of these patents.
U.S. Pat. No. 6,363,324 to Hildebrant, which has two GPS receivers, one in car and another in the handheld device, and discloses a display using a direction arrow and an elevation marker to indicate the direction to a parked vehicle. The Hildebrant receivers retrieve and store the location coordinates once the vehicle is parked. Hildebrant is limited in that two GPS devices are required.
U.S. Pat. No. 6,791,477 and No. 7,068,163, both issued to Sari et al. (“Sari”). The Sari patents disclose a locator device (key “faub” (sic) or wireless telephone) that retrieves a waypoint from a second device in response to a triggering event such as the parking of a vehicle. The waypoint is determined by the second device using coordinates retrieved prior to the triggering event. Sari is limited in that two GPS devices are required, and that the waypoint is transmitted between devices, creating a risk of a corrupted or missed waypoint.
There is a need for a method of locating a vehicle that uses a single GPS device, ideally in a one-step operation that does not require any modification of the vehicle.
There is also a need for a method of locating a vehicle that functions autonomously, enabling the recording of the vehicle's location on a GPS-enabled device without any user intervention and without the requirement for noteworthy modifications to the vehicle. Ideally, such a method would use a device that is unobtrusive and requires minimal or no modification to the vehicle.
There is further a need for a method of locating a vehicle that does not rely on retrieving coordinates after the vehicle is parked, to increase the likelihood of the coordinates being captured and stored in a timely fashion so that the co-ordinates are in very close proximity to the vehicle's actual location.
It is an object of this invention to partially or completely fulfill one or more of the above-mentioned needs.
SUMMARY OF THE INVENTION
The invention comprises, in one embodiment, a method of locating a vehicle, comprising: a) connecting a removable locator device to the vehicle, said locator device automatically noting when it has been connected to the vehicle and then using locating technology to retrieve, at regular intervals, location coordinates for the current location of said locator device, said location coordinates approximating the location of the vehicle; b) sensing a loss of connection between the locator device and the vehicle which is indicative of the vehicle being parked; c) automatically storing, as a waypoint on the locator device, the last location coordinates retrieved prior to sensing said loss of connection; and, d) removing the locator device from the vehicle to enable use of the locator device to return to the stored waypoint, wherein the stored waypoint represents the approximate location of the vehicle. When the user wishes to return to their vehicle, they use the locator device to guide them back to the waypoint representing the approximate location of their vehicle.
The locator device is preferably an electronic device capable of determining or retrieving its location, preferably a device that uses GPS technology, such as a commercial GPS receiver, a cell phone or PDA with a built-in GPS receiver, a cell phone or PDA that is GPS-capable (e.g. has a GPS chipset) or a similar device. Alternatively, the locator device may be a cell phone or PDA that uses an alternate method of locating cell phones such as, but not limited to, cell phone triangulation.
In an alternative embodiment, the locator device emits a signal to confirm the successful recording of the waypoint and to remind users to take the locator device with them when they exit their vehicles.
The invention further comprises a system for locating a parked vehicle, comprising a locator device, the locator device being removably coupled to the vehicle and capable of using locating technology to retrieve, at regular intervals, location coordinates for the current location of said locator device, said location coordinates approximating the location of the vehicle, and the locator device including the ability to detect a loss of connection to the vehicle, storing the last retrieve location coordinates as a waypoint approximating the location of the vehicle, and guiding the user back to the waypoint representing the approximate location of their vehicle.
The invention further comprises, in another embodiment, a method of locating a vehicle, comprising: a) locating a beacon device in the vehicle, the beacon device being capable of wireless signal communication according to preset parameters; b) detecting, on a locator device, the presence of the beacon device in the vehicle via the wireless signal; c) automatically initiating and using locating technology to establish current location coordinates for the locator device upon detecting the beacon device; d) using location technology to update the current location coordinates of the locator device at regular intervals for as long as the locator device remains within signal range of the beacon device, the signal range being such that a person would still be within close range of their vehicle (e.g. 10 meters or less) when the locator device was moved out of range of the signal; automatically storing, as a waypoint on the locator device, the last updated location coordinates upon the locator device ceasing to detect the presence of the beacon device, wherein the stored waypoint represents the approximate location of the vehicle. When the user wishes to return to their vehicle, they use the locator device to guide them back to the waypoint representing the approximate location of their vehicle.
The beacon device may communicate with the locator device continuously, or may communicate with the locator device on a periodic basis. The time interval between communications should not exceed the approximate time that it would take a person to walk a distance from his vehicle to a location at which he or she would no longer be fairly easily able to determine the location of his or her vehicle (i.e. 60 seconds). The shorter the signal interval, the more accurately the location of the vehicle will be noted in the locator device and the less effect a signal failure would have on the determination of the vehicle location.
The beacon device and locator device will use a communications technology such as, but not limited to, Bluetooth or RFID as a means to recognize and communicate with one another. The locator device is an electronic device, capable of determining or retrieving its location, preferably a device that uses GPS technology, such as a commercial GPS receiver, a cell phone or PDA with a built-in GPS receiver, a cell phone of PDA that is GPS-capable (e.g. has a GPS chipset) or a similar device. Alternatively, the locator device may be a cell phone or PDA that uses a means for locating cell phones such as, but not limited to, cell phone triangulation or WiMAX.
The invention further comprises a system for locating a parked vehicle, comprising: a) a beacon device that is located in the vehicle, the beacon device being capable of wireless signal broadcasting according to preset parameters b) a locator device operative to detect the wireless signal of the beacon device, and to automatically initiate and use location technology to update its current location for as long as the locator device remains within signal range of the beacon device and to record the last location as a waypoint upon ceasing to detect the wireless signal, wherein the locator device denotes the waypoint as the approximate location of the parked vehicle, and guiding the user back to the waypoint representing the approximate location of their vehicle.
Other and further advantages and features of the invention will be apparent to those skilled in the art from the following detailed description thereof, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in more detail, by way of exemplary embodiments. The exemplary embodiments described herein constitute only possible implementations of the described invention and it is recognized that one skilled in the art may be able to devise alternate equivalent embodiments of the invention. The exemplary embodiments are herein below described with reference to the accompanying drawings, in which like numbers refer to like elements, wherein:
FIG. 1 is an exemplary embodiment of the present invention;
FIG. 2 is a flowchart showing the process for establishing a waypoint approximating a vehicle's location according to the present invention;
FIG. 3 is a flowchart showing the process for guiding a user to the waypoint established by the process of FIG. 2 ;
FIG. 4 is a screen capture off a locator device when the system is on but not in active use;
FIG. 5 is a screen capture off a locator device during the location monitoring step;
FIG. 6 is a screen capture off a locator device when the trigger event has occurred and the parked vehicle's approximate location has been captured;
FIGS. 7 and 7 a are screen captures off locator devices which relate to when the user prompts the locator device to guide the user back to the approximate location of their parked vehicle;
FIG. 8 is a screen capture off a locator device during the return to waypoint phase when the distance between the user's current location and the approximate location of the parked vehicle is significant enough such that the locator device cannot readily be displayed on a map at the same time;
FIG. 9 is a screen capture off a locator device during the return to waypoint phase when the distance between the user is close enough to the approximate location of the parked vehicle such that the locator device can display both of these points on a map at the same time;
FIG. 10 is a screen capture off a locator device for the alternative embodiment which depicts the locator device prompting the user to report as to whether they can see their vehicle;
FIG. 11 is a screen capture off a locator device that depicts the locator device resetting after a trigger event;
FIG. 12 is a flowchart showing the process for establishing a waypoint approximating a vehicle's location according to an embodiment of the present invention; and
FIG. 13 is a flowchart showing the process for establishing a waypoint approximating a vehicle's location according to an alternative embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present inventive system and method comprises a locator device 20 , as shown in FIG. 1 , which is capable of determining its location (via GPS or other location determining systems), recording a waypoint of its present, and providing directions to a recorded waypoint from its current location. The locator device 20 is operative in the present invention to automatically set a waypoint approximating the location of a parked vehicle and to enable a user to return to that waypoint, and thus the vehicle, at a later time.
The locator device 20 is preferably an electronic device capable of determining or retrieving its location, preferably a device that uses GPS technology, such as a commercial GPS receiver, a cell phone or PDA with a built-in GPS receiver, a cell phone or PDA that is GPS-capable (e.g. has a GPS chipset) or a similar device. Alternatively, the locator device may be a cell phone or PDA that uses an alternate method of locating cell phones such as, but not limited to, cell phone triangulation.
As shown in FIG. 2 , the locator device 20 is initially activated (step 110 ) prior to user entering vehicle or while user is in the vehicle. Once activated, the locator device 20 automatically launches the system (step 112 ), and then regularly determines its present location coordinates (step 114 ) using GPS or an equivalent location coordinate system. The locator device 20 then monitors (step 116 ) for a triggering event. If this triggering event is not detected, the process continues (step 118 ). Once the triggering event is detected, the locator device 20 records a waypoint (step 120 ) corresponding to the last set of location coordinates. This waypoint then acts as a proxy for the vehicle's location.
To return to the waypoint, and thus the vehicle, the user follows the steps as shown in FIG. 3 . First, the user activates the locator device 20 (step 210 ) with instructions to return to the established waypoint. The locator device 20 then acquires its current location using GPS or other locating technology (step 212 ). The locator device 20 displays the user's current location on a graphical map, with the user's current location indicated by a symbol such as a triangle that depicts the direction that the user is walking. The locator device 20 determines if the distance from the user's current location and the vehicle's approximate location is such that these two waypoints can be displayed on a graphical map on the locator device 20 display at the same time (step 214 ). If both the user's current location and the location of the vehicle can not be displayed on the map at the same time (e.g. the two points are more than 100 meters apart, depending on the scale of the map), then the locator device 20 display shows, and also displays an arrow depicting the general direction toward the approximate location of the vehicle (step 216 ). When the distance to the waypoint is sufficiently reduced such that both the user's location and the waypoint fit on the map scale, the general direction arrow toward the approximate location of the vehicle no longer appears and the waypoint is shown (step 218 ) by a suitable symbol, such as a car. A second triggering event occurs when the user has returned to the approximate location of their vehicle (step 220 ), at which point the locator device 20 resets (step 222 ).
Additionally, or alternatively, the locator device 20 can display a highlighted route on the map from the user's current location to the waypoint representing the approximate location of the parked vehicle. As described, the preferred output device for the locator device 20 is a visual graphic display, however, a text display and/or speakers can also be used as output devices. In combination with, or as an alternative to the map, the user can be provided with a set of text instructions and/or spoken instructions to guide them from their current location to the waypoint. The instructions can be provided as a list (preferred for text instructions), or as needed as the user progresses towards the waypoint (preferred for spoken instructions).
A series of screen captures from a cellular phone implementation of the present inventions are shown as FIGS. 4-11 . In FIG. 4 , the locator device 20 is idle, and the location of the vehicle is unknown, as marked by a symbol of a car with a question mark 400 . In FIG. 5 , the trigger event has occurred, GPS or other locating technology has been initiated, and the locator device 20 proceeds to update and maintain the vehicle's location co-ordinates 500 .
In FIG. 6 the trigger event denoting that the user has removed the locator device 20 from the vehicle has occurred, at which point the locator device 20 notes the last known waypoint as the approximate location of the vehicle. The parked vehicle's approximate location is denoted via a symbol (such as a car) 600 on a map of the area around the approximate location of the parked vehicle 610 .
In FIGS. 7 and 7 a , the user has activated the locator device 20 and has prompted 700 the locator device 20 to indicate a route to the waypoint representing the approximate location of the parked vehicle. In FIG. 8 , the user's location and heading are marked by a triangle 800 . As the approximate location of the parked vehicle is a significant distance 810 from the user 800 and is thus located outside the boundaries of the map, a directional graphic 820 is shown indicating the general direction toward the waypoint from the user's position 800 .
As depicted in FIG. 9 , when the user 900 and the approximate location of the vehicle 910 are close enough 920 to be on the same map (approximately 100 meters), the directional graphic ( FIG. 8 , 820 ) no longer appears on the map.
In FIG. 11 , when a second trigger event occurs to denote that the user has returned to the approximate location of their vehicle, the locator device 20 resets 1100 .
Example 1
In one embodiment of the present invention a locator device 20 , such as a portable GPS mapping device, is placed within a vehicle and coupled to the vehicle's power supply. The locator device is designed such that it can be easily removed from the vehicle by the user and later used to guide the user back to the stored waypoint representing the approximate location of the vehicle. The process for using the locator device is shown via flowchart in FIG. 12 .
Operationally, if the locator device 20 is not already on, then the user turns it on (step 1210 ). The user connects the locator device 20 to the vehicle using the locator device's existing external power input port (step 1212 ). The order of steps 1210 and 1212 is interchangeable, depending on the nature of the device and the user's preferences. The locator device 20 automatically senses the connection of an external power source. The locator device 20 then monitors its current location on a regular basis (step 1214 ) using GPS signals or similar location systems. The locator device 20 also monitors (step 1216 ) for the cessation of the connection to the external power source. As long as the power source remains connected (step 1218 ), the locator device 20 continues to determine its current location.
The cessation of the external power source is readily sensed by units such as portable GPS units and cell phones as these devices can automatically determine that they are no longer being powered by an external source (in this case being the vehicle). This loss of an external power source serves as the triggering event for the locator device as described in FIG. 2 . Thus, when the external power source connection is terminated, the locator device stores the last recorded GPS coordinates as a waypoint (step 1220 ), serving as a proxy for the location of the parked vehicle. The driver then removes the locator device 20 (step 1222 ) when exiting the vehicle and is able to later use the stored waypoint on the locator device 20 to return to the parked vehicle as described in FIG. 3 , with the connecting of the locator device 20 to the vehicle's power supply serving as the trigger event to reset the locator device 20 .
As an additional feature, the locator device 20 can emit an audible tone and/or provide a text message to confirm that the waypoint was recorded. An audible tone can also provide a reminder for the user to take the locator device from the vehicle.
In some vehicles, the vehicle ceases to provide power to its external power ports when the vehicle is turned off. In these instances, the locating device 20 will lose external power from the vehicle when the vehicle is turned off. This loss of external power serves as the triggering event. However, some vehicles continue to supply power to external devices even when the user has removed the key from the ignition. In that case, the locator device 20 must be physically disconnected to register the cessation of an external power supply and the disconnection will act as the triggering event.
Alternatively, the location can be stored in response to a triggering event from the user or user's vehicle, such as manual activation by the user on the locator device 20 , by a voice command from the user, the engine being shut off, the door locks being disengaged, or the transmission being set to “Park”, the last three representing the type of event that results in the vehicle terminating the external power source.
By storing the location on the locator device 20 , the need for the user to carry a second device, such as a key fob, is eliminated. Additionally, there is no need to modify the vehicle to provide a signal to the locator device 20 , although minor modifications to produce the triggering event may be desirable for the purpose of the alternative embodiments detailed above. Lastly, as there is no communication with a second device required, there is no transmission of information that can be degraded, corrupted, or possibly stolen.
Another advantage gained is that the removable locator device 20 is expected to have a larger display and greater functionality than a key fob or similar device, making it easier for the driver to view the navigational instructions to return to the vehicle and taking into account the current challenges of incorporating global positioning system technology into a device small enough to be placed on a key chain. The larger size also enables additional features, such as a combined text and map display, which would likely not be clearly visible on a smaller device.
A further advantage gained is that, unlike prior art devices, such as those disclosed by Wilkinson and Ayed, by initiating the global positioning or other locating system when the user first connects the locator device 20 to the vehicle's power source, the locator device 20 can reasonably be expected to have sufficient time to interact with the global positioning or other locating system prior to the user parking their vehicle and thus be able to secure a waypoint that, with reasonable accuracy, represents the current location when the user parks their vehicle.
Example 2
Another embodiment of the inventive system and method presented herein comprises using a short-range beacon device 10 which is placed in the vehicle, and which incorporates short-range wireless communications technology, such as Class 2 Bluetooth communications functionality. This beacon device 10 is detectable by a locator device 20 when the locator device 20 is within signal range of the beacon device 10 . Using Bluetooth, for example, the beacon device's signal range would be approximately 10 meters, subject to the power and sensitivity of the transmitting and receiving devices, and reductions from interference and blockage. The locator device 20 is user-portable and preferably a cellular phone or GPS mapping device. The process for using the locator device 20 is shown via flowchart in FIG. 13 .
In operation, as shown in FIG. 13 , if the locator device 20 is not already on, then the user turns it on (step 1310 ), at which point the application automatically launches in the background. The locator device 20 continuously attempts to detect the signal from the beacon device 10 (step 1312 ), and then attempts to establish a Bluetooth piconet with the beacon device 10 , according to Bluetooth protocols for establishing connections between Bluetooth-enabled devices. If the beacon is not detected, the locator device will idle (step 1314 ) for a pre-set time period before attempting to detect the beacon device 10 again (step 1314 ). The beacon signal can be emitted continuously, or at regular intervals, preferably of less than 60 seconds.
Once the beacon device 10 is detected by the locator device 20 , the locator device 20 automatically initiates and uses its locating technology (e.g. GPS) to monitor its current location (step 1316 ). The locator device 20 then repeats the process of detecting the signal from the beacon device 10 . Once the beacon signal is detected, the locator device then (step 1318 ) returns to monitoring its current location and repeats the process. Thus, as long as the locator device 20 continues to detect the signal from the beacon device 10 , the locator device 20 regularly updates its current location as the approximate location of the vehicle.
When the locator device 20 no longer detects the beacon device 10 , most likely because the locator device 20 has been moved out of range of the beacon device 10 by the user after he or she parks and walks away from his or her vehicle, the locator device 20 automatically records the last monitored coordinates as a waypoint (step 1320 ) and enters an idle state (step 1322 ) until activated by the user. Thus, the locator device can then be used to return to recorded waypoint, which will approximate the location where the vehicle is parked. The driver is able to later use the stored waypoint on the locator device 20 to return to the parked vehicle as described in FIG. 3 , with the user returning to the vehicle and bringing the locator device 20 back into range of the beacon device 10 serving as the trigger event to reset the locator device 20 .
As depicted in FIG. 10 , when the user brings the locator device 20 back into range of the beacon device 10 , a text box appears on the locator device screen indicating text to the effect of “Do you see your car?” (step 1000 ). If the user selects “Yes”, then the locator device resets and returns to Maintaining Car Position mode (as described above in FIG. 11 ). If the user selects “No”, then the locator device continues to display the user's current position and the car icon depicting the waypoint that approximates the location of the vehicle. If the user stays in range of the beacon device 10 for a period of time (e.g. an additional 15 seconds), the locator device 20 prompts them with the above question again. This cycle continues until the user selects “Yes” or until the locator device 20 notes that (1) it is in range of the beacon device 10 and (2) that the locator device 20 is moving at a rate consistent with a vehicle in motion. At this point the locator device 20 “assumes” that the user has entered the vehicle and has forgotten to press “Yes”, and reverts to Maintaining Car Position mode (as described in FIG. 11 ).
As an additional feature, the locator device 20 can emit an audible tone and/or provide a text message to confirm that the waypoint was recorded. An audible tone can also provide a reminder for the user to take the locator device 20 from the vehicle.
The beacon device 10 is effectively a ‘dumb’ device, merely allowing the locator device to detect it according to preset parameters. By structuring the beacon device 10 in this fashion, several advantages are gained. First, the work required to detect loss of signal (i.e. that the car is parked and the user has left the vehicle) and record the waypoint is passed on to the locator device, thus likely making the beacon device less expensive to manufacture and less likely to malfunction. Second, by operating on the basis of the presence or absence of the beacon signal, the need to actually detect the car parking or a similar event is eliminated, reducing the probability of failure to record the waypoint at the appropriate time.
The beacon device 10 can be battery-powered, self-powered by other means (e.g. solar cells), adapted to plug into a power source (i.e. cigarette lighter or power socket) in the vehicle, or permanently affixed to and powered by the vehicle.
Bluetooth is preferred for the wireless communication between the beacon device 10 and the locator device 20 , as the signal range is low enough to provide activation near the vehicle's location, while also providing encryption such that a particular beacon can be associated with a particular locator device, thus preventing interference and false signals from other beacons during normal use.
As an alternative to initial beacon detection step 1312 , the locator device 20 can be user-activated, eliminating the need for the initial detection of the beacon. However, user activation creates the potential for the user to fail to activate the locator device 20 , which is avoided by automatic activation.
INDUSTRIAL APPLICABILITY
By storing the location on the locator device 20 , the need for the user to carry a second device for the sole purpose of locating their vehicle, such as a key fob, is eliminated. Additionally, there is no need to modify the vehicle to provide a signal to the locator device 20 , although minor modifications to produce the triggering event may be desirable for the purpose of the alternative embodiments detailed above. Lastly, as there is no communication with a second device required, there is no transmission of information that can be degraded, corrupted, or possibly stolen.
Another advantage gained is that the removable locator device 20 is expected to have a larger display and greater functionality than a key fob or similar device, making it easier for the driver to view the navigational instructions to return to the vehicle and taking into account the current challenges of incorporating global positioning system technology into a device small enough to be placed on a key chain. The larger size also enables additional features, such as a combined text and map display, which would likely not be clearly visible on a smaller device
A further advantage gained is that, unlike prior art devices, such as those disclosed by Wilkinson and Ayed, by initiating the global positioning system when the user first connects the locator device 20 to the vehicle's power source (or, in the alternate embodiment, when the locator device 20 first enters the range of the beacon device 10 ), the locator device 20 can reasonably be expected to have sufficient time to interact with the global positioning system prior to the user parking their vehicle and thus be able to secure a waypoint that, with reasonable accuracy, represents the current location when the user parks their vehicle.
There is the possibility that the user is able to find and return to their vehicle without the need to refer to the locator device 20 and to the stored waypoint therein. As the steps to record the waypoint are preferably fully automated “(noting connection to external power or noting that device has entered range of beacon, launching GPS, monitoring position, recording a waypoint), they will continue to take place (unless user has deactivated the locator device 20 ) and this process is unaffected by the user's decision.
However, if the user elects to not use the locator device 20 to help them return to their vehicle, then the method to return to the vehicle, which must be initiated by user, no longer takes place. However, the locator device 20 still needs to reset to start tracking location again when user gets back into their vehicle and moves on to their next destination.
Considering Example 1, when the user reconnects the locator device 20 to the vehicle's power supply then the locator device 20 automatically resets, regardless of whether the user activated the locator device 20 to return to the vehicle. As such, the user electing to not use the locator device does not have any implications in this context for the embodiment described in Example 1.
Considering Example 2, the locator device 20 notes when it is back in range of beacon device 10 . If locator device 20 stays in range of beacon device 10 for an extended period of time (e.g. in excess of 60 seconds) then the locator device assumes that the vehicle is back in motion and the locator device 20 automatically resets as previously described.
While the above examples have been presented in the context of locating parked passenger vehicles, particularly automobiles, the device method is equally applicable to other vehicles (e.g. transport trucks, boats, motorcycles, bicycles) that are parked by a driver at a location that must be returned to at a later time.
This concludes the description of presently preferred embodiments of the invention. The foregoing description has been presented for the purpose of illustration and is not intended to be exhaustive or to limit the invention to the precise form disclosed. It is intended the scope of the invention be limited not by this description but by the claims that follow. | The invention comprises a method of locating a vehicle, comprising: a) connecting a removable locator device to the vehicle, said locator device automatically noting when it has been connected to the vehicle and then using locating technology to retrieve, at regular intervals, location coordinates for the current location of said locator device, said location coordinates approximating the location of the vehicle; b) sensing a loss of connection between the locator device and the vehicle; c) automatically storing, as a waypoint on the locator device, the last location coordinates retrieved prior to sensing said loss of connection; and, d) removing the locator device from the vehicle to enable use of the locator device to return to the stored waypoint, wherein the stored waypoint represents the approximate location of the vehicle. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is the United States national phase under 35 U.S.C. §371 of PCT International Application PCT/EP2009/005128, filed on Jul. 14, 2009, and claiming priority to German Application No. 10 2008 033 020.5, filed on Jul. 14, 2008. Both applications are incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] Embodiments relate to methods and devices for establishing a routing metric in mesh networks, in particular according to standard IEEE 802.11s for Wireless Mesh Networks, wherein the routing messages sent on various paths from the source node via the mesh nodes of the mesh network to the target node are interpreted in order to determine the best path for sending data packets from the source node to the target node.
[0004] 2. Background of the Related Art
[0005] WO 2008/122674 A2 relates to a method for operating a mesh-type network, in particular according to standard IEEE 802.11s, wherein the network comprises multiple network nodes. From this it is known that six addresses are to be used in the data packets.
[0006] In the PCT application PCT/EP2009/003271 filed on May 7, 2009, a method and device for generating at least one extension of an allocation message for wireless mesh networks are described, in which the creation of possible allocation tables for data packets to be transmitted is described.
[0007] A fundamental principle of wireless mesh networks or mobile ad hoc networks is the forwarding of data packets from other nodes through the mesh nodes. This means that a mesh node also needs power for sending and receiving data packets, even if the node itself has nothing to send or receive. This can cause more rapid battery consumption by battery-operated mesh nodes.
[0008] To extend battery life, battery-operated devices often also use an energy-saving mode, which puts their wireless interfaces temporarily into a sleep mode. This sleep mode requires only a very small amount of power, but devices in sleep mode cannot send or receive data packets. There is no loss of data, because the data packets can be stored temporarily until the device in energy-saving mode comes out of its sleep mode. However, this increases the delay in transmitting the packet. Depending on the sleep mode duration, this can be a significant amount of time, especially with multi-hop connections through devices in energy-saving mode in wireless mesh networks or mobile ad hoc networks.
[0009] Standard IEEE 802.11s on WLAN Mesh Networking, which is currently being developed as Version “IEEE P802.11™/D2.0 Draft STANDARD for Information Technology—Telecommunications and Information Exchange between Systems—Local and metropolitan area networks—Specific requirements, Part 11: Wireless LAN Medium Access Control (MAC) and Physical Layer (PHY) specifications, Amendment <number>: Mesh Networking,” March 2008, pages 1-XVII and 1-242—hereinafter designated as “IEEE P802.11s/D2.0 Draft Standard”—describes in its Section 11 B.9, pages 181-206, the routing protocol “Hybrid Wireless Mesh Protocol (HWMP),” which includes a management variable that establishes whether or not a mesh node should forward data packets to other mesh nodes. If no data packets should be forwarded, the routing messages are processed by HWMP in such a way that no path can be created through these nodes. However, because such non-forwarding nodes can be only the end or start point of a path, the mesh network might break into two or more sections if that node is the only connection.
[0010] In the publication by Ian D. Chakeres, Elizabeth M. Belding-Royer: “Transparent Influence of Path Selection in Heterogeneous Ad hoc Networks,” 15th IEEE International Symposium on Personal, Indoor and Mobile Radio Communications (PIMRC), Barcelona, Spain, September 2004, 3 pages, a characteristic of the Ad hoc On-Demand Distance Vector (AODV) is used in selecting the path. The target node responds in Standard AODV [see also Charles E. Perkins, Elizabeth M. Belding-Royer, Samir R. Das: “Ad hoc On-Demand Distance Vector (AODV) Routing,” IETF RFC 3561 (Experimental), July 2003, pages 1-36] only to the first route request message; subsequent route request messages are ignored. For this reason, forwarding of route request messages to battery-operated mesh nodes is delayed, so that route request messages from paths without battery-operated interim mesh nodes or with the fewest battery-operated interim mesh nodes are received first by the target node. HWMP from IEEE P802.11s/D2.0 Draft Standard is indeed based on AODV, but it recognizes all route request messages to the target mesh node. This mechanism therefore cannot be used in an IEEE P802.11s/D2.0 Draft-Standard mesh network with HWMP.
[0011] In the publication by Michelle Gong, Kazuyuki Sakoda, Jarkko Kneckt: “Thoughts on Interaction between Power Management and Path Selection,” July 2007, IEEE 802.11, Document 11-07/2095r3, pages 1-23 and in particular pages 17-18, two ideas are mentioned regarding how paths through battery-operated mesh nodes can be avoided:
[0012] In the first idea, which is only roughly outlined, mesh nodes are classified depending on their power source (power cable or battery) and on the battery status (non-critical/critical). This classification is relayed by beacons, so that routing messages can be forwarded selectively.
[0013] In the second idea, a wake-up bit is attached to the routing messages. If it is not added, battery-operated mesh nodes ignore those routing messages. If it is added, those routing messages are processed through the battery-operated mesh nodes. If a node wants to create a path, initially the wake-up bit is not added, so that in the case of successful path creation, no battery-operated devices are included in that path. If no path can be created, the wake-up bit is added, so that now battery-operated devices can also be considered for creating the path.
[0014] This method has three significant disadvantages:
[0015] The long wait time until a path is found, if only paths through battery-operated devices are available.
[0016] A path through multiple battery-operated mesh nodes with a very good path metric is preferred over a path with only one battery-operated mesh node but a somewhat poorer path metric, even if the poorer path is qualitatively satisfactory and has a better power balance.
[0017] The target mesh node receives no information about whether or not a path runs through battery-operated mesh nodes.
[0018] In the publication by Liwen Chu, George Vlantis: “Symmetrical Airtime Link Metric Report and Path Loop Avoidance,” April 2008, IEEE 802.11 Document 11-08/0636r0, pages 1-10 and in particular pages 3-4, it is proposed that battery-operated mesh nodes add the length of the beacon interval divided by 2 to the link metric. This proposal was made specifically for the airtime link metric included in the IEEE P802.11s/D2.0 Draft-Standard. It means that battery-operated mesh nodes are rarely selected, but the target mesh node receives no information about whether or not a path runs through battery-operated mesh nodes.
BRIEF SUMMARY OF THE INVENTION
[0019] Embodiments of the invention establish paths in wireless mesh networks or mobile ad hoc networks in such a way that mesh nodes which are battery-operated or in energy-saving mode are used as interim nodes in a path only if this is allowable based on the required connectivity in the mesh network or on preset guidelines.
[0020] Using the invented method, when establishing a routing metric in mesh networks, in particular according to IEEE standard 802.11s for Wireless Mesh Networks, the routing messages sent on various paths from the source node via the mesh nodes of the mesh network to the target node are interpreted in order to determine the best path for sending the data packets from the source node to the target node.
[0021] In this process, in each routing message sent from the source node through the various paths to the target node, a quantity of bits, preferably two bits, is used for the number of mesh nodes in the path that are in energy-saving mode or are battery-operated, while the remaining bits in the routing message are used for the path metric.
[0022] The selection of the best path is preferably based on preset selection rules. In general, the preferred path selected is the one that has the fewest mesh nodes or hops and whose path metric lies within a preset threshold value, such that if the number of mesh nodes that are battery-operated or in energy-saving mode is the same, the path with the better path metric is selected.
[0023] Various embodiments may have the following significant advantages:
[0024] The invention improves the consideration of battery-operated mesh nodes and mesh nodes in energy-saving mode during path selection in wireless mesh networks.
[0025] The target node that is affected by a particular path selection receives explicit quantitative information about the presence and number of battery-operated devices in the corresponding paths.
[0026] The actual path metric, which often reflects the wireless environment and often disregards the battery operation of individual devices in the path, is not changed. This means that the target node receives correct information about the path metric, regardless of the number of battery-operated devices in the path.
BRIEF DESCRIPTION OF THE FIGURES
[0027] Four exemplary embodiments of the invention are described using the attached figures. They show:
[0028] FIG. 1 : an example for a path metric field with 32 bits, in which the “number of battery-operated mesh nodes in the path” is transmitted in HWMP with two bits (N=3).
[0029] FIG. 2 : an example of a mesh network for the explanation of four exemplary embodiments according to FIGS. 3-6 .
[0030] FIG. 3 : for a first exemplary embodiment in table form with four possible paths, the 30 respective allocated path metric values m_A, m_:B, . . . , m_X, the number of respective hops, and the respective selection of possible paths according to rules a) to h) for the mesh network in FIG. 2 , wherein none of the mesh nodes involves a device in energy-saving mode or a battery-operated device.
[0031] FIG. 4 : for a second exemplary embodiment in table form with four possible paths, the respective allocated path metric values m_A, m_:B, . . . , m_X, the number of respective hops, and the respective selection of possible paths according to rules a) to h) for the mesh network in FIG. 2 , wherein only the mesh node: MP 7 involves devices in energy-saving mode or battery-operated devices.
[0032] FIG. 5 : for a third exemplary embodiment in table form with four possible paths, the respective allocated path metric values m_A, m_:B, . . . , m_X, the number of respective hops, and the respective selection of possible paths according to rules a) to h) for the mesh network in FIG. 2 , wherein only the mesh nodes: MP 4 and MP 7 involve devices in energy-saving mode or battery-operated devices.
[0033] FIG. 6 : for a fourth exemplary embodiment in table form with four possible paths, the respective allocated path metric values m_A, m_:B, . . . , m_X, the number of respective hops, and the respective selection of possible paths according to rules a) to h) for the mesh network in FIG. 2 , wherein only the mesh nodes: MP 5 and MP 7 involve devices in energy-saving mode or battery-operated devices.
DETAILED DESCRIPTION OF THE INVENTION
[0034] It is integral to the invention that two parameters are used as routing metrics:
[0035] the existing routing metric
[0036] the number p of mesh nodes in the path that are battery-operated or operating in energy-saving mode.
[0037] From a technical functionality standpoint, the new parameter “number of mesh nodes in the path that are battery-operated or operating in energy-saving mode” actually contains the “number of mesh nodes in the path that will not or should not forward any data packets for other mesh nodes.” The two most important reasons for such a method are:
[0038] battery operation, because it saves the battery,
[0039] energy-saving mode, which causes wait times when forwarding and is often used by battery-operated devices.
[0040] For this reason, the new parameter is called “number of mesh nodes in the path that are battery-operated or operating in energy-saving mode,” even though the corresponding devices counted in it are not necessarily battery-operated and not all battery-operated devices must be counted in it, e.g., if they are only temporarily battery-operated and are also not in energy-saving mode, such as laptops. Whether a mesh node is counted in this new parameter should be established by a configuration parameter such as a flag or an MIB (Management Information Base) variable.
[0041] The value range for the parameter “number of mesh nodes in the path that are battery-operated or operating in energy-saving mode” is a positive whole number from 0 to N, where N means that N or more battery-operated mesh nodes are in the path.
[0042] Each battery-operated node increases the parameter p for the “number of mesh nodes in the path that are battery-operated or operating in energy-saving mode” by 1 when the path metric is updated, unless the parameter p has already reached its maximum value of N:
[0000]
P
new
=
P
old
+
1
P
old
<
N
N
P
old
=
N
[0043] N is set depending on the desired granularity of this parameter versus the resources required for it (number of bits). If only one bit is used, then N=1 and only 2 values are possible. In practice, this means that only the statement of whether there are battery-operated mesh nodes in the path or not is possible. If more than one bit is used, then quantitative statements about the number of battery-operated mesh nodes in the path are also possible. Depending on the size of the mesh network, 2 bits (N=3) may be sufficient.
[0044] The target node now receives routing messages, in particular route request and path request messages, which in addition to the existing routing metric also have a statement regarding the presence of battery-operated mesh nodes in the corresponding path. This additional information can now be considered when selecting the path. In this way, different goals can be sought using different path selection rules.
[0045] Possible path selection rules a) to h), for determining whether Path A or Path B in the mesh network is “better,” are listed below.
[0046] The following definitions apply to these rules:
[0047] P_A is Path A,
[0048] P_B is Path B,
[0049] P_A<P_B means that Path A is better than Path B,
[0050] m_A is the path metric of Path A,
[0051] m_B is the path metric of Path B,
[0052] m_X is the path metric of Path X,
[0053] m_A<m_B means that the path metric for Path A is better than the path metric for Path B,
[0054] n_A is the number of battery-operated mesh nodes in Path A,
[0055] n_B is the number of battery-operated mesh nodes in Path B,
[0056] n_X B is the number of battery-operated mesh nodes in Path X,
[0057] h_A is the number of hops in Path A,
[0058] h_B is the number of hops in Path B,
[0059] h_X is the number of hops in Path X.
[0060] For path selection according to the invention, the characteristics of two arbitrary paths A and B from among all possible paths X are compared to each other. The following rules a) to h) are applied using the four exemplary embodiments according to FIGS. 3-6 .
[0000] a) Only paths with no mesh nodes that are battery operated or operating in energy-saving mode are used!
[0061] Conditions: n_A=n_B=0, otherwise the path is not considered.
[0062] P_A<P_B, if (m_A<m_B) and (n_A=n_B=0)
[0000] b) The path with the best metric is used.
[0063] The presence of mesh nodes that are battery-operated or operating in energy-saving mode is not considered.
[0064] P_A<P_B, if m_A<m_B
[0000] c) The best of the paths with the fewest mesh nodes that are battery-operated or operating in energy-saving mode is used.
[0065] Conditions: n_A is the minimum of all n_X
[0066] P_A<P_B, if (n_A<n_B) or ((n_A=n_B) and (m_A<m_B))
[0000] d) For each mesh node in the path that is battery-operated or operating in energy-saving mode, a “penalty” value Ps is added to the path metric.
[0067] P_A<P_B, if m_A+n_A*p s <m_B+n_B*p s [* indicates multiplication]
[0000] e) From among all paths with a metric that is better than or equal to the path metric threshold value T_p, the path with the fewest mesh nodes that are battery-operated or operating in energy-saving mode is selected.
[0068] T_p can be determined here either with absolute dependence on the metric used or relative to the best metric value (T_p=min(m_X)+å*min(m_X), where å is a positive real number and preferably 0≦å≦1).
[0069] Conditions: m_A≦T_p and m_B≦T_p and n_A is the minimum of all n_X with m_X≦T_p
[0070] P_A<P_B, if ((n_A<n_B) and (m_A≦T_p) and (m_B≦T_p)) or ((n_A=n_B) and (m_A<m_B) and (m_A≦T_p) and (m_B≦T_p))
[0000] f) From among all paths with an average link metric that is better than or equal to the link metric threshold value T_l, the path with the fewest mesh nodes that are battery-operated or operating in energy-saving mode is selected.
[0071] T_l can be determined here either with absolute dependence on the metric used or relative to the best metric value (T_l=min(m_X/h_X)+å*min(m_X/h_X), where å is a positive real number and preferably 0≦å≦1).
[0072] Conditions: m_A/h_A≦T_l and m_B/h_B≦T_l and n_A is the minimum of all n_X with m_X/h_X≦T_I
[0073] P_A<P_B, if ((n_A<n_B) and (m_A/h_A<T_l) and (m_B/h_B≦T_l)) or ((n_A=n_B) and (m_A<m_B) and (m_A/h_A≦T_l) and (m_B/h_B≦T_l))
[0000] g) The path with the smallest portion of mesh nodes that are battery-operated or operating in energy-saving mode is used. P_A<P_B, if (n_A/h_A<n_B/h_B) or ((n_A/h_A=n_B/h_B) and (m_A<m_B))
h) Combinations of the rules are also possible.
[0074] For example, only paths with no mesh nodes that are battery operated or in energy-saving mode can be considered first [Rule a)].
[0075] Only when there are no such paths is another rule used, which also considers paths with battery-operated mesh nodes [e.g., Rule b), c), d), e), f), or g)].
[0076] For the maximum value N of the parameter p=“Number of battery-operated mesh nodes in the path,” N=3 appears to be an optimal value for mesh networks with up to about 50 mesh nodes, for the following reasons:
[0077] N=3 allows more precise differentiation than N=1 (1 bit). A path with a good metric but 1, 2, or 3 battery-operated devices can be weighed against a path with a poorer metric but no battery-operated devices.
[0078] N=3 can be represented with 2 bits to save space.
[0079] 3 bits would go up to N=7. A difference of whether 4 or 7 battery-operated mesh nodes are now in the path does not often lead to a different path selection. Paths with that many battery-operated mesh nodes are already undesirable.
[0080] The invention improves the consideration of mesh nodes that are battery-operated or operating in energy-saving mode and mesh nodes in energy-saving mode during path selection in wireless mesh networks.
[0081] The target node that is affected by a particular path selection receives explicit quantitative information about the presence and number of devices that are battery-operated or operating in energy-saving mode in the corresponding paths.
[0082] The actual path metric, which often reflects the wireless environment and often disregards the battery operation or energy-saving mode of individual devices in the path, is not changed. This means that the target node receives correct information about the path metric, regardless of the number of battery-operated devices in the path.
[0083] The invention has no additional wait time as in the aforementioned publication by Michelle Gong, Kazuyuki Sakoda, Jarkko Kneckt: “Thoughts on Interaction between Power Management and Path Selection,” July 2007, IEEE 802.11, Document 11-07/2095r3, see in particular pages 17-18, where battery-operated mesh nodes are considered only if the path request is repeated. The invention does consider battery-operated mesh nodes in the first path request, but can still make the same decision as in this publication by Michelle Gong et al. (“best path that contains no mesh nodes that are battery-operated or operating in energy-saving mode” and “best path regardless of the number of mesh nodes in the path that are battery-operated or operating in energy-saving mode”) and can also make many more granular assessments.
[0084] By applying the various rules during path selection in the target node, the use of devices that are battery-operated or operating in energy-saving mode and the quality of the path (path metric) can be weighed against each other depending on the established goals. The routing protocol HWMP (Hybrid Wireless Mesh Protocol) specified in the “IEEE P802.11s/D2.0 Draft Standard” uses a metric field in its routing messages (route request, route reply, etc.) that is four bytes (32 bits) long. In order to convert the invention into HWMP, for example, m bits in this metric field can be used for the new parameter p=“number of mesh nodes in the path that are battery-operated or operating in energy-saving mode.” The available space for the existing metric field is then shortened to (32−m) bits.
[0085] FIG. 1 shows, as an example, the complete 32-bit metric field of HWMP messages with the expansion by means of the invention. Here the uppermost two bits are used for the new parameter p for the “number of mesh nodes in the path that are battery-operated or operating in energy-saving mode.” In the example from FIG. 1 , two bits are used for this new parameter p, which corresponds to the optimum considered value of N=3 in the invention. Thus, 30 bits remain available for the path metric and two bits for the “number of battery-operated mesh nodes in the path.” The value of the path metric can be stated as any number that can be represented with 30 bits and is used by the network for the corresponding path according to the “IEEE P802.11s/D2.0 Draft Standard.” As a rule, according to this standard, a total of 32 bits is allocated for defining the path metric value, whereas in the invention described above only 30 bits are used for the path metric value, and the remaining 2 bits that have become available, here in FIG. 1 the uppermost two bits, are used for the new parameter p for the “number of mesh nodes that are battery-operated or operating in energy-saving mode.”
[0086] The path selection according to the invention is illustrated for all of the rules established in the invention using the wireless mesh network example shown in FIG. 2 . Here various mesh nodes are considered to be mesh nodes in energy-saving mode or battery-operated nodes, i.e., mesh nodes that increase the new parameter p during the path search.
[0087] For the additional parameters used in rules a) to h), the following values are considered to be given in the four exemplary embodiments described in FIGS. 3 to 6 :
[0088] “Penalty value” P s =80 for rule d)
[0089] Path metric threshold value T_p=min(m_X)+c*min(m_X) with c=0.2 and min(m_X)=460
[0090] Path metric threshold value T_p=552
[0091] Link metric threshold value T_I=120 (fixed value)
[0092] FIG. 2 shows an example of a mesh network for the explanation of four exemplary embodiments according to FIGS. 3-6 .
[0093] The mesh network has the eight mesh nodes MP 1 , MP 2 , MP 3 , MP 4 , MP 5 , MP 6 , MP 7 , and MP 8 . There are many possible paths from source node MP 1 to target node MP 8 , all of which run through mesh node MP 5 . Each of the mesh nodes MP 1 , MP 2 , MP 3 , MP 4 , MP 6 , MP 7 , and MP 8 has a connection to two neighboring nodes. However, mesh node MP 5 has a connection to each of the four neighboring mesh nodes MP 3 , MP 4 , MP 6 , and MP 7 . Each connection to two neighboring mesh nodes has an assigned link metric value that is written for it. The smaller each link metric value, the “better” its connection. “Better” can mean, for example, that the connection costs are lower or that the data transfer quality is better or that it is a faster data connection. The sum of the link metric values for a path is the path metric value, which is expressed by the rightmost 30 bits in the 32-bit path metric field in FIG. 1 , such that the “number of battery-operated mesh nodes in the path” in HWMP is expressed with two bits (N=3) in bit 31 and bit 32 .
[0094] Each of FIGS. 3 to 6 contains a table for the respective path selection. The tables are arranged according to the same matrix layout, for which the representative table layout in FIG. 3 is explained below. The first column lists the four possible paths. The second column contains the sums of all link metric values for each possible path. The third column gives the number of hops (hop count), which corresponds to one fewer than the number of nodes per path; i.e., either path in the first two rows has a total of 5 nodes without the source node, so 4 hops.
[0095] In the fourth column, for the application of each rule a) to h), an “x” indicates whether this path is selected or may not be selected (shown by gray crosshatching), according to each of the rules. The four exemplary embodiments differ by variations in whether and/or how the mesh nodes are equipped with batteries or devices operating in energy-saving mode. Each such mesh node with a battery or device operating in energy-saving mode is printed in bold in the left column.
[0096] For the path in the first row designated as MP 1 -MP 4 -MP 5 -MP 6 -MP 8 , which corresponds to the upper line in FIG. 1 , the path metric value of 460=120+120+110+110 results from the sum of the four individual link metric values (2×120+2×110=460). The required average link metric value of m_A/h_A for rule f) comes out to 460:4=115. For example, for FIG. 3 and rule f), m_A/h_A=115≦TI=120 meets the first condition for rule f). Because no devices that are battery-operated or operating in energy-saving mode are contained in the path, all of the other conditions are also met, so an “X” is placed in the field under rule f) in the first row. This path is therefore available according to rule f).
[0097] For the path in the second row designated as MP 1 -MP 4 -MP 5 -MP 7 -MP 8 , which corresponds to the upper line in the left half and the lower line in the right half, the path metric value of 500=120+120+130+130 results from the sum of the four individual link metric values (2×120+2×130=500). The required average link metric value of m_A/h_A for rule f) comes out to 500:4=125. For example, for FIG. 3 and rule f), the first condition m_A/h_A=125≦T_l=120 is not valid because it does not fulfill the first condition of rule f), so the field under rule f) is crosshatched in black, indicating that this path is not available.
[0098] For the paths in the third or fourth rows, the average link metric m_A/h_A required for rule f) is 535:5=107 or 575.5=115.
[0099] FIG. 3 shows, for a first exemplary embodiment in table form with four possible paths, the respective allocated path metric values m_A, m_:B, . . . , m_X, the number of respective hops, and the respective selection of possible paths according to rules a) to h) for the mesh network in FIG. 2 , wherein as a special case none of the mesh nodes involves a device in energy-saving mode or a battery-operated device. In this case the result for all rules a) to h) is that the upper path ( FIG. 2 ) in the first row of the table is selected. For the path in the second row, the average link metric value m_A/h_A=500:4=125, which is greater than the maximum allowable threshold value T_l=120, so this path is not available according to rule f), and therefore the corresponding table field is crosshatched in black. The same criteria apply to the other black-crosshatched fields in this table.
[0100] FIG. 4 shows, for a second exemplary embodiment in table form with four possible paths, the respective allocated path metric values m_A, m_:B, . . . , m_X, the number of respective hops, and the respective selection of possible paths according to rules a) to h) for the mesh network in FIG. 2 , wherein only the mesh node: MP 7 involves devices in energy-saving mode or battery-operated devices. The result for the path selected or rejected according to rules a) to h) is shown in the fourth column by an “x” being entered or by black crosshatching.
[0101] FIG. 5 shows, for a third exemplary embodiment in table form with four possible paths, the respective allocated path metric values m_A, m_:B, . . . , m_X, the number of respective hops, and the respective selection of possible paths according to rules a) to h) for the mesh network in FIG. 2 , wherein only the mesh nodes: MP 4 and MP 7 involve devices in energy-saving mode or battery-operated devices. The result for the path selected or rejected according to rules a) to h) is shown in the fourth column by an “x” being entered or by black crosshatching.
[0102] FIG. 6 shows, for a fourth exemplary embodiment in table form with four possible paths, the respective allocated path metric values m_A, m_:B, . . . , m_X, the number of respective hops, and the respective selection of possible paths according to rules a) to h) for the mesh network in FIG. 2 , wherein only the mesh nodes: MP 5 and MP 7 involve devices in energy-saving mode or battery-operated devices. The result for the path selected or rejected according to rules a) to h) is shown in the fourth column by an “x” being entered or by black crosshatching.
[0103] As a general rule, the invention searches for the path that has the fewest nodes or hops and whose path metric lies below a predetermined threshold value. If the evaluated paths have the same number of nodes that are battery-operated or operating in energy-saving mode, it takes the path with the better path metric—see rules e) and f). Here the path metric is the quality for transferring data packets from the source node through the nodes in the mesh network to the target node, whereby, for example, they can also be defined as connection costs (e.g., telephone charges from the USA through Kenya to Germany may be cheaper than through Great Britain or vice versa), which must be paid by the user to the network operator. The path metric can also indicate the number of hops and therefore also the signal delay time, because, for example, telephone conversations through one or more satellites have signal delay times that are too long, such that there are long pauses in the telephone conversation before a response can be sent. | The invention relates to a method and a device for which, for determining a routing-metric for a mesh-network, in particular according to standard IEEE 802.11s, routing messages sent in wireless mesh networks or mobile ad-hoc-networks, on various paths of source nodes, via the mesh nodes of the mesh networks to the target nodes, are evaluated in order to determine the best path for transferring data packets from source nodes to target nodes. Said nodes are battery-operated and mesh nodes are only used in the energy-saving mode as intermediate nodes of a path when this can not be prevented due to necessary connectivity in the mesh network or due to predetermined guidelines. Also, in each routing message sent from source nodes to target nodes via various paths, a plurality of bits, preferably two bits, are used for the number of mesh nodes operating in the path in the energy-saving mode or are battery-operated when the remaining bits of the routing-message are used for the path metric. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an ophthalmic apparatus for measuring and observing an eye and, more particularly, to an ophthalmic apparatus provided with a system to indicate alignment information and others to an operator.
2. Description of Related Art
Ophthalmic apparatuses for measuring and observing generally have optical systems for observing an examinee's eye, because those apparatuses require the accurate alignment between the apparatus and the examinee's eye. For the observing optical system, there are some kinds of an optical system for photographing the examinee's eye with a CCD camera and the like and then projecting the image of the eye on a TV monitor, and another optical system for directly observing the examinee's eye through an observing lens.
The former system commonly displays the alignment information and examined data with the image of the eye in the same field of view on a TV monitor, by introducing displaying luminous flux to the observing optical system or by utilizing a character displaying circuit and a graphic displaying circuit and the like.
The latter direct observing system utilizes introducing luminous flux for displaying the information into an observing optical system and, alternatively, displaying the information at out of observation visual field of an examiner so that the examiner observes the examinee's eye and a display portion alternately.
However, the former system should be provided with CCD cameras and TV monitors and others and therefore causes the increased cost of apparatus and large-sized apparatus. The system is not suitable at all for hand-held type apparatus consequently.
An apparatus with the latter system, wherein a display unit is disposed at out of the observation visual field of the examiner, has a troublesome problem that the the examiner must turn his eye on the examinee's eye and the display alternately. The system for introducing the luminous flux from the display unit into the observation visual field must provide the optical path for the displaying luminous flux and dispose a light synthesizing member. Accordingly, the apparatus with the system, increasing in size, is not always suitable for hand-held type apparatus.
SUMMARY OF THE INVENTION
The present invention has been made in view of the above circumstances and has an object to overcome the above problems and to provide an ophthalmic apparatus having a system by which the examiner can obtain the information with his eye turning on the examinee's eye, and usable for hand-held type apparatus.
Additional objects and advantages of the invention will be set forth in part in the description which follows and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
To achieve the objects and in accordance with the purpose of the invention, as embodied and broadly described herein, an ophthalmic apparatus for measuring and observing an eye of an examinee of this invention comprises observing optical system through which an examiner observes the examinee's eye, and displaying means for providing indication marks to the cornea of the examinee's eye, the indication marks showing necessary information for the operator, wherein images of the indication marks reflected by the cornea are observed as superimposed on the examinee's eye.
In another aspect of the present invention, an ophthalmic apparatus for measuring the shape of the cornea of an examinee's eye comprises an observing optical system for observing the examinee's eye, an index projecting optical system for projecting an index onto the examinee's eye to measure the shape of the cornea, a detecting optical system for detecting the index projected by the index projecting optical system, an alignment detecting optical system for projecting indexes for alignment including working distance onto the examinee's eye and for detecting images of the indexes reflected by the cornea, displaying means for displaying alignment condition through the observing optical system, and measured data displaying means for displaying measured data obtained by the detecting optical system, wherein the each component is comprised in an apparatus body of a hand-held type apparatus, and displaying luminous flux from the measured data displaying means is introduced to the cornea of the examinee's eye, so that the examiner observes the measured data through the observing optical system.
According to the present invention, with a very simple construction, the examiner can obtain useful information to operate the apparatus without turning his eye from the examinee's eye.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of this specification illustrate an embodiment of the invention and, together with the description, serve to explain the objects, advantages and principles of the invention. In the drawings,
FIG. 1 is a diagram to show an optical arrangement of an optical system of an ophthalmic apparatus according to the present invention;
FIG. 2 is a schematic diagram to show an arrangement of index projecting optical systems and LEDs.
FIG. 3 is a schematic diagram to explain alignment operation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A detailed description of one preferred embodiment of an ophthalmic apparatus embodying the present invention will now be given referring to the accompanying drawings.
FIG. 1 shows a side view of an optical system of an ophthalmic apparatus in the embodiment.
Numeral 1 indicates an eye of an examinee and numeral 2 indicates an eye of an examiner respectively. In FIG. 1, the apparatus body 3, which is a cornea shape measurement apparatus of hand-held type in the present embodiment, is provided with a through hole 4 through which the examiner can observe the examinee's eye 1, and an objective lens 5 fitted in the through hole 4. The examiner's eye 2 therefore observes the examinee's eye 1 through the objective lens 5 for magnifying the examinee's eye in monocular vision. The present embodiment utilizes an apparatus for monocular observation, but can also use an apparatus for binocular observation.
The apparatus body 3 further includes an illumination light source 6 for fixation target, a fixation target plate 7 provided with a spot aperture, a concave lens 8 for projecting an image of the fixation target on the fundus of the examinee's eye 1 in cooperation with a focusing lens mentioned below, and a dichroic mirror 9a for reflecting an optical axis of light of fixation target coaxially to an optical axis of detecting optical system, a beam splitter 9b for reflecting a light of fixation target coaxially to a light of observing optical system, and index projecting optical systems 10a-10d for measuring the shape of a cornea of the examinee's eye 1.
The index projecting optical systems 10a-10d are arranged, as shown in FIG. 2, at 90-degrees angle apart from each other in the same circle centering the optical axis of the observing optical system, each of which is constituted of a LED 11 for emitting light of near infrared area, a spot diaphragm 12 and a collimator lens 13. When detecting working distance (alignment condition), the collimator lens 13 of the index projecting optical system 10a is disposed out of the optical path. Technical context thereof has been disclosed in Japanese Patent Application No. 4(1992)-224896 corresponding to U.S. Pat. No. 5,463,430.
In the apparatus body 3, also provided are a focusing lens 14, a telecentric diaphragm 15 arranged at a focus point of the focusing lens 14, a beam splitter 16 for dividing light into two light beams, one-dimensional image sensors 17a and 17b each of which is arranged on each optical path of two light beams so as to cross their detecting directions with each other, and cylindrical lenses 18a and 18b. The cylindrical lenses 18a and 18b are disposed between the telecentric diaphragm 15 and each of the one-dimensional image sensors 17a and 17b respectively so that each axis of the cylindrical lenses 18a and 18b coincides with each detecting directions of the image sensors 17a and 17b.
LEDs 19 are disposed at regular intervals in a circle (twelve LEDs in the present embodiment, as shown in FIG. 2), each of which is provided with a spot diaphragm 20 and a collimator lens 21. Spot light from the LEDs 19 are reflected by the cornea and the cornea reflecting images of the spot light arranged in a circle can be utilized as a substitution for mire-ring. The LED 19 is also used for an indicator to indicate alignment condition of the apparatus, when the alignment condition is indicated by four LEDs 19 disposed at up-and-down and right-and-left positions in the circle.
Numeral 22 shows a display unit for displaying measured data including errors, for which liquid crystal display and dot matrix type display and others are usable. The display unit 22 displays the data in reversed picture, so that the data image is provided for the examiner as normal image when the reversed image is projected on and reflected by the cornea. A display unit for displaying normal pictures is also usable in the embodiment if the normal picture is reversed by a mirror to be projected on the cornea. The display unit 22 can display measured data and an indication showing a right or left eye, which is input by the examiner, so that the examiner can look the information including the measured data as superimposed on the examinee's eye.
Operation of the apparatus described above will be explained as below.
The examinee looks fixedly at a fixation target image from the fixation target light source 6 and the plate 7, and the examiner observes the examinee's eye 1 through the objective lens 5 to magnifying the eye. Observing the examinee's eye as above, the examiner conducts alignment operation in accordance with the following procedure simultaneously.
Alignment in vertical and horizontal directions is detected based on positions of index images provided of the index projecting optical systems 10c and 10d reflected by the cornea of the eye 1, which are arranged symmetrically to the optical axis of measuring light, more specifically, based on direction or distance of the coordinates of a middle point between two index images in comparison with the coordinates of a middle point which ought to be positioned in proper alignment.
The light of index images reflected by the cornea are reflected by the beam splitter 9b toward the focusing lens 14 and then focused by the focusing lens 14 on the one-dimensional image sensors 17a and 17b along each detecting direction. The one-dimensional image sensors 17a and 17b detect two-dimensional positions of the index images reflected by the cornea. Microcomputer (not shown) processes coordinates of a middle point between the index images and compares it with coordinates of a middle point which ought to be positioned in proper alignment. As a result, if the measuring optical axis is positioned upward to the examinee's eye 1, LED 19 disposed at a lower position is turned on (or blinked on and off) to show the examiner a direction to move the apparatus, as shown in FIG. 3. The examiner moves the apparatus in the moving direction accordingly. As soon as alignment in vertical and horizontal directions is completed, LEDs 19 disposed in a moving direction, i.e., at up-and-down and right-and-left positions respectively are turned on.
To adjust working distance of the apparatus, the following operation is conducted.
The collimator lens 13 of the index projecting optical system 10a is first removed out of the optical path to detect the working distance. And then, regarding index images reflected by the cornea, one of which is provided by the index projecting optical system 10a and another by the index projecting optical system 10b, their images height are compared. This utilizes the characteristics that, if the working distance is changed, height of the index image formed by a light source at infinity is settled, but that of the index image formed by a light source at finity is changeable, if the working distance is changed. The detailed explanation thereof is described in U.S. Pat. No. 5,463,430 proposed by the present applicant.
The image height of index images formed by the finite light source and the infinite light source respectively are compared based on the result detected at the one-dimensional image sensors 17a and 17b, and thereby suitability of the working distance is judged. LEDs 19 are slowly blinked on and off if the apparatus is closer to the examiner compared with the proper working distance, and rapidly blinked on and off if the apparatus is too close to the examinee's eye 1.
Completing the alignment as above, measuring the shape of a cornea of the examinee's eye 1 is succeedingly conducted. The shape of a cornea can be calculated if three index images are detected as described in Japanese Laid-Open Patent No. 61(1986)-85920. It is therefore possible to measure the shape of the cornea as the collimator lens 13 of the index projecting optical system 10a is stayed out of the optical path. In the present embodiment, however, to obtain more accurate data, the collimator lens 13 of the optical system 10a is moved into the optical path by a motor when a signal is generated to indicate completion of alignment, so that the shape of a cornea is measured based on four coordinates of index images provided by the four index projecting optical systems 10a-10d.
The data for the shape of the cornea processed at the microcomputer is displayed in the display unit 22 through a displaying circuit, and the displaying luminous flux of the display unit 22 is turned toward the cornea of the examinee's eye 1. The examiner can observe the data image reflected by the cornea as superimposed on the examinee's eye.
The present invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. For instance, the above embodiment utilizes blinking situation of LED 19 to indicate the suitability of the working distance, and besides, a LED emitting two colors; red and green can further be utilized, so that the suitability of the working distance can be indicated with three colors; red, green and orange.
The foregoing description of the preferred embodiment 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 embodiment 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. | An ophthalmic apparatus for measuring and observing an eye of an examinee comprising an observing optical system through which an examiner observes the examinee's eye, and a displaying device for providing indication marks to the cornea of the eye, the indication marks showing necessary information for the operator, wherein images of the indication marks reflected by the cornea are observed as superimposed on the examinee's eye. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present invention claims priority from Russian Patent Application No. 2015103552 filed Feb. 3, 2015, which is incorporated herein by reference.
TECHNICAL FIELD
The present invention relates to a contactless determination of the amplitude, frequency and phase of oscillation of blades in turbo-machines and can be used to detect faults of blades during their operation and to display the fatigue strength of the blade material.
BACKGROUND OF THE INVENTION
There are known a process and a device for determining the amplitude, frequency and phase of oscillation in turbo-machine blades, based on the strain measurement of blades (Leontiev M. K. Strain measurement in aviation gas-turbine engines. Instructional manual—Moscow: MAI. 2001, pages 24-34—in Russian), consisting in the following: strain gauges are glued on the blades, the wires from the strain gauges are laid down along the blade, locking piece, wheel disc and shaft for leading them up to a particular current collector the signals of which are amplified and supplied to recording equipment.
The drawbacks of the known process and of the device for putting it into practice are as follows: a limited number of simultaneously checked blades and, as a result, an insufficient reliability of the blade oscillation parameter determination, as well as the impossibility to carry out strain measurements of blades in each turbo-machine unit.
The closest prior art for the present invention as to the technical concept is a process for determining oscillation parameters of turbo-machine blades, disclosed in the patent application GB1147737 published on Feb. 4, 1969 and consisting in the following: time intervals between the pulses of two contactless pulse detectors located in the plane of a turbo-machine wheel rotation are measured and the amplitudes of speeds and of translations of blade ends are calculated on the basis of said time intervals; then the frequency and the phase (with the precision of up to a decimal point) of the blade oscillations are determined and the maximum travels of the blade ends (deviations from the initial position) are statistically found for determining, with these results, the amplitude of the blade ends oscillations.
This known process is put into practice with a device disclosed in the patent application GB1147737 published on Feb. 4, 1969 and containing a unit of peripheral sensor (primary transducers), a sensor of full revolution of the turbo-machine working wheel and a sensor placed near the blade root, pulse shapers for said sensor, a unit for converting time intervals into a code, a control unit, an output register and an electronic computer.
The drawbacks of the known process and the device for putting the same into practice are as follows: a long time for making measurements and a complicated structure of the device due to the use of a high number of sensors. Otherwise, it is impossible to determine the initial oscillation phase for each blade.
SUMMARY OF THE INVENTION
In the present invention, all the oscillation parameters for each blade are determined with the use of one on-line sensor, which enables to determine the oscillation parameters of each blade during variations of the turbo-machine rotation shaft speed (of the turbo-machine operation mode modification).
For achieving the mentioned technical result, in the method for determining the blade oscillation parameters in a turbo-machine rotating working wheel, when the blade end travels in front of a sensor, reading values of a single pulse signal formed by the sensor are obtained in a number that is not lower than that of unknown parameters of a harmonic or polyharmonic oscillation, and the origin of a single pulsed signal readings obtained for each blade is synchronized with the blade end position relative to the sensor according to a given level of the single pulsed signal. Then the values of the harmonic or polyharmonic oscillation parameters of the blade are calculated with the use of the obtained values of the single pulsed signal reading origins and of the value of the turbo-machine shaft (working wheel) revolution period.
The turbo-machine shaft revolution period can be measured with a gauge of a full rotation of the turbo-machine shaft or as a time interval between single pulsed signals detected by the gauge from the same blade, since the number of blades (single pulses for a full revolution) is known.
For achieving the mentioned technical results, the device for putting into practice the above disclosed process comprises:
a peripheral sensor adjusted in the turbo-machine body,
a gauge of full rotation of the turbo-machine shaft mounted onto the fixed part of the turbo-machine,
a pulse shaper of the gauge of full rotation of the shaft,
a pulse shaper of the peripheral sensor,
a unit for converting time intervals into a code,
an electronic computer,
an analog-to-digital converter,
a low-pass filter the input of which is connected to the output of the peripheral detector, its output being connected to the information input of the analog-to-digital converter and to the input of the pulse shaper of the peripheral detector, the output of the pulse shaper of the peripheral detector is connected to a synchronizing input of the analog-to-digital converter, the digital outputs of the analog-to-digital converter are connected to the first part of the input digits of the digital interface of an electronic computer, the second part of the input digits of the digital interface of the electronic computer being connected to the output digit positions of the time interval converter unit the synchronizing input of which is connected to the pulse shaper output of the gauge of full rotation of the shaft; the third and the fourth parts of the input digits of the digital interface of the electronic computer are connected, respectively, to the output of the pulse shaper of the peripheral detector and to that of the pulse shaper of the gauge of full rotation of the shaft, and the input of the pulse shaper of the gauge of shaft full revolution is connected to the output of the gauge of shaft full revolution. The electronic computer represents an output unit of the device and allows one to accept, to memorize and to process input data, to store and to output final information under the form needed by the user.
An exciter for the gauge of full revolution of the turbo-machine shaft can be used under the form of a revolution mark mounted onto the turbo-machine rotor.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a structural diagram of the device putting into practice the process of the present invention.
FIG. 2 illustrates the shape of output signals of the peripheral sensor (a primary converter).
DETAILED DESCRIPTION
The phase, frequency and amplitude of oscillations of the blades of a rotating turbo-machine wheel according to the present invention are determined as follows.
A peripheral sensor (a primary converter), for example, an eddy current sensor is mounted into the turbo-machine body in the close vicinity to the mechanical trajectory of the blade tip. Under working conditions or under a transient operating condition of the turbo-machine, single pulsed signals of the peripheral sensor that are generated at the passage of blade tips ends near-by are recorded.
To calculate the parameter values of a harmonic or polyharmonic oscillation of a blade on the basis of values of readings obtained for a single pulsed signal, the shape of a signal generated at the interaction of a particular kind of a primary converter with the tip end of a moving and simultaneously oscillating blade is modeled. For such a modeling, use is made of known analytical expressions describing signal shapes. For example, a pulse at the output of an eddy current sensor can be represented (described) by an analytical expression of a Gaussian pulse (see Nondestructive control and diagnostics: Reference book/V. V. Kluyev, F. R. Sosnin, A. V. Kovalev, et al.; edited by V. V. Kluyev, 2 nd edition, corrected and completed—Moscow; Mashinostroyenie, 2003, p. 401—in Russian), the independent variable of which comprises a functional dependence defining a law of the blade tip motion and the signal shape, in particular: front slope, duration and amplitude.
On the basis of a signal shape model and after solving a set of equations in which the values of obtained readings for a single pulsed signal, an algorithm and a program for determining the blade oscillation parameters are worked out. The explanation for the above mentioned is given below.
For each single pulsed signal, several amplitude-time readings are selected (according to the number of unknown parameters of polyharmonic oscillations of the blade: amplitude, frequency and initial phase of each harmonic oscillation); the readings obtained are substituted in the analytical expression defining the shape of the single pulsed signal; a set of nonlinear equations is formulated (at least 3 equations when the blade is under monoharmonic oscillation); the set of nonlinear equations is solved with the use of, for example, nonlinear approximation methods, and the blade oscillation parameters are determined.
Assume that, for example, a peripheral eddy current sensor generates, at the passage near-by of a blade tip, a bell-shape pulse that can be described with the expression for a Gaussian pulse (see “Nondestructive control and diagnostics: Reference book”/V. V. Kluyev, F. R. Sosnin, A. V. Kovalev, et al.; edited by V. V. Kluyev, 2 nd edition, corrected and completed.—Moscow; Mashinostroyenie, 2003, 656 p—in Russian)
s
(
y
)
=
exp
(
-
y
2
2
a
y
2
)
,
where y is the travel of the blade tip, a y is a parameter of the Gaussian pulse.
Suppose that a blade of a rotating blade wheel oscillates according to the sinusoidal law with the amplitude A. Then the travel of the blade end will have two components: a rotary component and an oscillatory one, and will be defined by the expression:
y ( t )= Rω K t+A sin(ω π t +φ),
where R is the wheel radius, ω K is the angular frequency of the wheel rotation, ω π and φ represents the angular frequency and the initial phase of the blade oscillations, respectively.
In this case, the output signal of the peripheral eddy current sensor, in the presence of oscillations, will be defined as:
s
(
t
)
=
exp
(
-
1
2
a
t
2
×
(
t
+
A
R
ω
k
sin
(
ω
π
t
+
f
)
)
2
)
.
And, in the absence of oscillations, respectively:
s
(
t
)
=
exp
(
-
1
2
a
t
2
·
t
2
)
,
where
a t = a y R ω κ
is a parameter of the Gaussian pulse having the time dimensionality.
The shape of output signals from the peripheral eddy current detector for both cases is illustrated in FIG. 2 .
To determine unknown parameters of the blade oscillation, such as: amplitude A, frequency ω π and initial phase φ, it is necessary to solve, while analyzing the peripheral eddy current sensor output signal, a set of at least 3 nonlinear following equations:
{
s
(
t
1
)
-
exp
(
-
1
2
a
t
2
·
(
t
1
+
A
R
ω
κ
sin
(
ω
π
t
1
+
φ
)
)
2
)
=
0
s
(
t
2
)
-
exp
(
-
1
2
a
t
2
·
(
t
2
+
A
R
ω
κ
sin
(
ω
π
t
2
+
φ
)
)
2
)
=
0
s
(
t
3
)
-
exp
(
-
1
2
a
t
2
·
(
t
3
+
A
R
ω
k
sin
(
ω
π
t
3
+
φ
)
)
2
)
=
0
,
where origins of readings of a peripheral eddy current sensor signal from an oscillating blade at the times t 1 , t 2 and t 3 are assigned as initial data for approximation. To determine unknown parameters of the blade oscillation, use is made, for example, of nonlinear approximation methods.
The device for determining the blade oscillation parameters of the turbo-machine rotating wheel ( FIG. 1 ) comprises a contactless peripheral sensor 1 , for example, an eddy current one, mounted in the turbo-machine body 2 in the plane of the wheel rotation facing the mechanical trajectory of the blade tips 3 , a low-pass filter 4 the input of which is connected to the output of the peripheral sensor 1 , an analog-to-digital converter 5 the information input of which is connected to the output of the low-pass filter 4 , a rectangular pulse shaper 6 of the peripheral detector 1 the input of which is connected as well to the output of the low-pass filter 4 ; the output of the shaper 6 is connected to the synchronizing input of the analog-to-digital converter 5 ; an exciter 7 (a mark, for example, made as a metallic pin on the disc of the blade wheel or on the turbo-machine rotor) of a gauge of full shaft revolution mounted on the turbo-machine rotor; a contactless gauge 8 of full shaft revolution, for example an eddy current one, mounted on the fixed part of the turbo-machine and facing the mark 7 motion trajectory; a pulse shaper 9 of the gauge of full shaft revolution the input of which is connected to the output of the gauge 8 of full shaft revolution; a unit 10 for converting time intervals into a code the synchronizing input of which is connected to the output of the shaper 9 ; an electronic computer 11 , for example an IBM-type PC, the first part of the input digits of the digital interface of which is connected to the digital outputs of the analog-to-digital converter 5 , the second part of the input digits of the digital interface of the electronic computer 11 being connected to the output digit positions of the time interval converter unit 10 , the third and the fourth parts of the input digits of the digital interface of the electronic computer 11 are connected, respectively, to the outputs of the pulse shapers 6 and 9 ; the electronic computer being an output unit of the device, enabling to accept, to store and to process input data, while implementing the algorithm of nonlinear approximation for solving a set of nonlinear equations to determine unknown oscillation parameters, and to store and to output final information under the form needed by the user.
The device ( FIG. 1 ) putting into practice the process for determining the blade oscillation parameters of the turbo-machine rotating wheel operates as follows. The contactless peripheral sensor 1 , for example an eddy current one, mounted in the body 2 of the turbo-machine in the plane of the wheel rotation plane opposite to the motion trajectory of the blade tips 3 , generates electric bell-shape pulses as a result of interaction with the blade tips ends, with the amplitude U blade max , that are further supplied to the input of the low-pass filter 4 with the cut-off frequency of, for example, 100 kHz, providing suppression of high-frequency noise. Later on, the filtered signal is supplied to the information input of the analog-to-digital converter 5 and is supplied simultaneously to the rectangular pulse shaper 6 of the peripheral detector, for example, a comparator with the comparison level 0.1 U blade max , to form pulses corresponding to particular blades. The rectangular pulses formed in amplitude and in duration by the shaper 6 are supplied to the synchronizing input of the analog-to-digital converter 5 , the leading edge of which represents the start and the cut-off of which represents the end of numeralization of continuous (analog) bell-shape pulses of the peripheral sensor 1 . The exciter (mark) 7 of the gauge of full shaft revolution mounted, for example, on the turbo-machine rotor, while passing by the contactless gauge 8 of full shaft revolution, for example, an eddy current one, interacts therewith, the gauge 8 of full shaft revolution generates a pulsed signal with the amplitude U revol. max , which is supplied to the rectangular pulse shaper 9 of the gauge of full shaft revolution, for example, a comparator with the comparison level 0.1 U revol. max . The rectangular pulse shaped in amplitude and in duration is then supplied to the input of the unit 10 converting a time interval (a revolution period of the turbo-machine rotor) into a code that is later supplied from the output of the unit 10 to the second part of the input digits of the digital interface in the electronic computer 11 , for example, an IBM-type PC. Besides, the rectangular pulses designed to synchronize and to control the recording and calculation of information parameters are supplied from the outputs of the shapers 6 and 9 respectively to the third and fourth parts of the input digits of the digital interface in the electronic computer 11 . The electronic computer 11 represents an output unit of the device that implements the possibility to obtain and to memorize code readings of the analog-to-digital converter 5 for each blade as well as the code readings of the unit 10 converting a time interval (a revolution period of the turbo-machine rotor) to store and to make necessary calculations in order to run the nonlinear approximation algorithm while solving a set of nonlinear equations to determine unknown parameters of blade oscillations and to deliver information to the user in a needed form. | Method for determining oscillation parameters of turbo-machine blades consists in that when the blade tip travels in front of a sensor, reading values of a single pulsed signal formed by the sensor are obtained in a number that is not lower than that of unknown parameters of a harmonic or polyharmonic oscillation of the blade, the origin of a single pulsed signal readings obtained for each blade being synchronized with the blade tip position relative to the sensor according to a given level of the single pulsed signal; then the values of the harmonic or polyharmonic oscillation parameters of the blade are calculated with the use of the obtained values of the single pulsed signal reading origins and of the value of the turbo-machine shaft revolution period. | 5 |
This is a continuation-in-part of co-pending application Ser. No. 06/942,259 filed on 12/16/1986 now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to coupling a membrane to the skin of a human being, for instance as a patient undergoing therapeutic or diagnostic treatment.
For purposes of medical diagnostic and/or therapeutic treatment, it has become more and more customary to use certain equipment by means of which radiation or waves such as shock waves or ultrasonic vibrations are coupled into the body of the patient without invasive surgery and without incurring any radiation energy losses or at least under and without conditions in which any losses are minimized.
As a first preparatory step for attaching a membrane to the skin, the body hair in the area in question is usually shaved off, and a gel layer is placed upon that bare skin. Now, the membrane of the medical treatment device or apparatus is forced against that gel layer. The purpose of this procedure is to provide an airfree and gapless coupling of the membrane to the skin, i.e. without inclusion or interposing of air bubbles. The membrane is in engagement and interfaces with the gel layer; the gel layer on the other hand is placed onto the skin directly and there should be no air bubbles anywhere. This being the desired state, it was found however that in practice bubbles are included, in the gel layer for example, through carelessness on part of the technician or nurse. These bubbles may be small but still their presence is highly detrimental and may in fact render questionable the success of the treatment i.e. the effect of the treatment may be diminished or even become ineffective entirely. Of course, medical technicians or physicians can acquire adequate manual skill and proficiency in the application of the gel layer such that indeed air bubbles are not included. This skill however is highly personal and simply cannot be expected as a matter of course.
It has, therefore, been suggested to evacuate the space between the skin of the patient on one hand and the membrane on the other hand, and to provide an immediate and direct contact between membrane and skin without, hopefully, intrusion of air bubbles. It was found in practice, however, that this bubblefree connection be guaranteed and is not even improveable through skillful handling. For these reasons therefor, one had to proceed in certain instances in a rather cumbersome fashion. For example, lithotripsy by means of shock waves such as the comminution of kidney stones has been practiced by placing the patient into a tub that is filled with water; the water is the coupling medium between the skin and the shock wave generator and focusing device, whereby however, the water had to be carefully degassed. This procedure solves the problems of coupling the shock waves into the body of the patient, but it is obvious that placing the patient into a tub just for that purpose is a rather cumbersome way of proceeding. Still, this has been practiced in the past quite successfully but on the other hand it is apparent that there is room for improvement.
DESCRIPTION OF THE INVENTION
It is an object of the present invention to provide a new and improved device by means of which unskilled or semi-skilled personnel, for example, in a hospital, a clinic or the like, can prepare a patient by coupling the membrane of a treatment apparatus to the skin of the patient without the inclusion of air bubbles.
In accordance with the preferred embodiment of the present invention, it is suggested to attain the object by providing a membrane such that a movable and/or displaceable wiper is placed on one of its sides by means of which the membrane is locally pushed onto a gel layer that has been placed on the skin of the patient and facing the other side of the membrane, the wiper locally and progressively causes the membrane to be forced against the gel layer while any air bubble is so to speak, pushed out of the contact area. Therefore, an areal element will be provided with gel or adhesive, and the coupling process exposes the element (membrane) simultaneously to tension and compression, and this combination insures a good tight connection between the membrane, and the skin of the body of the patient.
DESCRIPTION OF THE DRAWINGS
While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter which is regarded as the invention, it is believed that the invention, the objects and features of the invention and further objects, features and advantages thereof will be better understood from the following description taken in connection with the accompanying drawings in which:
FIG. 1 illustrates a membrane held within a frame and presumed to be a part of a diagnostic or therapeutic piece of equipment, showing the inventive wiper in accordance with the preferred embodiment of the present invention for practicing the best mode thereof;
FIGS. 2 and 3 illustrates modification or details as far as a wiper in FIG. 1 is concerned;
FIG. 4 is a section view through the device membrane shown in FIG. 1; and
FIG. 5 is a view similarly to FIG. 4 but in a different embodiment of the invention.
Preceding now to the detailed description of the drawings, FIG. 1 illustrates a frame 2 being so to speak a window or the like for a therapeutic or diagnostic medical equipment and through which e.g. shock waves or ultrasonic waves may pass. The frame particularly is comprised of front bars or walls 6 and side walls 8. An elastic membrane 4 is clamped in between these walls and held taught by them. An articulated bearing 10 is provided in one of the walls being in this case, one of the side walls 8 which however is basically arbitrary and has to do primarily with questions of manual accessability under consideration of the physical dimensions of the equipment to which that membrane is connected whenever this particular frame 2 is made a part of diagnostic or therapeutic apparatus.
As shown in FIG. 4a bore 12 is provided with a socket configuration for a ball and socket bearing which includes further a ball-like element 10. A small rod 14 is slidably mounted within that ball for sliding along arrow X. Rod 14 can also be pivoted by means of the handle 16 in direction of arrow Y (FIG. 1) and arrow Z in FIGS. 4 and 4a. Thus, this particular bar or rod 14 is provided for axial and angular displacement, it can so to speak, be shifted into and out, from under the membrane 4 and wipe along its undersides. The rod 14 has an outer end that extends laterally from the frame and is provided with a handle 16 while a wiper blade 18, similar to a windshield wiper of a car or the like, is provided on the other end of rod 14. This wiper blade 18 may be provided just as a single wiper lip as shown in FIG. 2, or there maybe a plurality of such wipers 20 as shown in FIG. 3. Alternatively, the wiper may be provided by means of a fairly hard bristle.
FIG. 4 illustrates a section view of FIG. 1 shown in addition the skin 23 of the body 22 of a patient. In this case, one can see the membrane 4 as being more or less close to the skin 23 while a gel layer 24 is interposed. The frame 2 in this case is mounted at the end of bellows 26 for purposes of adjusting pressure as well as elevation of the membrane vis-a-vis some other equipment which is not shown. The interior 34 of the bellows 26 is for example, filled with water.
Another bellows 26' is shown in FIG. 5, the frame 2 there has indents or grooves 28, and pin ends 30 and 31 of a wiper rod 32 can roll in these grooves 28. The wiper may in this case be moved for example by means of a small motor or manually under utilization of a handle analogous to one shown in FIG. 4. In any event, the wiper is moved along the frame. The wiper blades are made of an elastic material. As the wiper is rotated and progressively wipes along the underside of the membrane and rolls along grooves 28, a gapless abutment of the membrane 4 obtains against the skin 23 of the body 22 of the patient. One or more of these roller kind of wipers may be moved from the center towards the frame end; also, it is possible that the lips or the wiper drum itself is made expandable or one can provide vibration in that the roller vibrates in some fashion for purposes of removing any air bubbles from the gel layer 24.
Generally speaking, any of the inventive devices is used as follows. The body 22 of the patient rest for example on a suitable support which is not shown, while the other equipment is stationary, and positioned adjacent to the skin 23 of the patient to which it is to be coupled. Now the rest is lowered so that the body 22 of the patient with the skin 23 comes into contact with the gel covered membrane 4. This membrane 4 on the other hand can be adjusted then or later by means of the bellows 26. The membrane in fact serves as a closure for an anterior space 34 which is filled with water. A shock wave generator and focusing device is provided at the other end of the bellows or some other piece of equipment for providing any kind of radiation or vibration is provided at that other lower end or the bottom. Some pressure i.e. some excessive pressure over the ambient atmospheric pressure is applied.
Now, by means of any of the wiper blades 18, through manual or motor driven wiper motion, the membrane is locally urged against the skin of the patient along a line and that local line of pressure application is moved outwardly as the wiper is swivelled or rolled from the center of the membrane towards the frame. In either case, air bubbles will be moved as the wiper progresses from the center to the outside and the bubbles are shifted so to speak, along and out of the area. Whether or not bubbles remain trapped somewhere in or along the periphery is inconsequential because the area in contact is not made critical in terms of dimensions and boundaries.
The invention is not limited to the embodiments described above, but all changes and modifications thereof, not constituting departures from the spirit and scope of the invention are intended to be included. | A membrane is coupled to the skin of a human being, there being a gel layer provided between the membrane and the skin, the apparatus comprises a wiping structure movably mounted in a frame, one side of the membrane facing away from the skin and locally and progressively the membrane is forced against the gel layer and the skin so that progressively air bubbles in the gel layer are driven out of that layer and the layer is interposed bubblefree between the skin and the membrane. The wiper may swivel or roll; there may be plural wiper blades. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to merchandising systems. More specifically, this invention relates to a system in which a number of related but different size products are hung from respective hangers in a planogram at a retail outlet. Still more specifically, the invention relates to such an arrangement in which it is important that the proper products are stocked on the proper hangers.
In retail outlets it is common to suspend products in transparent packages such as blister packs--that is, in transparent plastic housings backed by a stiff card with a hanging opening in its upper end--from hangers which are supported on vertical pegboards. The hangers are typically made of wire bent into an elongated U-shape with the legs of the "U" having upward horns which engage into openings in the pegboard, the ends of the horns pressing forwardly against the rear surface of the pegboard to support the hangers in cantilever fashion. Products in blister packs are then suspended on the hangers which pass through the openings in the respective cards.
It is often the case in a retail outlet that a number of proximate hangers are provided with the intention that packs carrying different size items be suspended respectively from the hangers. It happens, however, that stock persons are not reliably conscientious about seeing that the blister packs are stored on the intended hangers for the respective sizes. Thus, dry cell batteries, for instance, which come in different sizes, (e.g. "C", "D", "AA" and "AAA") will be hung in various indiscriminate arrangements. For instance, "AA" battery packs may get hung on the "D" size battery pack hanger just because the "AA" battery hanger is full and there is room on the "D" hanger and the stock person is too rushed or lazy to take the overage back to the stockroom.
Subsequently, when a bunch of "D" size battery packs arrive, the stock person may see the "D" size rack is full and not unload the "AA"s from the "D" rack and fill up "D" size battery hanger as it should be. As a consequence, the bewildered customer is confronted with a "D" hanger full of "AA" battery size blister packs and has to assume that the store is out of "D" size batteries. Or he may simply buy the wrong size.
It also happens that when the battery pack hangers of a given brand become empty, battery packs of a rival manufacturer will find their way onto the hangers of the first brand, creating further customer confusion.
2. Description of Related Art including Information Disclosed under §§1.97 to 1.99
The prior art does not meet or satisfy this problem. In the prior art there are display hangers of the type described which are designed for use with pegboards, for instance, in which identifying indicia are provided on a separate support element above the hangers. Examples are:
U.S. Pat. No. 3,245,547 issued Apr. 12, 1966 to Felkay
U.S. Pat. No. 3,645,485 issued Feb. 29, 1972 to Gold
U.S. Pat. No. 4,783,033 issued Nov. 8, 1988 to Valiulis.
The art also includes hanger structures of the same general type as described, including anti-pivot means. An example is the disclosure in Schayer U.S. Pat. No. 3,070,339 which issued Dec. 25, 1962. The Wilkens U.S. Pat. No. 3,481,482 provides a pilfer-proof arrangement wherein the pack has a special opening and a special hook is provided at the front of the hanger so that the blister pack must be manipulated to remove it from the hanger.
Farther afield, in the area of laundry racks there are means by which tags attached to laundry items are apertured in a way that checks out with a shape of a element used to identify the owner of the laundry items. Thus, laundry tags are provided with shaped openings that fit onto shaped body members if they are to be correlated with the laundry identified by that body member. Examples of such arrangements are the old patents U.S. Pat. No. 1,343,423 which issued Jun. 15, 1920 to J. H. Todd and U.S. Pat. No. 1,644,155 which issued Oct. 4, 1927 to R. O. Scott. Such devices and arrangements, however, are of no help in considering the merchandising problem described above.
SUMMARY OF THE INVENTION
The present invention relates to a merchandising system comprising an elongate hanger having a rear end adapted to be secured to a vertical surface such as a pegboard and a front end, the front end being formed with a head having a periphery of a certain shape to identify to a stock person or a shopper a product to be hung on the hanger. The system further includes the identified product having a hanging opening at its upper end, the opening also having the certain shape.
In an embodiment of the invention the product can be aligned with and made to receive and pass over the head so that the product can hang on its identifying hanger. On the other hand, products having a different size or identity will not fit over the head because their openings are not similarly shaped.
Thus, the stock person will be forced into stocking the hangers with their proper respective size of product and will be unable to put products of a different size or a different manufacturer on the improper hangers because the openings in the different size or different manufactures's products do not fit over the head of the first manufacturer. Happily, the customer will not be bewildered by the indiscriminate stocking which in the past has been commonplace. The customer will see the proper size items on the proper hangers, the hangers clearly identifying to the shopper the products on that particular hanger.
All of this has the retailer as the beneficiary of a more orderly stocking, customers who can find at first try the precise product they are looking for without requiring the retailer's attention, and a readily apparent condition of the state of the displayed inventory.
BRIEF DESCRIPTION OF THE DRAWINGS
Further objects and features of the invention will be clear from a reading of the following specification and reference to the drawings, all of which shown non-limiting embodiments of the invention. In the drawings:
FIG. 1 is a front plan view of a section of a planogram pegboard having a hanger embodying the invention, and a blister pack with the opening in the blister pack aligned with the front of the hanger;
FIG. 2 is a perspective view similar to FIG. 1 with a pair of blister packs installed on the hanger;
FIG. 3 is a top plan view showing a hanger embodying the invention installed on a pegboard;
FIG. 4 is a side view;
FIG. 4a is an enlarged section view taken on the line 4a--4a of FIG. 4;
FIG. 4b is the outline of an opening to go with the FIG. 4a hanger;
FIG. 5 is a view of a head of a hanger taken in the plane of the indicia and showing portions of the hanger extending rearward therefrom;
FIG. 5a is a fragmentary view of a blister pack backing card showing its opening to correspond with the head of FIG. 5;
FIG. 6 is the view of a head of a different hanger taken in the plane in the indicia and showing portions of the hanger extending rearward therefrom;
FIG. 6a is a fragmentary view of a blister pack backing card having an opening corresponding to the head of FIG. 6;
FIG. 7 is a top plan view of a hanger of modified form with a portion of the top broken away;
FIG. 8 is a side elevational view of the hanger of FIG. 7 installed on a pegboard;
FIG. 9 is a sectional view taken on the line 9--9 of FIG. 8;
FIG. 10 is a view of the front end of the hanger of FIG. 8;
FIG. 11 is a top plan view of yet another modification of a hanger;
FIG. 12 is a side elevational view of the form of the invention shown in FIG. 11 installed on a pegboard; and
FIG. 13 is a view taken on the plane of the indicia of the head of FIG. 12.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A system embodying the invention is generally designated 10 in FIG. 1. It comprises a pegboard 12 having the usual pattern of aligned holes 14. The system further includes the hanger generally designated 16 and the product generally designated 18.
The product 18 in the arrangement shown is a package of dry cell batteries 20 encased in the transparent housing 22 of a blister pack having the conventional backing card 24.
The blister arrangement may be as shown with the card on the back of the blister 22 or it may be a more symmetrical arrangement with an opening in the backing card, the batteries 20 on the plane of the card and blister housings 22 on the sides of the card to allow both sides of the batteries to be visible from the side. It is also envisioned that the blister pack can be a completely transparent housing having a double thickness panel extending up therefrom. In any event, whether it is a backing card, a central card or a transparent panel, the upper end thereof is formed with a hanger opening 26.
As is customary, the product is suspended on the hanger 16 by having the opening 26 pass through the front end of the hanger.
FIG. 2 shows a pair of products 18 suspended from a hanger 16. Clearly the hanger 16 could be made to support a number of additional products, two being shown as exemplary.
Referring now to FIGS. 3 through 4a, the hanger 16 comprises, as is conventional, a U-shaped wire element 30. At the rear of the element, at the ends of legs of the "U" are respectively a pair of horns 32, each of which has the customary offset or dog leg 34 (FIG. 4) so that in use the horns pass through holes 14 of the pegboard and come to rest with the portions of the horns above the offset 34 bearing forwardly on the back of the pegboard and the portions of the horns below the offset 34 bearing rearwardly on the front of the pegboard 12 to support the hanger cantilever fashion. The front of the hanger 16 is tipped upwardly at 36a, also as is conventional, to avoid products being displaced forwardly off the hanger.
Referring to an essential element of the invention, attention is now directed to the head 38 of the hanger, formed, molded or otherwise secured to the front of the hanger 16. The periphery of the head 36 is in the shape of an indicia which serves to identify the product which is to be installed on the hanger. This identification is, of course, meaningful to the stock person who will see in the specific case involved that the hanger in question is to be stacked with "D" size batteries. It is also meaningful, however, to the shopper who is looking for a replacement "D" size battery and understands that batteries on this hanger are of "D" size.
It will be noted from FIGS. 1 through 4a in the examples shown that the top and bottom of the "D" extend above and below the confines of the front of the hanger. This is, of course, an important feature of the invention because the extensions of the head 38 in vertical dimensions beyond the levels of the top and the bottom of the hanger on either side (FIG. 4a) dictate the shape of the opening and will preclude the installation of the improper products on the hanger involved.
Between the legs of the "U" of the hanger (FIG. 4a) is a filler 40. It comprises molded plastic halves 40a and 40b cemented together between the two legs of the U-shaped wire element 30. These halves together form the outline of the configuration of the head 38 so that the outline of the head in the preferred version extends all the way along the hanger. This affords particular assistance in the removal of the product from the hanger so that the card does not "catch" on the head as the card is withdrawn. The filler at the front of the hanger and the head may comprise a separate piece
FIG. 4b is an outline of the opening 26. The central part 26a of the opening is shaped the same as the head 38 and the lateral extensions 26b are designed to accommodate the sides of the hanger 16 to either side of the head. Thus, in installing a product 18 on the hanger 16 the stock person will first align the central part 26a of the opening with the head 38 and pass the card over the head 38. From this point the sides of the hanger 16 are received through the lateral enlargement 26b and the proper product 18 is now installed on the hanger. Clearly, additional products may be installed until the hanger is full. In the removal of the products from the hanger 16, the card is drawn forwardly up the rise 36 at the front end of the bight (FIG. 4) so that lateral enlargements 26b move forward beyond the sides of the hanger and finally the opening 26a moves forward of the head 38 to free the card for purchase.
FIGS. 5 and 6 show different heads representing both to the stock person and the shopper different sizes of batteries to be installed on the respective hangers (not shown). FIGS. 5a and 6a the hanger in FIGS. 5 and 6 respectively. Note that in FIG. 6a the indicia "AAA" of the head is so large as to virtually cover the entire width of the hanger. It should be understood that other indicia are similarly provided for "C" and "AA" batteries as well as others.
FIGS. 7 through 10 relate to a modified form of hanger 16'. In this form the U-shaped element 30' is foreshortened and more in the shape of a "V". It includes the bight 36' and the horns 32' shaped as in FIG. 4. The hanger further comprises two molded plastic halves (FIG. 9) which are cemented together and which clamp the wire U-shaped element 30' between them. The plastic halves comprise the upper plate 42 and the lower plate 44, the lower plate having molded recesses adapted to receive the legs and bight of the U-shaped element 30'. As in the earlier embodiment, the upper and lower surfaces of the plastic halves are formed with ribs which carry rearwardly the contours of the periphery of the indicia of the head (FIG. 9). FIG. 10 is a view of the front end of the embodiment of FIGS. 7 through 9.
A further embodiment of the invention is shown in FIGS. 11 through 13 wherein the wire U-shaped element 30" is formed with the bight inflected upwardly (FIG. 12). At the front of this embodiment is a molded piece 50 which includes the head 38" and a rearwardly and downwardly extending body which is fitted onto the bight of the U-shaped element 30". As shown, and for convenience particularly in removing product, the body is formed with the contours of the periphery of the indicia of the head 38". As shown, these rearward outlines may be tapered down to the thinness of the wire of the U-shaped element 30". The embodiment shown in FIGS. 11 through 13 is employed in the same fashion as the other embodiments.
The rear of the wire element 30" is formed with the horns 32" as shown best in FIG. 12 and which engage the pegboard in similar fashion to those described so that the hanger is supported cantilever fashion.
In the embodiments disclosed herein the head and opening are described as having the shape of an indicia, that is, a letter, for instance, representing a size. Some of the benefits of the invention may be preserved in embodiments in which the head and opening are of a unique shape (e.g. a triangle or rectangle) with the symbolizing indicia merely lettered on the head. The indicia shape is, of course, preferred.
The invention thus described provides means for assuring that products are stocked properly on their respective hangers because the system forces the stock person to conscientiously install the proper product with the proper heads. The heads, of course, will thwart the introduction of the improper products because the openings in the improper products do not provide the proper outline for the head and the head will block their passage. As a result, the products are properly stocked and at a glance the customer can see and pick off the product that he wants by merely reading the head. Finally, the retailer himself can see that the hangers are properly stocked and which ones are in need of reordering.
Other embodiments of the invention are possible without departing from the spirit of the invention. Thus, while the invention has been shown in only a few embodiments, it is not so limited but is of a scope defined by the following claim language which may be broadened by an extension of the right to exclude others from making or using the invention as is appropriate under the doctrine of equivalents. | A merchandising system comprises an elongate hanger having a rear end adapted to be secured to a vertical surface such as a pegboard and a front end formed with a head having a periphery of a certain shape to identify a product to be hung on the hanger. The system further includes the identified product having a similarly shaped hanging opening at its upper end. The opening can be aligned with and made to receive and pass over the head so that the product can hang on its identifying hanger. Products having a different size or identity will not fit over the head because their openings are not similarly shaped. | 1 |
FIELD OF THE INVENTION
This invention generally relates to an advertising display panel, and more particularly to a point of sale advertising display panel for mounting on securable panels such as on the front door panel of a vending machine.
BACKGROUND OF THE INVENTION
Hard copy advertising by means of billboards, display panels and the like remains as one of the most effective widespread means for reaching and influencing purchasers in close time-proximity to their purchasing decisions. Point of sale display panels (i.e., those placed in close proximity to the item being purchased, or at the location where a purchaser makes his or her actual final purchase selection from a plurality of choices), have been found to be particularly effective at conditioning a purchaser to select the product or service advertised on the point of sale display. Point of sale advertising can be particularly effective when strategically placed on a vending machine. A purchaser approaching a vending machine is already committed to purchasing a product held by the machine. The question is which one? Many purchasers do not make their final selection until the last possible moment. For such purchasers, point of sale advertising placed on the machine where the purchaser cannot help but see it, can effectively influence his/her final selection.
Such point of sale displays must be aesthetically unobtrusive so as to fit in with the decor of the item on which they are placed, yet be fairly tamper proof so that their display contents cannot be changed by unauthorized personnel. They should also be easy to operate so that advertising display pieces can be readily changed or replaced when desired without undue complications. Such displays should also preferably be of a construction that is adaptable for use in a large variety of applications, and preferably accommodate easy retrofitting installation to varied equipment or uses and for ready installation on machines which have not been specifically designed to accommodate such displays.
The present invention provides a relatively inexpensive yet reliable point of sale display panel that addresses the above needs and preferences. The display panel of this invention is very simple in construction, aesthetically pleasing and universally adaptable to varied applications, and enables ease of use with a high tamper proof tolerance.
SUMMARY OF THE INVENTION
The present invention provides a display panel and fastening system therefor. In a preferred embodiment, the display is mounted on the door of a vending machine. The preferred embodiment display includes a rear panel, which is appropriately secured to the door by for example adhesive or screws; a front panel, which is secured to the rear panel by means of a hinge; and a window on the front panel, through which one can view a sheet disposed between the front panel and the rear panel. A latch on the front panel engages a catch on the rear panel to releasably lock the former relative to the latter and enclose the sheet in between. The latch can be released only by gaining access to the opposite side of the rear panel, which is accessible only from the inside of the vending machine door. Thus, when the door is locked, the display cannot be opened and the sheet can be removed only by authorized personnel having access to the inside of the vending machine. Many of the advantages of the present invention should become apparent from the more detailed description that follows.
BRIEF DESCRIPTION OF THE DRAWING
With reference to the Figures of the Drawing, wherein like numerals represent like parts and assemblies throughout the several views,
FIG. 1 is a front view of a preferred embodiment vending machine constructed according to the principles of the present invention, shown in a closed configuration;
FIG. 2 is a front view of the vending machine of FIG. 1, shown with its door in an open configuration;
FIG. 3 is a plan view of the display frame on the vending machine of FIG. 1 illustrated in an open configuration;
FIG. 4 is a plan view of a frame window for the display frame of FIG. 3;
FIG. 5 is a profile of one of the prongs of the display frame of FIG. 3;
FIG. 6 is a partial sectioned side view of a door on the vending machine of FIG. 1, the frame of FIG. 3, and the frame window of FIG. 4, all shown together in an assembled state; and
FIG. 7 is a partial sectioned side view of an alternative embodiment vending machine door and externally mounted sign.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The display panel of this invention is particularly adapted for point of sale applications wherein it is desirable to give a purchaser a final suggestion before the purchaser makes his/her actual selection. The display panel is uniquely configured for attachment to and use with a panel member such as a door or the like that can be secured such that the display panel can only be opened and accessed either from or through the back side of the panel. Since one of the most practical applications for the invention is in combination with the front door or panel of a vending machine, for providing point of sale advertising to a purchaser making selections from the vending machine, the preferred embodiment of the invention will be described in association with a vending machine.
A preferred embodiment vending machine constructed according to the principles of the present invention is designated as 100 in FIGS. 1-2. The vending machine 100 could be of any type well known in the art, as for example, a snack and/or beverage type of dispenser such as shown in U.S. Pat. No. 4,061,245 or Des. 316,728 or the Model LCM1 or Model 111 vending machines sold by Automatic Products International, Ltd. To the extent that the disclosures or teachings of U.S. Pat. No. 4,061,245 or Des. 316,728 are needed for a more complete understanding of the invention, they are herein incorporated by reference. The vending machine 100 generally includes a base or main compartment 110 and a door 120 which cooperate to define a housing or enclosure. Hinges 111 and 112 interconnect one side of the door 120 to one side of the base 110, thereby allowing the former to pivot relative to the latter. A lock, including interengaging components 119 and 129, selectively interconnects an opposite side of the door 120 to an opposite side of the base 110, thereby selectively preventing the former from pivoting relative to the latter, and discouraging unauthorized access to the inside of the enclosure.
The vending machine 100 may store goods in rows, for example, in the region designated as 114. The goods may be visible through a window 124 on the door 120. A mechanism known in the art functions to deliver individual units of the goods to a tray designated as 115. The tray 115 is accessible through a slot 125 in the door 120. A depository 126 accepts money, and a control panel 127 facilitates selection of a particular good for delivery to the tray 115. To the extent that the deposited money exceeds the price of the good, a mechanism known in the art returns excess change to a receptacle 128.
The vending machine 100 also includes a sign or display 200, the components of which are shown in greater detail in FIGS. 3-6. In the preferred embodiment, the display 200 includes a rear panel 220, a front panel 240, and a window 260, as well as fasteners suitable for mounting the rear panel 220 to the door 120.
The rear panel 220 includes a generally flat and rectangular sheet 221 of polypropylene having in the preferred embodiment a mean thickness of approximately one-tenth of an inch. Linear ridges or embossments 222 and 223 extend along opposite ends of the sheet 221. Relatively smaller ridges 228 extend intermittently along opposite sides and one end of the sheet 221 (inward of the ridge 222 on the end of the sheet 221 that is common to both).
In the preferred embodiment, holes 230 have frustoconical sidewalls and are formed through the rear panel 220 proximate each of the four corners thereof. Each hole 230 is sized and configured to receive the head of a fastener, such as a screw. Also, two rectangular slots 232 are formed through the sheet 221, proximate the ridge 223, for reasons discussed below.
A living hinge 239 connects an end of the front panel 240 to the end of the sheet 221 opposite the slots 232. In other words, the rear panel 220 and the front panel 240 may be said to be integrally molded together and/or pivotally secured relative to one another.
The front panel 240 includes a generally flat and rectangular frame 241 of polypropylene having a mean thickness of approximately one-tenth of an inch. The perimeter of the front panel 240 is similar in size and shape to that of the rear panel 220. Linear ridges or embossments 244 and 245 extend along opposite sides of the frame 241. When the front panel 240 is folded toward the rear panel 220 and into substantially parallel relationship therewith, the two panels 240 and 220 cooperate to form a parallelepiped housing bordered by the sheets 241 and 221, the end walls or ridges 222 and 223, and the side walls or ridges 244 and 245. The front panel 240 borders a rectangular opening 246 in the front face of the parallelepiped housing.
A plurality of posts or stakes 250 are disposed about the perimeter of the frame 241 and protrude rearward therefrom (toward the rear panel 240) for reasons discussed below. Also, two prongs or latches 252 are disposed at the end of the frame 241 opposite the hinge 239 and protrude rearward, as well. Both the prongs 252 and the posts 250 are integrally molded to the frame 241.
A profile of one of the prongs 252 is shown in FIG. 5. Each prong 252 includes a relatively narrow stem 254 and a relatively larger head 255. The head 255 cooperates with the frame 241 and the stem 254 to define a notch 258 between the head 255 and the frame 241. An angled surface 256 is disposed on the head 255 and faces in the same general direction as the notch 258.
As the front panel 240 is folded toward the rear panel 220 and into substantially parallel relationship therewith, each of the angled surfaces 256 engages an edge of a respective slot 232, thereby causing a respective stem 254 to yieldingly bend. As either head 255 fully penetrates a respective slot 232, the notch 258 reaches the edge of the slot 232, and the resilience of the stem 254 biases the stem 254 and head 255 back toward their previous, unstressed orientation (extending perpendicular from the frame 241). In this manner, each of the heads 255 locks in place behind the rear panel 220. Each of the prongs 252 may be subsequently unlocked or unlatched simply by gaining access to the rear of the rear panel 220 and pushing the heads 255 back into complete alignment with their respective slots 232 and out same.
The frame window 260 includes a generally flat and rectangular sheet 261 of acrylic having a mean thickness of approximately one-sixteenth of an inch. The perimeter of the frame window 260 is sized and shaped to lie within the parallelepiped housing defined by the ridges 222 and 223 and the ridges 244 and 245, as well as the sheet 221 and the frame 241. A lip 267 extends about the entire perimeter of the sheet 261, thereby enhancing the structural integrity of the frame window 260 and also providing a structural border for a piece of cardboard or other sheet good to be displayed behind the window 260.
A plurality of holes 270 are formed through the sheet 261 about the perimeter thereof. The holes 270 correspond in number and arrangement with the posts 250 on the frame 241. Each of the holes 270 is surrounded by a cylindrical depression 271. The window 260 is secured to the frame 241 by inserting each post 250 through a respective hole 270 and then subjecting the posts 250 to heat (or some other form of melting energy) until the tips of the posts 250 melt into tabs or buttons within the depressions 271. Once so secured, the window 260 may be described as a part of the front panel 240, and/or the front panel 240 may be described as having a window 260.
As shown in FIG. 6, the display 200 may be secured to the vending machine 100 by inserting fasteners through the holes 230 in the rear panel 220 and into holes 130 in door 120, and by forming an opening 132 in the door 120 to accommodate the prongs 252. Alternatively, the rear panel 220 could be secured to the vending machine door panel 120 by means other than such as fasteners by adhesive or by double-sided tape (not shown). Once the rear panel 220 is secured in place on the door 120, a sheet good 290, such as a cardboard sign, may be disposed between the window 260 and the rear panel 220. The front panel 240 may then be pushed toward the rear panel 220 until the prongs 252 latch into place. The prongs 252 may then be unlatched only by gaining access to the inside of the door 120 and the heads 255 on the prongs 252.
The present invention has been described with reference to a preferred embodiment and a specific application. However, those skilled in the art will recognize additional embodiments and/or applications which nonetheless fall within the scope of the present invention. For example, alternative connectors, such as bolt and lock nut combinations or a cotter pin arrangement, could be used in lieu of the prongs 252. Further, the display panel and rear accessible connector means structure is not limited for use with vending machine door panels, but could be used with any type of panel wherein a rear-activation arrangement is desirable.
One alternative embodiment of the present invention is designated as 300 in FIG. 7. The alternative embodiment display 300 includes a front panel 340 and a window 360, each of which is similar in many respects to its respective counterpart on the preferred embodiment 100. Since there is no rear panel on the alternative embodiment 300, the front panel 340 includes a ridge or embossment 349 extending entirely about its perimeter. Also, the prongs 352 function to secure both the front panel 340 and the entire display 300 relative to the vending machine door 120'. Thus, additional prongs 352 (not shown) are disposed at the opposite end of the front panel 340 in lieu of the hinge 239 on the preferred embodiment 100.
Relatively smaller holes 130' are formed in the door 120' to receive the heads of the prongs 352. Relatively larger openings 132' are formed in the door 120' to accommodate the heads of the prongs 352. The openings 132' also provide access sufficient to facilitate unlatching of the prongs 352 from the inside of the door 120'.
The principles of the present invention could also be applied to items other than vending machines. In this regard, the present invention may be seen to provide a display fastening system suitable for use relative to all sorts of enclosures and/or lockable doors or panels. Accordingly, the scope of protection to be afforded the present invention is to be limited only to the extent of the claims which follow. | A display is releasably mounted on the outside of an enclosure. The display may be released from the enclosure upon gaining access to the inside of the latter. In a preferred embodiment, the display is a sign, and the enclosure is a vending machine. The sign includes a rear panel, which is secured to the door of the vending machine, and a front panel which is connected to the rear panel by means of a hinge. A fastener on the front panel, disposed generally opposite the hinge, protrudes through a hole in the rear panel and into an opening in the vending machine door. The relative sizes of the fastener and the hole are such that a portion of the fastener snaps into place on the opposite side of the rear panel. | 6 |
FIELD OF THE INVENTION
[0001] The present invention relates to microfilament manufacturing method and manufacturing apparatus therefore and the nanofilament obtained. More specifically, the present inventions relate to microfilament manufacturing means that enables the microfilament to be attenuated until it is nanofilament by achieving a super high draw ratio by irradiating using an infrared light beam.
BACKGROUND OF THE INVENTION
[0002] Fibers with fiber diameters smaller than 1 μm, that is, nanometer sized (from several nanometers to several hundreds of nanometers) fibers have gained attention in recent years as revolutionary materials of the future in a broad range of applications such as IT, bio, environmental and other applications. The nanofibers have typically been prepared using an electro-spinning method (henceforth sometimes abbreviated to “ES method”). (See U.S. Pat. No. 1,975,504; You Y., et al Journal of Applied Polymer Science , Vol. 95, p. 193-200, 2005.) However, the ES method is a complicated manufacturing method since polymer needs to be dissolved in solvent and the solvent must be removed from the product obtained. In addition, molecules lack orientation in the filament obtained, and many quality problems such as the presence of small resin particles, referred to as balls and shots were encountered in the fiber aggregates obtained.
[0003] The inventors previously invented a means to obtain microfilaments and non-woven fabrics using a super high draw ratio that exceeded one thousand through molecular orientation conducted according to an infrared method. (See Japanese Patent Publication No 2003-166115 and 2004-107851; International Publication No. WO2005/083165A1; Akihiro Suzuki and one other “ Journal of Applied Polymer Science ”, Vol. 88, p. 3279-3283, 2003; Akihiro Suzuki and one other, “ Journal of Applied Polymer Science ”, Vol. 92, p. 1449-1453, 2004; Akihiro Suzuki and one other, “ Journal of Applied Polymer Science ”, Vol. 92, p. 1534-1539, 2004.) These are simple means, and microfilaments with molecular orientation and non-woven fabrics thereof were obtained. The present invention is a further development of the same theme and relates to a means that allows microfilaments to be manufactured continuously and consistently by enabling filaments to be attenuated into nanofilaments.
DISCLOSURE OF THE INVENTION
Problems to be Solved by the Invention
[0004] The present invention further develops the inventors' previous technology described above. The objective of the invention is to make it possible to readily obtain a filament comprising a microfilament that may be as small as a nanofilament and non-woven fabrics that is an aggregate thereof using a simple means without requiring a special high precision, high performance apparatus. Furthermore, the present invention relates to the nanofilaments obtained according to the manufacturing means of the present invention from large diameter filaments comprising polyesters such as poly(ethylene terephthalate), poly(ethylene naphthalate) and the like, biodegradable polymers such as poly(lactic acid), poly(glycolic acid) and the like, and fluorinated polymers such as tetrafluoroethylene.perfluoroalkyl vinyl ether copolymers (PFA) and the like and to present a non-woven fabrics used in diverse applications such as medical applications, filters and the like.
Means to Solve the Problem
[0005] The present invention presents a drawing method that draws an original filament and attenuates it into the nanofilament range and an apparatus therefore. The original filament in the present invention refers to a filament previously manufactured and wound on a reel and the like. In addition, a filament obtained by cooling a molten material or coagulating a dissolved material in a spinning step may become an original filament in the present invention subsequent to the spinning step. Here the filament refers to a basically continuous fiber and is distinguished from staple fiber that varies in length from several millimeters to several tens of millimeters. The original filament preferably exists individually, but several to several tens of filaments may be gathered and used.
[0006] The filaments drawn in the present invention are all referred to as filaments, and those characterized as nanofilament fibers mentioned above are also included. A filament drawn in the present invention is drawn for at least several minutes without breaking in most cases and can be considered a continuous filament with a small filament diameter, d. However, staple fibers characterized as nanofilament fibers mentioned above can be manufactured depending upon the conditions.
[0007] The filament of the present invention may be a single filament comprising one filament or a multi-filament comprising multiple filaments. As far as the tension and the like on one filament are concerned, it is reported as “per single yarn”. However, the expression signifies “per single filament” when one filament is involved and, when a multifilament is involved, signifies “per individual single filament” that constitutes the multi-filament.
[0008] A feature of the present invention is the fact that a filament with a high degree of molecular orientation of at least 50% measured by birefringence can be used, and the fact that such a original filament with a high degree of orientation can be drawn to a super high draw ratio such as several hundred differentiates the method from other drawing methods. When an original filament is highly oriented as in this case, the drawing is often initiated using an expanded section with a diameter greater than the original filament diameter.
[0009] Filaments comprising thermoplastic polymers, for example, polyesters such as poly(ethylene terephthalate), aliphatic polyesters and poly(ethylene naphthalate); polyamides such as nylon (includes nylon 6 and nylon 66); polyolefins such as polypropylene and polyethylene; poly(vinyl alcohol) type polymers; acrylonitrile type polymers; fluorinated polymers such as tetrafluoroethylene.perfluoroalkyl vinyl ether copolymers (PFA); vinyl chloride type polymers; styrene type polymers; polyoxymethylene; ether ester type polymers and the like may be used as the original filament in the present invention. Poly (ethylene terephthalate), nylon (including nylon 6 and nylon 66) and polypropylene are particularly suited for manufacturing the microfilament and the non-woven fabrics comprising the microfilament of the present invention since they have good drawing properties and molecular orientation. In addition, biodegradable polymers and polymers that are degraded and absorbed in vivo such as poly (lactic acid), poly (glycolic acid) and the like and high strength, high elasticity filaments and the like such as polyarylates, aramides and the like are stretched well in the present invention using infrared beams and are particularly suited for manufacturing microfilaments and micro non-woven fabrics of the present invention. Composite filaments such as core-sheath type filaments and the like comprising the polymers may be used in the original filament. Now, the polymers mentioned above are sometimes referred to as polyester “types” and as polymers with polyester as the “main component” when the polymer mentioned above is present in at least 85% (by weight %).
[0010] An original filament transferred from a filament transportation device is drawn in the present invention. Various types of transportation device may be used as long as the transportation device can move a filament at a constant speed using a combination of nip rollers and several stages of drived rollers. In addition, when only a filament of constant length needs to be drawn, an original filament may be grasped with a chuck and may be supplied to an orifice after it travels downward at a constant rate.
[0011] The original filament moved by a filament transportation device is also allowed to pass through an orifice aided by a gas flow in the direction of the motion. The original filament is in an atmosphere maintained at P 1 pressure until the filament is transported into the orifice using the filament transporting device, and the space that is maintained at P 1 pressure is referred to as a filament supply chamber. Constant pressure does not particularly need to be maintained when P 1 is atmospheric pressure. An enclosure (a chamber) is needed to maintain the pressure when P 1 represents an added or reduced pressure, and a pressurizing pump or a pressure reducing pump is needed. The orifice entrance needs to be maintained at P 1 in the present invention, but the area in which the original filament is stored and the transportation section of the original filament do not necessarily have to maintain P 1 . However, maintaining both areas at the same pressure is preferred since installing separate chambers is complicated.
[0012] The section downstream from the orifice exit is maintained at P 2 and becomes a drawing chamber in which the original filament exiting the orifice is heated using an infrared light beam and is drawn. The original filament is moved inside the orifice by the air flow created by the pressure difference (P 1 −P 2 ) between the original filament supply chamber at P 1 and the drawing chamber maintained at P 2 . When P 2 is atmospheric pressure, the pressure does not need to be maintained at a constant level. When P 2 is an added pressure or reduced pressure, an enclosure (a chamber) is needed to maintain the pressure and a pressurizing pump or a pressure reducing pump is also needed.
[0013] The difference in P 1 and P 2 pressures is created when P 1 >P 2 . Based on the experimental results, P 1 ≧2P 2 is preferred. However, P 1 ≧3P 2 is more preferred, and P 1 ≧5P 2 is preferred most.
[0014] A particularly desirable way to conduct the present invention is for P 2 to be under reduced pressure (less than atmospheric pressure). By following this procedure, P 1 can be atmospheric pressure and the apparatus can be radically simplified. In addition, reducing the pressure is relatively simple to achieve. Furthermore, air that is ordinarily present at atmospheric pressure does not interfere with the air released from the orifice when it is released into an area of reduced pressure. This allows the released air and the filament accompanying it to be very stable. As a result, the drawing properties are stable, and the drawing can yield filaments with properties in the nanofilament category. In addition, when a high speed fluid is ejected from a nozzle, a large amount of accompanying flow occurs around the nozzle. Such accompanying flow is minimized under reduced pressure, and the filament flow exiting from the nozzle is not disturbed. These factors were thought to play a role in stabilizing the drawing process. A special feature of the present invention is that a filament characterized as a nano micron material is obtained using such a simple means.
[0015] Room temperature air is ordinarily used for P 1 and P 2 . However, heated air is used when a manufacturer wants to pre-heat an original filament or wants to heat treat a drawn filament. In addition, an inert gas such as nitrogen and the like is used to prevent filament oxidation and a gas containing water vapor or moisture is also used to prevent moisture loss.
[0016] The original filament supply chamber and the drawing chamber in the present invention are connected to the orifice. A high speed gas flow is created inside the orifice by the pressure difference, P 1 >P 2 , in the narrow space between an original filament and the internal diameter of the orifice. The internal diameter (D) of the orifice and the diameter (d) of the fiber should not be too different in order to generate a high speed gas flow. According to experimental results, a relative diameter range expressed as 1.2d<D<10d is acceptable. However, the range of 1.5d<D<7d is preferred, and the range of 2d<D<5d is most preferred. When the nozzle diameter is too large in comparison to the filament diameter, the gas flow through the nozzle is not very fast and the P 2 pressure is not sufficiently low. In addition, when the nozzle diameter is too close to the filament diameter, air flow resistance is generated, and the speed of the gas flowing through the nozzle does not rise. Furthermore, not only does the diameter of a drawn filament increase as the air flow exceeds the preferred range described above, but also the filament diameter becomes less consistent and lumps tend to form more readily.
[0017] The internal orifice diameter (D) refers to the diameter of the orifice exit section. However, the diameter (D) of the narrowest section is used when the orifice cross section is not circular. Similarly, the smallest diameter is used as (d) for a filament diameter when the cross section is not circular. The diameter is ordinarily measured at ten locations using the smallest cross section as the standard, and the mathematical average is used. The lower end of a vertically positioned orifice is designated as the exit since an original filament ordinarily passes from top to bottom. However, the upper exit from an orifice is designated as the exit when an original filament passes from the bottom to the top. Similarly, the exit is located to the side of an orifice when an orifice is positioned horizontally and an original filament passes horizontally.
[0018] An orifice interior structure that offers little resistance is preferred since a gas flows through the interior at high speed. The orifice in the present invention does not necessarily need to be cylindrical. Although the orifice cross section is preferably circular, an orifice with an elliptical or rectangular cross section may also be used when multiple numbers of filaments are allowed to pass or when a filament shape is elliptical or rectangular. In addition, the use of an orifice with a large entrance that allows easy access to an original filament in which the exit is the only narrow section is preferred since the resistance to the filament movement is low and the speed of the gas leaving the orifice exit is high.
[0019] The role of the orifice in the present invention is different from the role an air supply pipe plays prior to drawing in the previous inventions of the inventors and the like. The air supply pipe was previously used to aim a laser at a fixed position in a filament and played the role of transporting an original filament to the fixed position with as little resistance as possible. The present invention adds to the previous inventions and differs from them in that a high speed regulating gas flow is generated by the pressure difference between pressure P 1 in an original filament supply chamber and pressure P 2 in a drawing chamber. Now, tension is applied on a molten filament using an air sucker and the like in an ordinary spun bonded non-woven fabrics manufacturing process. However, the action mechanism and effects of the air sucker in spun bonded non-woven fabrics manufacturing process and the orifice in the present invention are completely different. In a spun bonded process, a molten filament is transported using a high speed fluid inside an air sucker and the filament diameter is attenuated almost completely inside the air sucker. In contrast, a solid original filament is transported by an orifice, and attenuating of the filament does not begin inside the orifice. In addition, a high speed fluid is generated by sending high pressure air into an air sucker in a spun bonded fabric production process. The present invention differs in that the high speed fluid inside the orifice is generated by the pressure differential between the chambers before and after the orifice. The effects are also different. The best filament diameter one can expect from the spun bonded fabric production process is about 10 μm, but a nanofilament obtained in the present invention is smaller in diameter than 1 μm making the present invention much more advantageous effectives.
[0020] In the present invention, the drawing is preferably conducted at a rate in the speed of sound region. The speed of air leaving an orifice is represented by the following equation (Graham's theorum) where ρ represents air density.
[0000] v={ 2( P 1 −P 2)/ρ} 1/2
[0021] Here, the results posted on Table 1 were calculated when P 1 was atmospheric pressure and P 2 was changed. Based on the results, the air speed (v) is in the speed of sound region (340-400 m/sec) when the reduced pressure zone P 2 was 30 kPa, 20 kPa and 6 kPa in the present invention. The results obtained by calculating the ratio (mach M) with the speed of sound are also posted to the table. A microfilament with a filament diameter in the nanometer range can be obtained using the present invention by raising the air speed (v) in a drawing chamber to the speed of sound range when the speed of sound range is defined as the area in which M is at least 0.98.
[0000]
TABLE 1
The Air Speed
P2
V
M
kPa
(m/sec)
at 298.5° K
50
289
0.834
30
342
0.987
20
365
1.05
6
396
1.15
The air speed at the orifice exit by the pressure change of the drawing chamber (degree of vacuum)
P1: atmospheric pressure
[0022] The original filament released from an orifice is heated at the orifice exit using an infrared light beam and is drawn by the tension applied to the filament by the high speed fluid from the orifice. The position directly under the orifice, based on experimental results, refers to the position in which the center of an infrared light beam is located 30 mm or less from the orifice tip. However, 10 mm or less is preferred, and 5 mm or less is most preferred. When a filament leaves the orifice, the original filament vibrates, does not remain in a set position and is not stable enough to be exposed to an infrared light beam. In addition, the tension applied to the filament by the high speed gas released from the orifice becomes weaker as the filament moves away from the orifice. The stability is thought to decrease also.
[0023] A feature of the present invention is the heating and drawing of an original filament using an infrared light beam. The infrared rays are defined as radiation with wavelengths of from 0.78 μm to 1 mm. However, the absorption attributed to a C—C bond in polymeric compounds is centered around 3.5 μm, and absorption bands of from 0.78 μm to 20 μm are particularly preferred. The infrared radiation in this zone is focused into a spot or a line using a mirror or a lens, and a heater referred to as a spot heater or line heater that concentrates the heating zone to an original filament can be used. A line heater is ideal when multiple numbers of original filament are moving in parallel lines.
[0024] A laser beam is particularly preferred as the infrared light beam in the present invention. Among lasers, carbon dioxide gas lasers with wavelengths of 10.6 μm and YAG (yttrium, aluminum, garnet type) lasers with wavelengths of 1.06 μm are particularly preferred. A laser can narrow the radiation range (light beam) and focuses on a specific wavelength. Therefore, a laser uses energy efficiently. The power density of a carbon dioxide gas laser of the present invention is at least 50 W/cm 2 , but a power density of at least 100 W/cm 2 is preferred and at least 180 W/cm 2 is most preferred. The super high draw ratio of the present invention is made possible by the concentration of high density energy power on a narrow drawing zone.
[0025] Now, irradiation using an infrared light beam in this case is preferably conducted from multiple locations. The reason for this preference is the difficulties encountered in drawing due to asymmetric heating caused by the heating of a filament from only one side when the melting temperature of a polymer is high, when fusion is difficult to achieve and when a filament is difficult to draw under any condition. Such multiple site irradiations may be achieved by using multiple light sources composed of infrared light beams but may also be accomplished by reflecting the beam from a single light source using mirrors to irradiate multiple times along the passage of an original filament. The mirrors may be fixed mirrors, but a rotating mirror such as a polygon mirror may also be used.
[0026] An original filament may be irradiated from multiple locations using multiple light sources as another means of irradiating from multiple locations. Multiple stable low cost laser emitters that are relatively small scale laser beam sources may be used as high powered light sources.
[0027] The original filament of the present invention is heated to a temperature suitable for drawing using an infrared light beam irradiated by an infrared heating means (includes lasers). An original filament is heated by the infrared light beam in the present invention. However, the range that is heated to a temperature suited for drawing is preferably within 4 mm up and down (8 mm length) along the filament axis direction in the center of the filament. The range of 3 mm up and down is more preferred, and the range of 2 mm up and down is most preferred. The diameter of the beam is measured along the axis direction of a filament in motion. When multiple original filaments are used, a slit-shaped beam may also be used. In such a case, the narrowest section preferably coincides with the axis direction of the original filament. The present invention was able to draw a filament to a nano range with a high degree of attenuating by suddenly stretching the filament in a narrow zone and was able to minimize the breakage caused by stretching. Now, when the filament irradiated with the infrared light beam is a multi-filament, the center of the filament described above refers to the center of the multi-filament bundle.
[0028] A filament drawn according to the present invention may be accumulated in a drawing chamber and removed but can also be wound in terms of an aggregate or non-woven microfilament fabrics by stacking the filament on a moving conveyer. Non-woven fabrics comprising nanofilament can be manufactured in the manner described above. As the conveyer in the present invention, a net-like moving body is ordinarily used, but the filament also may be accumulated on a belt or a cylinder.
[0029] Now, a laminated material on a cloth may be manufactured by accumulating the microfilament drawn according to the present invention on a cloth-like material in motion. An accumulated material or non-woven fabrics comprising nanofilament is particularly difficult to handle since the constituting filament is very fine, but the handling is improved when laminated with a cloth-like material in the manner described. In some applications, the filament can be used in applications such as filters and the like without any further treatment when the filament is laminated on commercially available spun bonded non-woven fabrics and the like. As the cloth-like material, a woven material, knit material, non-woven fabrics, felt and the like are used. In addition, the filament may be accumulated on a film in motion.
[0030] A filament drawn according to the present invention may be subsequently continuously wound on a bobbin, cheese, hank and the like through guide rollers and the like to prepare a wound product.
[0031] The objective of the present invention is to manufacture a microfilament by drawing an original filament using a super high draw ratio. The microfilament in the present invention refers to attenuated filament obtained by drawing an original filament at a ratio of at least one hundred. Of the microfilaments, those with a filament diameter smaller than 1 μm are specifically referred to as nanofilaments. The present invention can yield a nanofilament even from an original filament having a diameter of at least 100 μm by drawing the original filament at a draw ratio of at least 10,000.
[0032] The draw ratio (λ) in the present invention is represented by the following equation using the diameter (do) of an original filament and the diameter (d) of the filament after drawing. In this case, the calculation is executed using a constant filament density. The filament diameter is measured using a scanning electron microscope (SEM). A photograph of an original filament was taken at a magnification of 350, and a photograph of a drawn filament was taken at a magnification of 1,000 or more. An average of one hundred sites was reported.
[0000] λ=( do/d ) 2
[0033] One feature of the drawn filament obtained according to the present invention is the uniformity of the filament diameter. The filament diameter distribution was calculated using one hundred measurements on the SEM photograph described above using measurement software. The standard deviation was calculated from the measurement values and was used as a measure of filament diameter distribution.
[0034] The molecules in a drawn filament of the present invention become oriented upon drawing, and the filament is thermally stable. The drawn filament of the present invention has a very small filament diameter, and the molecular orientation of the filament is measured with difficulty. The thermal analysis results indicated that the drawn filament of the present invention did not simply become thinner but underwent molecular orientation. The differential thermal analysis (DSC) of an original filament and drawn filament was measured at a heating rate of temperature rise of 10° C./min using a THEM PLUS2 DSC8230 manufactured by Rigaku Co.
ADVANTAGEOUS EFFECTS OF THE INVENTIONS
[0035] The ES method previously used to manufacture nanofibers is complex manufacturing method that requires dissolution of a polymer in a solvent and removal of the solvent from the finished product and contributes to a high manufacturing cost. In addition, the finished product also encounters quality problems such as the presence of resin pieces referred to as lumps and balls, a broad filament diameter distribution and the like. In addition, the fiber obtained was short (staple fiber), and the length ranged from several millimeters to at most several tens of millimeters. However, basically continuous filaments that are at least several meters long can be obtained by using the present invention.
[0036] The present invention does not need a special high performance apparatus that operates at high precision, and a microfilament with improved molecular orientation can be obtained readily using a simple means. In addition, a draw ratio of at least 10,000 can be achieved using almost all thermoplastic polymers, and a super fine filament with a diameter of less than 1 μm in the nanofilament range can be manufactured. Furthermore, a super fine filament with a very narrow filament diameter distribution reflected in a standard deviation of 0.1 or lower can be obtained even though the average filament diameter is in the nanofilament range.
[0037] The pressure difference upstream and downstream from an orifice is utilized as the means to generate a high speed gas flow that imparts the drawing tension in the super drawing method of the present invention involving an infrared light beam. The approach creates a very stable high speed gas flow and yields not only a nanofilament but also enables a stable continuous operation as far as productivity is concerned.
[0038] The drawing process of the present invention is particularly stable due to the reduced pressure in the drawing chamber, and a stable nanofilament manufacturing process can be realized. An air flow released at high speed is not disturbed under reduced pressure, and a stable air flow is thought to be achieved.
[0039] In addition, the present invention can present long fiber non-woven fabrics comprising super fine filaments with diameters in the nanofilament range. Furthermore, a laminated material is also obtained by laminating the filament on non-woven fabrics such as commercially available spun bonded non-woven fabrics and the like.
[0040] The present invention can yield a super fine filament with a diameter in the nanofilament range from a filament comprising biodegradable polymers used in regenerated medical materials such as poly(lactic acid) and poly(glycolic acid) and the like that ordinarily have poor drawing properties. The ES method previously used to manufacture nanofibers used a solvent such as chloroform and the like, and the method not only required dissolution step and solvent removal step but also used such toxic solvents. The use of such solvents made it difficult to use the filaments in regenerated medical treatment applications.
[0041] The nanofilaments obtained according to the present invention not only dramatically improve filter efficiencies in conventional air filter applications but also are adaptable as revolutionary materials with a broad range of applications in IT, bio and environmental fields. Another feature of the present invention is that microfilaments and nanofilaments can be easily obtained from filaments of high performance polymers such as polyarylate type polymers, poly(ethylene naphthalates), fluorinated polymers and the like, previously considered difficult to attenuate due to the narrow range of conditions amenable for spinning and drawing thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] FIG. 1 is a conceptual process diagram for the production of a drawn filament of the present invention.
[0043] FIG. 2 is a conceptual diagram for an apparatus in which the original filament supply chamber of the present invention is at atmospheric pressure.
[0044] FIG. 3 is a conceptual diagram of an apparatus in which the original filament supply chamber is under added pressure and the drawing chamber is at atmospheric pressure.
[0045] FIG. 4 is a conceptual diagram of an orifice used in the present invention.
[0046] FIG. 5 is a conceptual diagram of an example of another orifice used in the present invention.
[0047] FIG. 6 is a conceptual diagram showing a case in which the infrared ray radiation of the present invention is reflected using a mirror.
[0048] FIG. 7 is a conceptual diagram displaying the state of a light beam when multiple infrared ray irradiation devices of the present invention are used.
[0049] FIG. 8 is a scanning electron microscope photograph (magnification: 10,000) of a poly(ethylene terephthalate) nanofilament drawn by the present invention.
[0050] FIG. 9 is a filament diameter distribution diagram for the nanofilament of the present invention shown in FIG. 8 .
[0051] FIG. 10 is a scanning electron microscope photograph (magnification: 3,000) of a poly(lactic acid) nanofilament drawn by the present invention.
[0052] FIG. 11 is a filament diameter distribution diagram for the nanofilament of the present invention shown in FIG. 10 .
[0053] FIG. 12 is a scanning electron microscope photograph (magnification: 5,000) of a PFA filament drawn by the present invention.
[0054] FIG. 13 is a scanning electron microscope photograph (magnification: 1,500) of a PEN filament drawn by the present invention.
[0055] FIG. 14 is a scanning electron microscope photograph (magnification: 3,000) of a PGA filament drawn by the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0056] The execution modes of the present invention are described below based on the figures. FIG. 1 is a conceptual diagram that shows the fundamental basis for the production of microfilaments in the present invention, and a cross section of an apparatus is shown. An original filament 1 is supplied from a reel 11 on which the filament had been wound, the filament is supplied at a constant rate using nip rollers 13 a and 13 b through a comb 12 and led to an orifice 14 . In the steps up to this point, the original filament supply chamber 15 is maintained at pressure P 1 . The pressure P 1 is adjusted using a duct 16 connected to a pressurizing pump (not illustrated), a valve 17 that controls the degree of pressurization, the rate of rotation of the pressurization pump and the like. Now, when the supply chamber 15 of the original filament is under reduced pressure, a vacuum pump is used in place of the pressurizing pump. A pressure gauge 18 ) is installed in the original filament supply chamber 15 , and the pressure is controlled.
[0057] A drawing chamber 21 under P 2 pressure is located downstream from the orifice 14 exit. The original filament 1 exiting the orifice 14 is introduced into the drawing chamber 21 along with a high speed air flow induced by the pressure difference (P 1 -P 2 ) between the original filament supply chambers 15 and the drawing chamber. The original filament 1 transferred is irradiated directly under the orifice using a laser generating device 5 with a laser beam 6 in a heating zone M of a constant width to the moving original filament. The laser beam 6 may be irradiated from multiple locations as shown in FIG. 6 and FIG. 7 . A laser beam power meter 7 is installed where the laser beam 6 reaches, and the laser power is preferably controlled to a constant level. The original filament is drawn upon heating by the laser beam 6 due to the downward tension on the lower section of the filament applied by the high speed air flow induced by the P 1 −P 2 pressure difference, moves downward in the form of a stretched filament 22 and accumulates below. The pressure P 2 is controlled using a duct 23 leading to a vacuum pump (not illustrated), a valve 24 that controls the degree of pressurization, the rotation rate of the vacuum pump, the bypass valves and the like. A pressure gauge 25 is installed in the drawing chamber 21 . Now, when the drawing chamber 21 is a pressurized chamber, a pressurization pump is used in place of a vacuum pump.
[0058] FIG. 2 is a cross sectional diagram of an apparatus showing an example in which the pressure, P 1 , in an original filament supply chamber is atmospheric pressure. The original filament that exits an orifice 14 yields a drawn filament 32 in a drawing chamber 31 through the same steps shown in FIG. 1 .
[0059] FIG. 3 is an angled view of an apparatus seen from the side showing an example in which the original filament supply chamber 41 is a pressurized chamber and the drawing chamber is under atmospheric pressure. Many original filaments 1 are wound on reels 42 and are attached to a platform 43 (only three filaments are shown to avoid complicating the diagram). The original filaments 1 a , 1 b and 1 c are moved by the rotation of transfer nip rollers 45 a and 45 b through snail wires 44 a , 44 b and 44 c used as guiding tools and are led to orifices 46 a , 46 b and 46 c . A drawing chamber under P 2 pressure that is atmospheric pressure is downstream from the orifice 46 exit and a specific chamber does not need to be installed. The original filament 1 exiting the orifice 46 is transferred to a drawing chamber along with a high speed air flow induced by the pressure difference P 1 -P 2 between the original filament supply chamber 41 and the drawing chamber. The moving original filament 1 is irradiated directly under the orifice with a line of infrared light beams 48 in a heating zone N of a constant width using an infrared ray irradiation device 47 . The original filament 1 is drawn by the tension applied to the lower part of the filament by the high speed air flow induced by the P 1 -P 2 pressure difference and moves down in the form of drawn filaments 49 a , 49 b and 49 c . The angled lines show the range of the heating section N of the infrared light beam along the moving route of the original filament 1 . The light beam that passes through without being absorbed by the original filament 1 is reflected by the concave mirror 50 shown by the dotted lines and is returned to the heating section N to condense the light. The concave mirror 50 is located on the infrared ray irradiation device 47 side also (however, a window is open in the progression section for the light beam from the infrared ray irradiation device), but the illustration is omitted. The drawn filaments 49 a , 49 b and 49 c accumulate on a moving conveyer 51 and form a web 52 . Air is withdrawn in the direction of the arrow (p) from the back side of the conveyer 51 by negative pressure suction and contributes stability to the web 52 movement. The web 52 on the conveyer 51 is pressed or embossed as needed and is wound in the form of non-woven fabrics.
[0060] Now, as far as the orifice in FIG. 3 is concerned, cylindrical orifices 46 a , 46 b and 46 c are installed for each of the original filaments. The orifice shown in FIG. 5 b that can allow numerous original filaments to simultaneously move may also be used as these orifices.
[0061] A rolled cloth-like material 54 attached to a platform 53 in FIG. 3 may be transferred to a conveyer, laminated with a web 52 to form a laminated material made from a web comprising microfilaments and a cloth-like material.
[0062] FIG. 4 shows a cross sectional view of one example of the orifice used in the present invention. The figure shows an original filament 1 with a filament diameter d exiting a simple cylindrical orifice 56 . The internal orifice diameter is D 1 at the exit. The filament 1 exiting the orifice is irradiated with an infrared light beam M. The infrared light beam M is positioned so that the distance L from the orifice exit to the center of the infrared light beam M is as short as possible.
[0063] Another example of an orifice is shown in the orifice cross section view of FIG. 5 . A type of an orifice 57 that has a large orifice entrance with a narrowing exit with an internal diameter of D 2 is shown in Fig. (a). An example of an orifice 58 that sends out numerous filaments simultaneously is shown in Fig. (b) with a conceptual diagram of a partial cross section. The exit diameter D 3 in Fig. (b) is shown with a diameter in the thickness direction that is the direction of narrowest section.
[0064] The infrared light beam used in the present invention is shown in FIG. 6 using an example in which an original filament is irradiated from multiple locations. A view from above is shown in Fig. A, and a side view is shown in Fig. B. The infrared light beam 61 a radiated by an infrared light beam irradiation device through a zone P (shown using dotted lines in the figure), reaches a mirror 62 , becomes an infrared light beam 61 b upon reflection by the mirror 62 and is again converted into an infrared light beam 61 c upon reflection by a mirror 63 . The infrared light beam 61 c passes through the zone P and irradiates an original filament at a position one hundred twenty degrees from the initial original filament irradiation location. The infrared light beam that passed through zone P becomes an infrared light beam 61 e upon reflection by a mirror 65 . The infrared light beam 61 e moves through the zone P and irradiates the original filament 1 at a position one hundred twenty degrees removed from the initial original filament irradiation location for the infrared light beam 61 c . In the manner described above, an original filament 1 can be evenly heated from symmetrically located positions that are one hundred twenty degrees from each other by generating three infrared light beam 61 a , 61 b and 61 c.
[0065] Another example of using an infrared light beam of the present invention in which an original filament is irradiated from multiple locations is shown in FIG. 7 . An example in which multiple light sources are used is shown using a plain view. The infrared light beam 67 a radiated from an infrared ray irradiation device is radiated toward an original filament 1 . In addition, an infrared light beam 67 b radiated from a separate infrared ray irradiation device is also radiated toward the original filament 1 . In the manner described above, multiple inexpensive laser transmission devices that are stabilized with relatively small scale light sources may be used as a high power light source to provide radiation from multiple light sources. Now three light sources are shown in the figure, but two may also be used and four or more may also be used. The multiple light sources described above are particularly effective for drawing multiple filaments.
Example 1
[0066] An undrawn poly(ethylene terephthalate) (PET) filament (filament diameter 182 μm) was used and was drawn using the drawing apparatus shown in FIG. 2 . The laser the emitter used at this point was a carbon dioxide laser emitter with laser output of 8 W, and the beam diameter (light beam) was 2.0 mm. The type of orifice shown in FIG. 5 a was used as the orifice, and the orifice diameter D 2 was 0.5 mm. The degree of vacuum in the drawing chamber was adjusted to 8 KPa. The supply speed of the original filament was changed from 0.1 m/min to 0.2 m/min, 0.3 m/min and 0.4 m/min, and the filament diameters of the filaments obtained are shown in Table 2. In addition, the filament diameters when the laser output was changed from two watts to eight watts are also shown. According to the data in the table, a nanofiber with an average filament diameter of 0.313 μm (313 nanometers) was obtained when using eight watts of laser power and a supply speed of 0.1 m/min. The standard deviation for the filament diameter was 0.078 at that point indicating a very uniform filament diameter distribution. Electron microscope photographs (magnification 10,000) of the filaments obtained using these conditions are shown in FIG. 8 . The photographs were obtained for filaments prepared under conditions that included a laser output of eight watts and original filament transport rates of 0.1 m/min (a), 0.2 m/min (b), 0.3 m/min (c) and 0.4 m/min (d). Nanofilaments with a filament diameter of less than 1 μm were obtained under other conditions also. The draw ratio reached a factor of 338,100 (about 340,000 fold) since the diameter of the original filament was 180 μm and that of the filament obtained was 0. 313 μm. The filament diameter distribution of the filaments obtained under these conditions is shown in FIG. 9 . The filament diameters were very even in all cases, and the data in Table 2 indicate that the standard deviation was often 0.3 or less. In good cases, the standard deviation was 0.2 or lower and, in some cases, was 0.1 or lower. Filaments with diameters smaller than 1 μm were obtained under most conditions, and the drawing factor was 33,000 or greater. In addition, the filaments drawn in the manner described above were subjected to DSC, and the results are shown in Table 3.
[0000]
TABLE 2
PET
Power
Density
Supply Speed
Supply Speed
Supply Speed
Supply Speed
W/cm 2
0.1 m/min
0.2 m/min
0.3 m/min
0.4 m/min
256.6
max
0.57 μm
max
0.78 μm
max
1.45 μm
max
2.33 μm
(8 W)
min
0.18 μm
min
0.22 μm
min
0.17 μm
min
0.23 μm
av.
0.31 μm
av.
0.39 μm
av.
0.63 μm
av.
079 μm
S.D.
0.078
S.D.
0.113
S.D.
0.231
S.D.
0.307
191.0
max
1.27 μm
max
1.37 μm
Max
1.76 μm
max
1.48 μm
(6 W)
min
0.20 μm
min
0.16 μm
min
0.24 μm
min
0.21 μm
av.
0.54 μm
av.
0.47 μm
av.
0.77 μm
av.
0.73 μm
S.D.
0.191
S.D.
0.197
S.D.
0.278
S.D.
0.254
127.0
max
2.52 μm
max
2.28 μm
Max
2.18 μm
max
2.27 μm
(4 W)
min
0.28 μm
min
0.19 μm
min
0.52 μm
min
0.61 μm
av.
0.79 μm
av.
0.82 μm
av.
1.15 μm
av.
1.13 μm
S.D.
0.419
S.D.
0.368
S.D.
0.315
S.D.
0.304
63.7
max
2.44 μm
max
5.13 μm
Max
6.97 μm
max
9.46 μm
(2 W)
min
0.56 μm
min
1.37 μm
min
1.42 μm
min
2.54 μm
av.
1.20 μm
av.
2.81 μm
av.
2.96 μm
av.
4.61 μm
S.D.
0.395
S.D.
0.829
S.D.
0.954
S.D.
1.035
Original filament supply speed and filament diameter (μm)
P2: 8 kPa
S.D.: Standard Deviation
[0000]
TABLE 3
PET DSC Measurements
Supply
Power
heat of
Speed
Density
m, p,
fusion
enthalpy
crystallinity
m/min
W/cm 2
° C.
J/g
J/g
%
0.4
256.6
257.7
−47.7
17.6
23.8
0.3
256.6
256.7
−57.6
12.8
35.4
0.2
256.6
256.9
−67.4
18.8
38.4
0.1
256.6
256.9
−54.2
10.7
34.4
0.1
191.0
257.7
−60.1
23.3
29.1
0.1
127.0
256.7
−71.1
30.4
32.2
0.1
63.7
257.5
−60.7
23.9
29.0
(Heating rate of temp. increase 10° C./min)
Example 2
[0067] The same undrawn poly(ethylene terephthalate) filament used in Example 1 was used as the original filament. The same drawing chamber and laser emitter used in Example 1 were used. The experiment was conducted using a filament supply speed of 0.1 m/min at different degrees of vacuum for the drawing chamber. When the degree of vacuum was 8 KPa, the average filament diameter was 0.31 μm as shown in Example 1. When the degree of vacuum was 6 KPa, the average filament diameter was 0.42 μm. When the degree of vacuum was 24 KPa, The average filament diameter was 0.82 μm. Filaments with filament diameters less than 1 μm were obtained even under these conditions.
Example 3
[0068] An undrawn poly(lactic acid) (PLLA) filament (filament diameter 75 μm) was used as the original filament and was drawn using the drawing apparatus of FIG. 2 . A carbon dioxide gas laser emitter with a laser output of eight watts was used for this case, and the beam diameter (light beam) was 2.0 mm. The type of orifice described in FIG. 5( a ) was used as the orifice, and the orifice diameter d 2 was 0.5 mm. The degree of vacuum in the drawing chamber was adjusted to 8 kPa. The original filament supply speed was changed from 0.1 m/min to 0.8 m/min, and the filament diameters of the filaments obtained are shown in Table 4. In addition, the filament diameters when the laser output was changed from two watts to eight watts are also shown in the table. According to the data in the table, a nanofiber with an average filament diameter of 0.13 μm (130 nanometer) was obtained when the laser power was eight watts (watt density 256.6 W/cm 2 ) and the supply speed was 0.1 m/min. The filament diameter standard deviation was 0.0356 in this case indicating a very uniform filament diameter distribution. The standard deviation for the drawn filament diameter was 0.2 or lower for most cases when the laser power density was high. Many samples had a standard deviation for the same of 0.1 or lower indicating that the filament diameter was very uniform. A scanning electron microscope photograph (magnification 3,000) of the nanofilament obtained under these conditions is shown in FIG. 10 . Nanofilaments with filament diameters less than 1 μm were also obtained under other conditions. The draw ratio reached 322,830 (about 320,000 fold) since the original filament was 75 μm and the filament obtained was 0.13 μm. The filament diameter distribution of the filament obtained under these conditions is shown in FIG. 11 . In addition, a filament with a filament diameter less than 1 μm was obtained under most conditions, and the ratio was at least 22,500 when the filament diameter was less than 0.5 μm.
[0000]
TABLE 4
PLLA
Power
Density
Supply Speed
Supply Speed
Supply Speed
Supply Speed
W/cm 2
0.1 m/min
0.4 m/min
0.6 m/min
0.8 m/min
63.7
max
8.41 μm
max
7.39 μm
max
23.3 μm
max
40.0 μm
(2 W)
min
0.58 μm
min
2.54 μm
min
2.17 μm
min
5.10 μm
av.
1.54 μm
av.
5.59 μm
av.
7.52 μm
av.
13.7 μm
S.D.
0.842
S.D.
1.004
S.D.
2.35
S.D.
9.40
127.0
max
0.66 μm
max
0.64 μm
max
1.50 μm
max
1.72 μm
(4 W)
min
0.16 μm
min
0.30 μm
min
0.27 μm
min
0.29 μm
av.
0.27 μm
av.
0.45 μm
av.
0.48 μm
av.
0.69 μm
S.D.
0.069
S.D.
0.074
S.D.
0.140
S.D.
0.254
191.0
max
0.36 μm
max
0.73 μm
max
0.69 μm
max
0.66 μm
(6 W)
min
0.08 μm
min
0.15 μm
min
0.14 μm
min
0.15 μm
av.
0.21 μm
av.
0.36 μm
av.
0.36 μm
av.
0.36 μm
S.D.
0.058
S.D.
0.109
S.D.
0.109
S.D.
0.117
256.6
Max
0.23 μm
max
0.56 μm
max
1.05 μm
(8 W)
min
0.5 μm
min
0.11 μm
min
0.10 μm
av.
0.3 μm
av.
0.29 μm
av.
0.31 μm
S.D.
0.036
S.D.
0.098
S.D.
0.171
Original filament supply speed and filament diameter (μm)
P2: 8 kPa
S.D.: Standard Deviation
Example 4
[0069] A filament (filament diameter 100 μm) comprising an undrawn tetrafluoroethylene.perfluoroalkyl vinyl ether copolymer (PFA) was used as the original filament, and the drawing was conducted using the drawing apparatus of FIG. 2 to initially obtain a drawn filament with a diameter of 6 μm (filament after primary drawing, ratio 277.8 fold). A secondary drawing was conducted on the filament from the primary drawing using the apparatus shown in FIG. 2 . The laser emitter and the like used in this case were the same devices used in Example 1. The type of orifice described in FIG. 5( a ) was used as the orifice, and the orifice diameter d 2 was 0.5 mm. The degree of vacuum in the drawing chamber was adjusted to 6 kPa. The filament diameters and the standard deviations for the filament diameters for the filaments obtained when the supply speed for the primary drawn filament was changed from 0.1 m/min to 0.2 m/min, 0.3 m/min and 0.4 m/min are shown in Table 5. A drawn nanofiber with a filament diameter of less than one micron was obtained. The standard deviations for many of the filaments were 0.1 or lower indicating that the filament diameters were very uniform. In addition, the filament was drawn by a ratio of at least one hundred even when the secondary drawing only was used, and some filaments were drawn by a ratio of at least four thousand. In addition, the draw ratio was at least ten thousand (ratio of ten thousand) in terms of total draw ratio (primary draw ratio×secondary draw ratio), and some were drawn to a draw ratio of at least one million (multiple of one million). A scanning electron microscope photograph (magnification five thousand) of a drawn filament is shown in FIG. 12 . The DSC experimental results for the filaments listed in Table 6 are also shown. The fusion calories increased with the decreasing average filament diameter, and the melting point was found to rise slightly.
[0000]
TABLE 5
PFA
Supply Speed m/min
0.1
0.2
0.3
0.4
max μm
0.67
0.69
0.72
0.71
min μm
0.067
0.099
0.19
0.22
av. μm
0.093
0.19
0.26
0.35
second draw
4,161
997
529
300
ratio
total draw
1,155,914
276,842
146,743
83,526
ratio
Standard
0.029
0.046
0.98
0.101
Deviation
Original filament supply speed and filament diameter (μm)
P2: 6 kPa
Power Density: 254.6 W/cm 2
first draw ratio: 227.8
[0000]
TABLE 6
PFA DSC Measurements
Supply Speed
heat of fusion
m.p.
m/min
J/g
° C.
0.1
−17.7
304.6
0.2
−16.7
303.8
0.3
−15.3
303.5
0.4
−15.2
302.4
(Power Density: 254.6 W/cm 2 )
Example 5
[0070] The filament obtained after the primary drawing in Example 4 was used as the sample, and the apparatus shown in FIG. 1 was used. A pressurizing pump was used to raise the pressure (P 1 ) in the original filament supply chamber to 120 kPa. The pressure (P 2 ) in the drawing chamber was set at 44 kPa, 30 kPa and 26 kPa for experiments using a vacuum pump. The results are shown in Table 7. Other conditions used were the same as those used in Example 4. Nanofilaments with an average filament diameter of less than 1 μm were obtained in these experiments. The standard deviation for the filament diameters was 0.2 or lower while the filament diameter was 0.097 μm and the filament diameter standard deviation was 0.03 when the degree of vacuum was high for P 2 .
[0000]
TABLE 7
PFA
P2
max filament
mini filament
av. filament
Standard
pressure
(μm)
(μm)
(μm)
Deviation
26 kPa
0.652
0.058
0.097
0.031
30 kPa
0.715
0.215
0.270
0.115
44 kPa
1.211
0.428
0.515
0.181
Original filament supply speed: 0.1 m/min
P1: 120 kPa
Power Density: 254.6 W/cm 2
Example 6
[0071] A filament (filament diameter 170 μm) comprising an undrawn poly(ethylene 2,6-naphthalate) (PEN) was used as the original filament, and the drawing was conducted using the drawing apparatus shown in FIG. 2 . The same laser emitter and the like used in Example 1 were used in this case. The beam diameter was 2.4 mm, and the beam was brought closer directly under the orifice so that the edge of the beam came in contact, and the center of the beam was used for irradiation 1.2 mm directly under the orifice. When the location at which the beam was used was moved 2 mm away while P 2 in Table 8 was 6 kPa, the average filament diameter was 0.295 μm and the standard deviation was 0.075. When the location was moved an additional 6 mm, the average filament diameter was 0.410 μm, and the standard deviation was 0.074, indicating the importance of irradiating an original filament with a beam extremely close to the orifice exit. The type of orifice shown in FIG. 5 a ) was used, and the orifice diameter (d 2 ) was 0.5 mm. Table 8 shows the experimental results when P 1 was atmospheric pressure and P 2 was changed. When P 2 was 30 kPa or lower, the average filament diameter was less than one micron. The filament standard deviation was 0.1 or lower indicating how very uniform the filament diameter was in spite of the fact that the filament obtained was such a fine nanofilament. When P 2 was 30 kPa or lower, the draw ratio was at least ten thousand and was found to be at least twenty-eight thousand. A scanning electron microscope photograph (magnification 1,500) of the filament obtained using the conditions shown in Table 8 are shown in FIG. 13 .
[0000]
TABLE 8
PEN
max
mini
av.
P2
filament
filament
filament
draw
Standard
pressure
(μm)
(μm)
(μm)
ratio
Deviation
6 kPa
0.400
0.120
0.259
149,073
0.054
20 kPa
0.660
0.330
0.463
46,648
0.062
30 kPa
0.760
0.420
0.595
28,247
0.064
40 kPa
1.720
0.850
1.186
7,110
0.187
Original filament supply speed: 0.1 m/min
Original filament diameter: 100 μm
Power Density: 177 W/cm 2
Example 7
[0072] A filament (filament diameter 100 μm) comprising undrawn poly(glycolic acid) (PGA) was used as the original filament and was drawn using the drawing apparatus shown in FIG. 2 . The same laser emitter and the like used in Example 1 were used in this case. The laser power density was 177 W/cm 2 , and a beam with a beam diameter of 2.4 mm was used for the irradiation 1.2 mm directly below the orifice. The type of orifice shown in FIG. 5( a ) was used as the orifice, and the orifice diameter (d 2 ) was 0.5 mm. The degree of vacuum in the drawing chamber was adjusted to 6 kPa. The filament diameters of the filaments obtained when the original filament supply speeds were changed from 0.1 m/min to 0.4 m/min, 0.8 m/min and 1.2 m/min are shown in Table 9. The data in the table indicates that nanofilament with an average filament diameter of 0.388 μm (388 nanometer) was obtained when the supply speed was 0.1 m/min, and the standard deviation for the filament diameter at the time was 0.096 indicating a very uniform filament diameter distribution. The scanning electron microscope photograph (magnification 3,000) of the nanofilaments obtained under the conditions is shown in FIG. 14 . Nanofilaments with filament diameters less than 1 μm were obtained under other conditions. The original filament was 100 μm, and the filament obtained was 0.388 μm. Therefore, the draw ratio reached 66,418 (about 66,000). The filament diameters were also uniform under other conditions, and the standard deviation was 0.2 or lower. In addition, filaments smaller than 1 μm were obtained under all conditions, and the draw ratios were at least 10,000 but also could be at least 100,000.
[0000]
TABLE 9
PGA
Supply Speed m/min
0.1
0.4
0.8
1.2
max μm
0.670
1.200
0.870
1.430
min μm
0.240
0.190
0.250
0.190
av. μm
0.388
0.464
0.482
0.537
draw ratio
191,951
134,234
124,396
100,218
Standard
0.096
0.123
0.137
0.172
Deviation
Original filament supply speed and filament diameter (μm)
P2: 6 kPa
Power Density: 177 W/cm 2
INDUSTRIAL APPLICABILITY
[0073] The microfilament of the present invention can not only be used in air filters and the like in which conventional microfilaments have been used, but also as a revolutionary material in a broad range of applications such as medical filters, IT performance materials and the like. | The objective of the present invention is to enable a microfilament that is a nanofilament to be manufactured continuously and consistently from all thermoplastic polymers without requiring a specialized high precision.high performance apparatus and also to present the nanofilament manufactured as described. The present invention comprises a microfilament in a nanofilament region and the manufacturing means thereof wherein a original filament transferred using a filament transfer means is supplied to an orifice under pressure P 1 and is heated and drawn using an infrared light beam directly under the orifice under pressure P 2 (P 1 >P 2 ). | 3 |
CO-PENDING APPLICATIONS
[0001] Various methods, systems and apparatus relating to the present invention are disclosed in the following co-pending applications filed by the applicant or assignee of the present invention:
[0002] U.S. Ser. Nos. 09/575,141, 09/575,125, 09/575,108, 09/575,109.
[0003] The disclosures of these co-pending applications are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0004] The following invention relates to a printhead assembly having a flexible printed circuit board to provide power and data to individual printhead modules in a printer.
[0005] More particularly, though not exclusively, the invention relates to a printhead assembly having a flexible printed circuit board for providing data and power connections to individual printhead modules in an A4 pagewidth drop on demand printhead capable of printing up to 1600 dpi photographic quality at up to 160 pages per minute. The flexible printed circuit board also has associated therewith a pair of busbars for carrying the power thereto.
[0006] The overall design of a printer in which the assembly can be utilized revolves around the use of replaceable printhead modules in an array approximately 8½ inches (21 cm) long. An advantage of such a system is the ability to easily remove and replace any defective modules in a printhead array. This would eliminate having to scrap an entire printhead if only one chip is defective.
[0007] A printhead module in such a printer can be comprised of a “Memjet” chip, being a chip having mounted thereon a vast number of thermo-actuators in micro-mechanics and micro-electromechanical systems (MEMS). Such actuators might be those as disclosed in U.S. Pat. No. 6,044,646 to the present applicant, however, might be other MEMS print chips.
[0008] In a typical embodiment, eleven “Memjet” tiles can butt together in a metal channel to form a complete 8½ inch printhead assembly.
[0009] The printhead, being the environment within which the assembly of the present invention is to be situated, might typically have six ink chambers and be capable of printing four color process (CMYK) as well as infra-red ink and fixative. An air pump would supply filtered air through a seventh chamber to the printhead, which could be used to keep foreign particles away from its ink nozzles.
[0010] Each printhead module receives ink via an elastomeric extrusion that transfers the ink. Typically, the printhead assembly is suitable for printing A4 paper without the need for scanning movement of the printhead across the paper width.
[0011] The printheads themselves are modular, printhead arrays can be configured to form printheads of arbitrary width.
[0012] Additionally, a second printhead assembly can be mounted on the opposite side of a paper feed path to enable double-sided high speed printing.
OBJECTS OF THE INVENTION
[0013] It is an object of the present invention to provide a printer assembly having a flexible printed circuit board and busbars for delivering power and data to printhead modules of the assembly.
[0014] It is a further object of the present invention to provide an improved printhead assembly.
SUMMARY OF THE INVENTION
[0015] The present invention provides a printhead assembly for a pagewidth drop on demand ink jet printer, comprising:
[0016] an array of printhead modules extending substantially across said pagewidth,
[0017] a flexible printed circuit board carrying data and power to said modules, the flexible printed circuit board also extending substantially across said pagewidth,
[0018] a pair of busbars electrically connected to the flexible printed circuit board and carrying power thereto, the busbars also extending substantially across said pagewidth.
[0019] Preferably said busbars are soldered to said flexible printed circuit board.
[0020] Preferably said flexible printed circuit board contacts individual fine pitch flex PCBs on each printhead module.
[0021] Preferably said flexible printed circuit board has a series of gold plated, domed contacts which interface with contact pads on said fine pitch flex PCBs.
[0022] Preferably the flexible printed circuit board extends from one end of the assembly for data connection.
[0023] Preferably said printhead modules are fixed to an elongate channel and an elastomeric ink delivery extrusion is situated between the modules and the channel and the flexible printed circuit board is sandwiched between the elastomeric ink delivery extrusion and the channel and extends around one edge of the extrusion to carry power and data to the printhead modules.
[0024] Preferably the busbars are situated between the flexible printed circuit board and the elastomeric ink delivery extrusion.
[0025] Preferably said gold plated, domed contacts and said contact pads are located alongside said printhead modules and are biased into mutual contact by a resilient force exerted thereon by said channel.
[0026] Preferably said flexible printed circuit board is bonded to the channel.
[0027] As used herein, the term “ink” is intended to mean any fluid which flows through the printhead to be delivered to print media. The fluid may be one of many different colored inks, infra-red ink, a fixative or the like.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] A preferred form of the present invention will now be described by way of example with reference to the accompanying drawings wherein:
[0029] [0029]FIG. 1 is a schematic overall view of a printhead;
[0030] [0030]FIG. 2 is a schematic exploded view of the printhead of FIG. 1;
[0031] [0031]FIG. 3 is a schematic exploded view of an ink jet module;
[0032] [0032]FIG. 3 a is a schematic exploded inverted illustration of the ink jet module of FIG. 3;
[0033] [0033]FIG. 4 is a schematic illustration of an assembled ink jet module;
[0034] [0034]FIG. 5 is a schematic inverted illustration of the module of FIG. 4;
[0035] [0035]FIG. 6 is a schematic close-up illustration of the module of FIG. 4;
[0036] [0036]FIG. 7 is a schematic illustration of a chip sub-assembly;
[0037] [0037]FIG. 8 a is a schematic side elevational view of the printhead of FIG. 1;
[0038] [0038]FIG. 8 b is a schematic plan view of the printhead of FIG. 8 a;
[0039] [0039]FIG. 8 c is a schematic side view (other side) of the printhead of FIG. 8 a;
[0040] [0040]FIG. 8 d is a schematic inverted plan view of the printhead of FIG. 8 b;
[0041] [0041]FIG. 9 is a schematic cross-sectional end elevational view of the printhead of FIG. 1;
[0042] [0042]FIG. 10 is a schematic illustration of the printhead of FIG. 1 in an uncapped configuration;
[0043] [0043]FIG. 11 is a schematic illustration of the printhead of FIG. 1 in a capped configuration;
[0044] [0044]FIG. 12 a is a schematic illustration of a capping device;
[0045] [0045]FIG. 12 b is a schematic illustration of the capping device of FIG. 12 a , viewed from a different angle;
[0046] [0046]FIG. 13 is a schematic illustration showing the loading of an ink jet module into a printhead;
[0047] [0047]FIG. 14 is a schematic end elevational view of the printhead illustrating the printhead module loading method;
[0048] [0048]FIG. 15 is a schematic cut-away illustration of the printhead assembly of FIG. 1;
[0049] [0049]FIG. 16 is a schematic close-up illustration of a portion of the printhead of FIG. 15 showing greater detail in the area of the “Memjet” chip;
[0050] [0050]FIG. 17 is a schematic illustration of the end portion of a metal channel and a printhead location molding;
[0051] [0051]FIG. 18 a is a schematic illustration of an end portion of an elastomeric ink delivery extrusion and a molded end cap; and
[0052] [0052]FIG. 18 b is a schematic illustration of the end cap of FIG. 18 a in an out-folded configuration.
DETAILED DESCRIPTION OF THE INVENTION
[0053] In FIG. 1 of the accompanying drawings there is schematically depicted an overall view of a printhead assembly. FIG. 2 shows the core components of the assembly in an exploded configuration. The printhead assembly 10 of the preferred embodiment comprises eleven printhead modules 11 situated along a metal “Invar” channel 16 . At the heart of each printhead module 11 is a “Memjet” chip 23 (FIG. 3). The particular chip chosen in the preferred embodiment being a six-color configuration.
[0054] The “Memjet” printhead modules 11 are comprised of the “Memjet” chip 23 , a fine pitch flex PCB 26 and two micromoldings 28 and 34 sandwiching a mid-package film 35 . Each module 11 forms a sealed unit with independent ink chambers 63 (FIG. 9) which feed the chip 23 . The modules 11 plug directly onto a flexible elastomeric extrusion 15 which carries air, ink and fixitive. The upper surface of the extrusion 15 has repeated patterns of holes 21 which align with ink inlets 32 (FIG. 3 a ) on the underside of each module 11 . The extrusion 15 is bonded onto a flex PCB (flexible printed circuit board).
[0055] The fine pitch flex PCB 26 wraps down the side of each printhead module 11 and makes contact with the flex PCB 17 (FIG. 9). The flex PCB 17 carries two busbars 19 (positive) and 20 (negative) for powering each module 11 , as well as all data connections. The flex PCB 17 is bonded onto the continuous metal “Invar” channel 16 . The metal channel 16 serves to hold the modules 11 in place and is designed to have a similar coefficient of thermal expansion to that of silicon used in the modules.
[0056] A capping device 12 is used to cover the “Memjet” chips 23 when not in use. The capping device is typically made of spring steel with an onsert molded elastomeric pad 47 (FIG. 12 a ). The pad 47 serves to duct air into the “Memjet” chip 23 when uncapped and cut off air and cover a nozzle guard 24 (FIG. 9) when capped. The capping device 12 is actuated by a camshaft 13 that typically rotates throughout 180°.
[0057] The overall thickness of the “Memjet” chip is typically 0.6 mm which includes a 150 micron inlet backing layer 27 and a nozzle guard 24 of 150 micron thickness. These elements are assembled at the wafer scale.
[0058] The nozzle guard 24 allows filtered air into an 80 micron cavity 64 (FIG. 16) above the “Memjet” ink nozzles 62 . The pressurized air flows through microdroplet holes 45 in the nozzle guard 24 (with the ink during a printing operation) and serves to protect the delicate “Memjet” nozzles 62 by repelling foreign particles.
[0059] A silicon chip backing layer 27 ducts ink from the printhead module packaging directly into the rows of “Memjet” nozzles 62 . The “Memjet” chip 23 is wire bonded 25 from bond pads on the chip at 116 positions to the fine pitch flex PCB 26 . The wire bonds are on a 120 micron pitch and are cut as they are bonded onto the fine pitch flex PCB pads (FIG. 3). The fine pitch flex PCB 26 carries data and power from the flex PCB 17 via a series of gold contact pads 69 along the edge of the flex PCB.
[0060] The wire bonding operation between chip and fine pitch flex PCB 26 may be done remotely, before transporting, placing and adhering the chip assembly into the printhead module assembly. Alternatively, the “Memjet” chips 23 can be adhered into the upper micromolding 28 first and then the fine pitch flex PCB 26 can be adhered into place. The wire bonding operation could then take place in situ, with no danger of distorting the moldings 28 and 34 . The upper micromolding 28 can be made of a Liquid Crystal Polymer (LCP) blend. Since the crystal structure of the upper micromolding 28 is minute, the heat distortion temperature (180° C. -260° C.), the continuous usage temperature (200° C.-240° C.) and soldering heat durability (260° C. for 10 seconds to 310° C. for 10 seconds) are high, regardless of the relatively low melting point.
[0061] Each printhead module 11 includes an upper micromolding 28 and a lower micromolding 34 separated by a mid-package film layer 35 shown in FIG. 3.
[0062] The mid-package film layer 35 can be an inert polymer such as polyimide, which has good chemical resistance and dimensional stability. The mid-package film layer 35 can have laser ablated holes 65 and can comprise a double-sided adhesive (ie. an adhesive layer on both faces) providing adhesion between the upper micromolding, the mid-package film layer and the lower micromolding.
[0063] The upper micromolding 28 has a pair of alignment pins 29 passing through corresponding apertures in the mid-package film layer 35 to be received within corresponding recesses 66 in the lower micromolding 34 . This serves to align the components when they are bonded together. Once bonded together, the upper and lower micromoldings form a tortuous ink and air path in the complete “Memjet” printhead module 11 .
[0064] There are annular ink inlets 32 in the underside of the lower micromolding 34 . In a preferred embodiment, there are six such inlets 32 for various inks (black, yellow, magenta, cyan, fixitive and infrared). There is also provided an air inlet slot 67 . The air inlet slot 67 extends across the lower micromolding 34 to a secondary inlet which expels air through an exhaust hole 33 , through an aligned hole 68 in fine pitch flex PCB 26 . This serves to repel the print media from the printhead during printing. The ink inlets 32 continue in the undersurface of the upper micromolding 28 as does a path from the air inlet slot 67 . The ink inlets lead to 200 micron exit holes also indicated at 32 in FIG. 3. These holes correspond to the inlets on the silicon backing layer 27 of the “Memjet” chip 23 .
[0065] There is a pair of elastomeric pads 36 on an edge of the lower micromolding 34 . These serve to take up tolerance and positively located the printhead modules 11 into the metal channel 16 when the modules are micro-placed during assembly.
[0066] A preferred material for the “Memjet” micromoldings is a LCP. This has suitable flow characteristics for the fine detail in the moldings and has a relatively low coefficient of thermal expansion.
[0067] Robot picker details are included in the upper micromolding 28 to enable accurate placement of the printhead modules 11 during assembly.
[0068] The upper surface of the upper micromolding 28 as shown in FIG. 3 has a series of alternating air inlets and outlets 31 . These act in conjunction with the capping device 12 and are either sealed off or grouped into air inlet/outlet chambers, depending upon the position of the capping device 12 . They connect air diverted from the inlet slot 67 to the chip 23 depending upon whether the unit is capped or uncapped.
[0069] A capper cam detail 40 including a ramp for the capping device is shown at two locations in the upper surface of the upper micromolding 28 . This facilitates a desirable movement of the capping device 12 to cap or uncap the chip and the air chambers. That is, as the capping device is caused to move laterally across the print chip during a capping or uncapping operation, the ramp of the capper cam detail 40 serves to elastically distort and capping device as it is moved by operation of the camshaft 13 so as to prevent scraping of the device against the nozzle guard 24 .
[0070] The “Memjet” chip assembly 23 is picked and bonded into the upper micromolding 28 on the printhead module 11 . The fine pitch flex PCB 26 is bonded and wrapped around the side of the assembled printhead module 11 as shown in FIG. 4. After this initial bonding operation, the chip 23 has more sealant or adhesive 46 applied to its long edges. This serves to “pot” the bond wires 25 (FIG. 6), seal the “Memjet” chip 23 to the molding 28 and form a sealed gallery into which filtered air can flow and exhaust through the nozzle guard 24 .
[0071] The flex PCB 17 carries all data and power connections from the main PCB (not shown) to each “Memjet” printhead module 11 . The flex PCB 17 has a series of gold plated, domed contacts 69 (FIG. 2) which interface with contact pads 41 , 42 and 43 on the fine pitch flex PCB 26 of each “Memjet” printhead module 11 .
[0072] Two copper busbar strips 19 and 20 , typically of 200 micron thickness, are jigged and soldered into place on the flex PCB 17 . The busbars 19 and 20 connect to a flex termination which also carries data.
[0073] The flex PCB 17 is approximately 340 mm in length and is formed from a 14 mm wide strip. It is bonded into the metal channel 16 during assembly and exits from one end of the printhead assembly only.
[0074] The metal U-channel 16 into which the main components are place is of a special alloy called “Invar 36”. It is a 36% nickel iron alloy possessing a coefficient of thermal expansion of {fraction (1/10)}th that of carbon steel at temperatures up to 400° F. The Invar is annealed for optimal dimensional stability.
[0075] Additionally, the Invar is nickel plated to a 0.056% thickness of the wall section. This helps to further match it to the coefficient of thermal expansion of silicon which is 2 × 10 −6 per ° C.
[0076] The Invar channel 16 functions to capture the “Memjet” printhead modules 11 in a precise alignment relative to each other and to impart enough force on the modules 11 so as to form a seal between the ink inlets 32 on each printhead module and the outlet holes 21 that are laser ablated into the elastomeric ink delivery extrusion 15 .
[0077] The similar coefficient of thermal expansion of the Invar channel to the silicon chips allows similar relative movement during temperature changes. The elastomeric pads 36 on one side of each printhead module 11 serve to “lubricate” them within the channel 16 to take up any further lateral coefficient of thermal expansion tolerances without losing alignment. The Invar channel is a cold rolled, annealed and nickel plated strip. Apart from two bends that are required in its formation, the channel has two square cutouts 80 at each end. These mate with snap fittings 81 on the printhead location moldings 14 (FIG. 17).
[0078] The elastomeric ink delivery extrusion 15 is a non-hydrophobic, precision component. Its function is to transport ink and air to the “Memjet” printhead modules 11 . The extrusion is bonded onto the top of the flex PCB 17 during assembly and it has two types of molded end caps. One of these end caps is shown at 70 in FIG. 18 a.
[0079] A series of patterned holes 21 are present on the upper surface of the extrusion 15 . These are laser ablated into the upper surface. To this end, a mask is made and placed on the surface of the extrusion, which then has focused laser light applied to it. The holes 21 are evaporated from the upper surface, but the laser does not cut into the lower surface of extrusion 15 due to the focal length of the laser light.
[0080] Eleven repeated patterns of the laser ablated holes 21 form the ink and air outlets 21 of the extrusion 15 . These interface with the annular ring inlets 32 on the underside of the “Memjet” printhead module lower micromolding 34 . A different pattern of larger holes (not shown but concealed beneath the upper plate 71 of end cap 70 in FIG. 18 a ) is ablated into one end of the extrusion 15 . These mate with apertures 75 having annular ribs formed in the same way as those on the underside of each lower micromolding 34 described earlier. Ink and air delivery hoses 78 are connected to respective connectors 76 that extend from the upper plate 71 . Due to the inherent flexibility of the extrusion 15 , it can contort into many ink connection mounting configurations without restricting ink and air flow. The molded end cap 70 has a spine 73 from which the upper and lower plates are integrally hinged. The spine 73 includes a row of plugs 74 that are received within the ends of the respective flow passages of the extrusion 15 .
[0081] The other end of the extrusion 15 is capped with simple plugs which block the channels in a similar way as the plugs 74 on spine 17 .
[0082] The end cap 70 clamps onto the ink extrusion 15 by way of snap engagement tabs 77 . Once assembled with the delivery hoses 78 , ink and air can be received from ink reservoirs and an air pump, possibly with filtration means. The end cap 70 can be connected to either end of the extrusion, ie. at either end of the printhead.
[0083] The plugs 74 are pushed into the channels of the extrusion 15 and the plates 71 and 72 are folded over. The snap engagement tabs 77 clamp the molding and prevent it from slipping off the extrusion. As the plates are snapped together, they form a sealed collar arrangement around the end of the extrusion. Instead of providing individual hoses 78 pushed onto the connectors 76 , the molding 70 might interface directly with an ink cartridge. A sealing pin arrangement can also be applied to this molding 70 . For example, a perforated, hollow metal pin with an elastomeric collar can be fitted to the top of the inlet connectors 76 . This would allow the inlets to automatically seal with an ink cartridge when the cartridge is inserted. The air inlet and hose might be smaller than the other inlets in order to avoid accidental charging of the airways with ink.
[0084] The capping device 12 for the “Memjet” printhead would typically be formed of stainless spring steel. An elastomeric seal or onsert molding 47 is attached to the capping device as shown in FIGS. 12 a and 12 b . The metal part from which the capping device is made is punched as a blank and then inserted into an injection molding tool ready for the elastomeric onsert to be shot onto its underside. Small holes 79 (FIG. 13 b ) are present on the upper surface of the metal capping device 12 and can be formed as burst holes. They serve to key the onsert molding 47 to the metal. After the molding 47 is applied, the blank is inserted into a press tool, where additional bending operations and forming of integral springs 48 takes place.
[0085] The elastomeric onsert molding 47 has a series of rectangular recesses or air chambers 56 . These create chambers when uncapped. The chambers 56 are positioned over the air inlet and exhaust holes 30 of the upper micromolding 28 in the “Memjet” printhead module 11 . These allow the air to flow from one inlet to the next outlet. When the capping device 12 is moved forward to the “home” capped position as depicted in FIG. 11, these airways 32 are sealed off with a blank section of the onsert molding 47 cutting off airflow to the “Memjet” chip 23 . This prevents the filtered air from drying out and therefore blocking the delicate “Memjet” nozzles.
[0086] Another function of the onsert molding 47 is to cover and clamp against the nozzle guard 24 on the “Memjet” chip 23 . This protects against drying out, but primarily keeps foreign particles such as paper dust from entering the chip and damaging the nozzles. The chip is only exposed during a printing operation, when filtered air is also exiting along with the ink drops through the nozzle guard 24 . This positive air pressure repels foreign particles during the printing process and the capping device protects the chip in times of inactivity.
[0087] The integral springs 48 bias the capping device 12 away from the side of the metal channel 16 . The capping device 12 applies a compressive force to the top of the printhead module 11 and the underside of the metal channel 16 . The lateral capping motion of the capping device 12 is governed by an eccentric camshaft 13 mounted against the side of the capping device. It pushes the device 12 against the metal channel 16 . During this movement, the bosses 57 beneath the upper surface of the capping device 12 ride over the respective ramps 40 formed in the upper micromolding 28 . This action flexes the capping device and raises its top surface to raise the onsert molding 47 as it is moved laterally into position onto the top of the nozzle guard 24 .
[0088] The camshaft 13 , which is reversible, is held in position by two printhead location moldings 14 . The camshaft 11 can have a flat surface built in one end or be otherwise provided with a spline or keyway to accept gear 22 or another type of motion controller. The “Memjet” chip and printhead module are assembled as follows:
[0089] 1. The “Memjet” chip 23 is dry tested in flight by a pick and place robot, which also dices the wafer and transports individual chips to a fine pitch flex PCB bonding area.
[0090] 2. When accepted, the “Memjet” chip 23 is placed 530 microns apart from the fine pitch flex PCB 26 and has wire bonds 25 applied between the bond pads on the chip and the conductive pads on the fine pitch flex PCB. This constitutes the “Memjet” chip assembly.
[0091] 3. An alternative to step 2 is to apply adhesive to the internal walls of the chip cavity in the upper micromolding 28 of the printhead module and bond the chip into place first. The fine pitch flex PCB 26 can then be applied to the upper surface of the micromolding and wrapped over the side. Wire bonds 25 are then applied between the bond pads on the chip and the fine pitch flex PCB.
[0092] 4. The “Memjet” chip assembly is vacuum transported to a bonding area where the printhead modules are stored.
[0093] 5. Adhesive is applied to the lower internal walls of the chip cavity and to the area where the fine pitch flex PCB is going to be located in the upper micromolding of the printhead module.
[0094] 6. The chip assembly (and fine pitch flex PCB) are bonded into place. The fine pitch flex PCB is carefully wrapped around the side of the upper micromolding so as not to strain the wire bonds. This may be considered as a two step gluing operation if it is deemed that the fine pitch flex PCB might stress the wire bonds. A line of adhesive running parallel to the chip can be applied at the same time as the internal chip cavity walls are coated. This allows the chip assembly and fine pitch flex PCB to be seated into the chip cavity and the fine pitch flex PCB allowed to bond to the micromolding without additional stress. After curing, a secondary gluing operation could apply adhesive to the short side wall of the upper micromolding in the fine pitch flex PCB area. This allows the fine pitch flex PCB to be wrapped around the micromolding and secured, while still being firmly bonded in place along on the top edge under the wire bonds.
[0095] 7. In the final bonding operation, the upper part of the nozzle guard is adhered to the upper micromolding, forming a sealed air chamber. Adhesive is also applied to the opposite long edge of the “Memjet” chip, where the bond wires become ‘potted’ during the process.
[0096] 8. The modules are ‘wet’ tested with pure water to ensure reliable performance and then dried out.
[0097] 9. The modules are transported to a clean storage area, prior to inclusion into a printhead assembly, or packaged as individual units. The completes the assembly of the “Memjet” printhead module assembly.
[0098] 10. The metal Invar channel 16 is picked and placed in a jig.
[0099] 11. The flex PCB 17 is picked and primed with adhesive on the busbar side, positioned and bonded into place on the floor and one side of the metal channel.
[0100] 12. The flexible ink extrusion 15 is picked and has adhesive applied to the underside. It is then positioned and bonded into place on top of the flex PCB 17 . One of the printhead location end caps is also fitted to the extrusion exit end. This constitutes the channel assembly.
[0101] The laser ablation process is as follows:
[0102] 13. The channel assembly is transported to an eximir laser ablation area.
[0103] 14. The assembly is put into a jig, the extrusion positioned, masked and laser ablated. This forms the ink holes in the upper surface.
[0104] 15. The ink extrusion 15 has the ink and air connector molding 70 applied. Pressurized air or pure water is flushed through the extrusion to clear any debris.
[0105] 16. The end cap molding 70 is applied to the extrusion 15 . It is then dried with hot air.
[0106] 17. The channel assembly is transported to the printhead module area for immediate module assembly. Alternatively, a thin film can be applied over the ablated holes and the channel assembly can be stored until required.
[0107] The printhead module to channel is assembled as follows:
[0108] 18. The channel assembly is picked, placed and clamped into place in a transverse stage in the printhead assembly area.
[0109] 19. As shown in FIG. 14, a robot tool 58 grips the sides of the metal channel and pivots at pivot point against the underside face to effectively flex the channel apart by 200 to 300 microns. The forces applied are shown generally as force vectors F in FIG. 14. This allows the first “Memjet” printhead module to be robot picked and placed (relative to the first contact pads on the flex PCB 17 and ink extrusion holes) into the channel assembly.
[0110] 20. The tool 58 is relaxed, the printhead module captured by the resilience of the Invar channel and the transverse stage moves the assembly forward by 19.81 mm.
[0111] 21. The tool 58 grips the sides of the channel again and flexes it apart ready for the next printhead module.
[0112] 22. A second printhead module 11 is picked and placed into the channel 50 microns from the previous module.
[0113] 23. An adjustment actuator arm locates the end of the second printhead module. The arm is guided by the optical alignment of fiducials on each strip. As the adjustment arm pushes the printhead module over, the gap between the fiducials is closed until they reach an exact pitch of 19.812 mm.
[0114] 24. The tool 58 is relaxed and the adjustment arm is removed, securing the second printhead module in place.
[0115] 25. This process is repeated until the channel assembly has been fully loaded with printhead modules. The unit is removed from the transverse stage and transported to the capping assembly area. Alternatively, a thin film can be applied over the nozzle guards of the printhead modules to act as a cap and the unit can be stored as required.
[0116] The capping device is assembled as follows:
[0117] 26. The printhead assembly is transported to a capping area. The capping device 12 is picked, flexed apart slightly and pushed over the first module 11 and the metal channel 16 in the printhead assembly. It automatically seats itself into the assembly by virtue of the bosses 57 in the steel locating in the recesses 83 in the upper micromolding in which a respective ramp 40 is located.
[0118] 27. Subsequent capping devices are applied to all the printhead modules.
[0119] 28. When completed, the camshaft 13 is seated into the printhead location molding 14 of the assembly. It has the second printhead location molding seated onto the free end and this molding is snapped over the end of the metal channel, holding the camshaft and capping devices captive.
[0120] 29. A molded gear 22 or other motion control device can be added to either end of the camshaft 13 at this point.
[0121] 30. The capping assembly is mechanically tested.
[0122] Print charging is as follows:
[0123] 31. The printhead assembly 10 is moved to the testing area. Inks are applied through the “Memjet” modular printhead under pressure. Air is expelled through the “Memjet” nozzles during priming. When charged, the printhead can be electrically connected and tested.
[0124] 32. Electrical connections are made and tested as follows:
[0125] 33. Power and data connections are made to the PCB. Final testing can commence, and when passed, the “Memjet” modular printhead is capped and has a plastic sealing film applied over the underside that protects the printhead until product installation. | A printhead assembly for a pagewidth drop on demand ink jet printer includes an array of printhead modules extending across the pagewidth. A flexible printed circuit board carries data and power to the modules and also extends across the pagewidth. A pair of busbars is electrically connected to the flexible printed circuit board to carry power to it. The busbars also extend across the pagewidth. | 1 |
BACKGROUND OF INVENTION
Field of Invention
The invention relates to cellular mobile radiotelephones. More particularly, the invention relates to a system for easily obtaining the electronic serial number (ESN) and mobile telephone number (MID) of a cellular telephone.
Each cellular telephone has a unique electronic serial number which resides within internal circuitry of the telephone, and serves to identify it to the cellular network. An invoice specifying the ESN of a cellular telephone usually accompanies its purchase. In addition, some telephones have the ESN printed on the handset. A few others are designed to provide a visual display of the ESN as it has been stored in the memory of the telephone, upon proper entry of a keystroke sequence on the keypad.
In addition, manufacturers of electronic test equipment currently produce two types of devices that can be used to extract the ESN and MID from a cellular telephone. The primary function of the first type of device is to program the numeric assignment module (NAM), and hence program or read the MID, of a cellular telephone. Currently, some manufacturers produce stand-alone machines. Others supply software which a personal computer uses to program a NAM by remotely controlling a standard EPROM programmer. Retrieving the ESN of a cellular telephone is an additional capability, besides programming the NAM, that some of these machines have.
However, with both types of devices, if removal of the NAM from the cellular telephone is required in order to program it, the ESN is not retrievable. Furthermore, operation of such devices requires hard-wiring between the device and the cellular telephone.
Another type of device which can be used to obtain the ESN and MID of a cellular telephone is used primarily to examine the electromagnetic transmissions of a cellular telephone. These devices receive and analyze the data transmitted by a cellular telephone, and can be programmed to extract the telephone's ESN and MID. Operation of such devices does not require hard-wiring between the device and the cellular telephone, but does necessitate sufficient proximity between the two, and a substantial number of technical modifications to the transmission analyzing device.
All of these devices are relatively expensive. Consequently, they are not widely available. Therefore, the ESN or the MID for a telephone is often not available, or becomes lost or misplaced, leaving the agent and/or user without easy access to the most important means for identifying and servicing the telephone.
Thus, when a user changes agents or has problems using his telephone in a cellular network, absence of the ESN or the MID can result in difficulty in providing prompt, satisfactory service. For example, when a user signs up with a new agent, the agent "activates" the telephone on the agent-carrier's cellular network, thereby authorizing its use for making calls. The activation process also involves entering the user's ESN into the system records of the carrier for billing and other purposes.
If this operation is not performed correctly, i.e. the ESN that the agent logs into the system does not match the telephone internal ESN, the cellular network will not permit the user to make calls. In most cases, a telephone that has been improperly activated with the carrier, by an agent, will merely receive a prerecorded general access denial message when the user attempts to place a cellular call. Presently, the denial messages of most carriers do not indicate a specific reason for denial. Consequently a user receiving such a denial message is not certain whether a faulty ESN or some other problem is the cause.
Therefore, before a user leaves the premises of an agent, after installation or service, both the user and agent need to know that the telephone is correctly activated. Moreover, if an activation is not correct, the agent needs an easy way to verify that the ESN is correct, the proper MID has been programmed into the phone, and know that some other problem must be addressed. Presently users, agents, and carriers have no easy, inexpensive means for determining or verifying the ESN or the MID of a cellular telephone.
In addition, a variety of technical problems can prevent a telephone from operating properly. Such problems may arise from factors relating to voice modulation/demodulation, radio frequency transmit/receive functionality, DTMF modulation, call processing capability, and battery power. Another need in the art is for an easy means for users, agents, or carriers to conveniently run performance tests on a telephone.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the invention to provide cellular agents with authorized access to a system that will allow them to verify or identify the ESN and the MID for a cellular telephone.
It is a further object to provide agents with a system to verify that failed activation is not due to use of an incorrect ESN.
It is another object of the invention to provide agents with a system that permits agents to run simple performance tests of cellular telephones.
These objects and other features and advantages are attained in a system that enables an authorized agent to dial a dedicated telephone number. The system answers the call with a voice message, prompts the agent for a password, and admits the agent onto the system upon correct entry of the password.
Upon entry, the system conducts a trunk trace of the incoming call via the cellular switch to identify the electronic serial number and mobile telephone number of the calling telephone. The computer then transmits a voice synthesized message conveying the telephone's (ESN) and (MID) to the agent.
As a further option, the system provides a performance test routine in which the agent is prompted to speak test messages into the telephone. The system records and then retransmits the audio messages to the agent, thereby permitting evaluation of the voice modulation, voice demodulation, battery power, dual tone multi-frequency (DTMF) modulation, and radio frequency transmit functionality of the telephone.
Operation of the present invention provides a number of benefits to users of the system. First, the system is relatively inexpensive. Users need not purchase any hardware since one construction of the present invention facilitates all call requests by subscribers of the cellular network served by a particular cellular switch for which the system is installed. In order to install the system at a particular cellular switch, cellular carriers only need to purchase a relatively inexpensive assortment of hardware. Another benefit is the mobility that the present invention allows its users. Users can take advantage of the features of the system regardless of their proximity to its hardware as long as they conduct the call within the cellular network served by the cellular switch for which the system is installed. Another benefit is the uncomplicated manner in which the present invention interacts with its users. Unlike the prior art, no programming or special adaptation of complicated electronic equipment is required. By using the keypad of a standard cellular telephone, users can access all of the available features.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a drawing of the hardware interconnections of the present invention;
FIG. 2 is a block diagram of the overall operation of the present invention;
FIG. 3 is a simplified flowchart of the first part of a personal identification number (PIN) retrieval process used by the application program of the present invention.
FIG. 4 is a simplified flowchart of the second part of the personal identification number (PIN) retrieval process, the trunk tracing routine process, the ESN/MID recitation process, and voice modulation diagnostic process as they are used in the application program of the present invention.
FIG. 5 is a simplified flowchart of the MID recitation and end sequence portions used in the application program of the present invention.
FIG. 6 is a block diagram of the trunk trace routine of the present invention.
FIG. 7 is a simplified flowchart of the main program used by the trunk tracing routine of the present invention.
FIG. 8 is a simplified flowchart of subroutine 1000 used by the trunk trace routine portion of the present invention.
FIG. 9 is a simplified flowchart of section 500 used by the trunk trace routine of the present invention.
FIG. 10 is a simplified flowchart of section 300 used by the trunk trace routine of the present invention.
FIG. 11 is a simplified flowchart of subroutines 900 and 2000 used by the trunk trace routine of the present invention.
FIG. 12 is a simplified flowchart of subroutine 5000 used by the trunk trace routine of the present invention.
FIG. 13 is a simplified flowchart of subroutine 3000 used by the trunk trace routine of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, a preferred embodiment of the invention will be described. The invention enables an authorized cellular mobile radiotelephone user or agent to quickly obtain the ESN, MID, and other information on the operation of a cellular telephone.
The authorized agent starts by dialing a predetermined telephone number. The system answers the call with a voice message, prompts the agent for a password, and admits the agent onto the system upon correct entry of the password.
The system then searches for and transmits to the agent a voice synthesized message conveying the telephone's electronic serial number (ESN) and mobile telephone number (MID).
The system also provides the agent access to a diagnostic routine in which the agent is prompted to record a voice sample on the system. The system then returns the recorded voice sample, so the agent may evaluate voice modulation, voice demodulation, battery power, dual tone multi-frequency modulation, and radio frequency transmit functionality of the telephone.
Referring to FIG. 1, the hardware of the system can be divided into cellular equipment, telephone company equipment, and computing equipment.
The cellular equipment necessary to operate the invention comprises a cellular network having a plurality of cell sites 52 interconnected with an electronic mobile exchange (cellular switch) 53 as is commonly used in the cellular industry. Cellular switch 53 is equipped with a standard communication port (switch port) 55 and a direct outward dial trunk 56. Switch port 55 interfaces with a personal computer 59 via a standard RS-232 interface 68.
The single member trunk 56 can only dial outward. It thereby routes incoming calls to cellular switch 53 outward to PSTN 57. However, trunk 56 cannot receive calls from the PSTN 57. Techniques for configuring such a trunk on the Motorola EMX2500 switch (which is the cellular switch used in the preferred embodiment) are available in Motorola's document titled "Fixed Network Equipment EMX2500™, Digital Standard Practices For 25 Channel Systems" (part no. 68P81055E20-A), which is incorporated herein by reference.
The telephone company equipment includes PSTN 57, which serves to relay calls from the cellular switch 53 to the personal computer 59 in the same way that normal, landline telephone calls are routed.
The personal computer 59 is compatible with IBM PC/XT models and operates on version 2.0 or later of IBM-DOS. Contained within computer 59 are standard RS-232 serial port card 60, standard clock with battery backup 61, standard hard disk 62, and standard voice synthesis circuitry board (voice board) 63 each of which directly connects to a central processor 49 also contained within computer 59.
The serial port card 60 may comprise any of a variety of commercially available IBM PC/XT compatible serial port cards. To facilitate communications with computer 59, serial port card 60 is configured to be the first serial port, COM1, according to nomenclature common to the art of personal computing. This board 60 connects to switch port 66 through RS-232 cable 68.
The voice board 63 (part no. 8033) is made by Natural Microsystems™. This board is configured as COM2, and contains a first 65 and a second 66 standard phone plug. A telephone line 67 connects first jack 65 to a wall jack 58, continuing on to couple with PSTN 57. This line should be a two wire circuit with a ringing voltage of approximately 100 Volts AC at 20 Hz. To second jack 66 attached a standard, single line telephone 64.
Natural Microsystems also provides a standard software package ("voice shell") with the purchase of the voice board 63. This software supports operation of voice board 63, and resides on hard disk 62 of computer 59 after installation thereon. Computer 59 runs the voice shell, which continually waits for an incoming telephone call. The system may handle only a single call at one time.
Upon receipt of an incoming call the voice shell initiates an application program. The application program includes a number of programming lines, referred to hereinafter as cards, which are shown in order of execution in Table I.
The application program performs a number of voice shell functions, and also initiates execution of a trunk search routine to identify the ESN and MID. After completion of the trunk search, the application program continues to completion.
Further understanding of the voice shell software is available by reference to the Watson™ Voice Information System™ reference guide (part no. 1154-00), which is incorporated herein by reference.
FIG. 2 generally illustrates the application program and sequence in which the present invention functions. Task 452 answers the ringing telephone line, using the voice shell, and accordingly executes the application program. The application program begins by retrieving one or more digits of a personal identification number (PIN) entered by the calling party. In task 453 control is passed to a trunk trace routine which will procure the ESN and MID of calling cellular telephone 51 from the local cellular switch. After completion of the trunk trace routine, control is returned to the application program. After completion of task 453, query 454 asks whether or not the PIN entry was valid. If task 453 determines that the PIN submitted by the calling party was invalid, task 455 proceeds to inform the calling party of the invalid PIN and hangs up.
Alternately, if task 453 found a valid PIN, query 457 asks whether the trunk trace performed in task 453 successfully obtained an ESN. If query 457 determines that no ESN was found, task 456 informs the calling party that the ESN was not found, thanks the calling party for accessing the system, and hangs up.
On the other hand, if query 457 determines that an ESN was found, then task 458 speaks the hexadecimal digits of the ESN to the calling party. Then, query 459 asks whether the trunk trace performed in task 453 successfully obtained a MID. If query 459 determines that no MID was found, task 460 informs the calling party that the MID was not found, thanks the calling party for accessing the system, and hangs up.
However, if query 459 determines that a MID was found, then task 461 speaks the digits of the MID to the calling party, and proceeds to task 462. Task 462 performs a diagnostic test by requesting the calling party to issue a voice sample, digitally recording that sample, and playing the sample back for receipt of the calling party.
After completion of task 462, task 463 concludes the routine by issuing a "thank you" message to the calling party, hanging up, and returning control from the application program to the voice shell. FIGS. 3, 4, and 5 further illustrate the operation of the application program. In addition, Table I lists the individual statements of code which make up the application program. Referring now to FIG. 3, the beginning of the application program is illustrated. In task 312, the application program is initiated by the voice shell upon receipt of a telephone call.
Table II, presented below, illustrates the organization of several 2-byte RAM registers which are used in the exchange of data between the application program and the trunk trace routine.
TABLE II______________________________________RAM REGISTER ADDRESSESRAM Address Content______________________________________A Was a valid PIN received? (99 = Yes, 0 = No; preset to 0)B through I After determining the ESN digits and converting them to suitable format, the application program places the converted digits in these RAM registers.K through T After determining the MID digits and convert- ing them to suitable format, the application program places the converted digits in these RAM registers.U through Z The application program stores the six PIN code digits here.______________________________________
Referring again to FIG. 3, task 313 presets RAM register A to 0, RAM register B to 36, and RAM register K to 36. Then, in task 314, voice board 63 speaks a welcome message and requests the caller to enter the six digit PIN using the keypad of cellular telephone 51. Query 315 determines whether the first DTMF digit is detected within nine seconds. If the answer to query 315 is negative, the program advances to task 316 for an early hang-up sequence which comprises task 328 of hanging up the telephone line and task 329 of returning control to the voice shell.
If the first digit was received within 9 seconds, as determined in query 315, task 317 stores the received digit in RAM register U. The program proceeds to task 318 which waits for the cellular telephone to enter the second digit of his/her PIN.
Query 319 determines whether the second DTMF was detected within nine seconds. If query 319 found proper entry of the DTMF digit, task 320 stores the digit in RAM register V. Alternately, if the answer to query 319 was negative, the program advances to task 316 for the early hang-up sequence.
The routine illustrated in FIG. 3 continues in FIG. 4. Referring to FIGS. 3 and 4 collectively, the software continues to advance in this same manner of waiting nine seconds for receipt of a digit (tasks 321, 324, 337, and 340) then alternately storing the digit (tasks 323, 326, 339, 342) in a RAM register or hanging up (task 316), until all six digits are received or no digit is received within the nine second limit.
Referring now to FIG. 4 individually, if the telephone holder successfully enters all six digits, the application program proceeds to task 343. Task 343 executes the trunk trace routine. The trunk trace routine will fill RAM register A depending upon whether or not the PIN received was valid, and store the telephone's ESN and MID in RAM registers B through I and K through T, respectively.
After completion of the trunk trace routine of task 343, the applications program proceeds to task 344. In task 344, the accumulator is filled with the contents of RAM register A minus 98. RAM register A is set to 99 by the trunk trace routine (shown later in task 110, FIG. 7) if the PIN solicited by the application program matches the list of valid PINs in the agent data file (shown in Table III). If query 345 does not find the value of the accumulator to be greater than zero, then a valid PIN was not received because RAM register A was preset to 0 to indicate receipt of no valid PIN (see FIG. 3, task 313), and 98 subtracted from 0 is not greater than 0. In this case, the voice board 63 executes task 346 which informs the telephone holder that the PIN received was invalid. Then, task 347 hangs up the telephone line, task 348 ends the application program, and control is returned to the voice shell.
On the other hand, if query 345 found the accumulator to be greater than zero, indicating entry of a valid PIN, the voice board 63 performs task 349. Task 349 speaks a message to the telephone user saying, "Your ESN is". After task 349, the task 350 calls upon the subroutine that begins at card 10 (described later). The subroutine that begins at card 10 pronounces "not found" and hangs up if the trunk trace was unsuccessful, or alternately pronounces the hexadecimal digits of the telephone's ESN and returns control to task 351.
In task 351, voice board 63 speaks to the telephone user saying, "Your mobile phone number is". Then, task 352 calls the subroutine that begins with card 11 (described later) which pronounces "not found" and hangs up if the trunk trace was unsuccessful, or alternately pronounces the hexadecimal digits of the telephone's ESN and returns control to task 363.
Task 363 begins a diagnostic test of telephone 51. In task 363, voice board 63 prompts the caller to speak into telephone 51. As soon as task 363 commences, voice board 63 (in task 364) starts recording a five second audio sample from the calling telephone 51.
Query 365 determines whether or not audio from the caller was received. If query 365 answers positively, task 368 causes voice board 63 to replay the recorded sample to the calling telephone. Otherwise, the system responds to the calling telephone in task 366 with a message indicating that no audio was detected. After task 366 or task 368, task 367 passes control of the application program to the routine at card 50 (shown in FIG. 5) in order to end the application program.
Still referring to FIG. 4, the subroutine that begins card 10, which was initiated by task 350, will be discussed. Generally, the subroutine that begins at card 10 pronounces "not found" if the trunk trace routine was unsuccessful in finding the ESN, or alternately speaks the hexadecimal digits of the telephone's ESN. This portion of the application program begins in task 378 by setting the accumulator equal to the contents of RAM register B.
RAM register B has particular importance since the applications program (see FIG. 3, task 313; presets RAM register B to 36 to indicate no ESN had been found. This value remains in RAM register B unless the trunk trace is successful in finding the ESN, whereupon values corresponding to the hexadecimal digits of the ESN are stored in RAM registers B through I (shown later). These values fall in a range from decimal 20 to 35. Following task 378, then, task 379 executes the subroutine that begins at the card having a number which matches the contents of the accumulator. Therefore, task 378 can call upon subroutines that begin with cards numbered 20 through 36.
Table IV, presented below, more fully explains these subroutines. Table IV matches the actual speech that the voice board 63 pronounces to the card numbers that begin subroutines that execute such pronunciation.
TABLE IV______________________________________APPLICATION PROGRAM CARD NUMBERSCard Number Word(s) pronounced______________________________________20 zero21 one22 two23 three24 four25 five26 six27 seven28 eight29 nine30 alpha31 baker32 charlie33 delta34 echo35 foxtrot36 not found______________________________________
Referring collectively to the list of Table IV and the instructions of FIG. 4, if the accumulator's value is 36 (preset value), task 379 will execute the subroutine that begins at card 36. Appropriately, when card 36 is called, it pronounces "not found".
On the other hand, task 379 calls upon cards 20 through 35, corresponding to the ESN's first hexadecimal digit, if the trunk trace routine properly found and placed the ESN in the RAM
Referring now to FIG. 4 individually, task 380 subtracts from the contents of the accumulator. Then, task 381 compares the accumulator with 0. An accumulator value greater than 0 indicates that the trunk trace routine did not find the telephone's ESN and place it in RAM registers B thorough I, since all values of the converted numbers correspond to numbers from 20 to 35 (see Table IV). Suitably, task 382 proceeds to end the application program by calling upon the routine at card 50 (shown in FIG. 5).
But, if query 381 found the accumulator to be less than or equal to zero, the program continues by pronouncing the rest of the hexadecimal digits of the calling telephone's ESN, starting with the first character in task 383.
Task 383 places the contents of RAM register C, which corresponds to the second hexadecimal digit of the ESN, in the accumulator. Subsequently, task 384 pronounces that digit by calling the card number matching the contents of the accumulator.
Referring now to FIGS. 4 and 5 collectively, the program similarly progresses to fill the accumulator with the contents of RAM registers D through I (tasks 385, 387, 389, 391, 393, 395) and call the hexadecimal digit-pronouncing cards corresponding to the contents of the accumulator (tasks 386, 388, 390, 392, 394, 396) until the entire ESN has been pronounced to the telephone holder. After completing these tasks. Task 397 returns control to location in the main program from where the subroutine beginning at card 10 was called.
Turning now to FIG. 5, the subroutine beginning at card 11 is discussed. This subroutine functions analogously to the function of the subroutine that begins at card 10. When the subroutine that begins at card 11 is called by the application program (task 352 of FIG. 4), the subroutine pronounces "not found" if the trunk trace was unsuccessful, or alternately speaks the decimal digits of the telephone's MID.
Since the trunk trace routine (which was executed by task 343 in FIG. 4) places the telephone's MID in RAM registers K through T upon a successful trunk trace, the subroutine that begins at card 11 commences, in task 407, by filling the accumulator with the contents of RAM register K. Subsequently, task 408 calls the subroutine that begins with a card matching the number that task 407 retrieved from RAM register K.
This number may have been one corresponding to one of the subroutines that pronounce hexadecimal digits (cards 20 through 35) or the single card that pronounces "not found" (card 36). After task 408, task 409 subtracts 35 from the contents of the accumulator so that query 410 can determine whether or not the trunk trace routine successfully placed the MID into the RAM registers.
Hence, if the new accumulator contains a value greater than zero, then the contents of RAM register K are greater than or equal to 36 (the value which the trunk trace routine had preset into RAM register K), and therefore the MID was not successfully placed in the RAM registers. In this case, the program advances to task 411 which ends the application program and returns control to the voice shell by advancing to the routine at card 50.
On the other hand, if query 410 found the accumulator to be zero or less, the program proceeds to load the accumulator with the contents of RAM registers L through T (tasks 412, 414, 416, 418, 420, 422, 424, 426, and 428) and call the subroutines which start at cards having numbers corresponding to the contents of the accumulator (tasks 413, 415, 417. 419, 421, 423, 425, 427, and 429) until the entire MID has been pronounced to the telephone holder. After completing these tasks, task 430 returns control to point from where the subroutine that begins at card 11 was called.
Still referring to FIG. 5, the routing that begins at card 50 routine will be described. This routine completes the application program, and comprises several steps. First, task 440 issues an audio "thank you" message to the telephone. Next, task 441 hangs up the telephone line. Lastly, task 442 ends the application program by returning control to the voice shell.
Referring now to FIG. 1, the switch translation software resides within the cellular switch, and serves to route calls made to *ESN (or another predetermined number) through the cellular switch. The switch translation software routes these incoming calls out of the cellular switch through single member direct outward dial trunk group 56, and on to the subscriber line of computer 59.
Switch translations such as these are commonly performed in cellular telephone by persons of ordinary skill in this art. A publication that directs the construction of such switch translations (on the Motorola EMX2500 switch) is Motorola's "Fixed Network Equipment EMX2500™ Digital Standard Practices For 24 Channel Systems" (part no. 68P81055E20-A).
Referring again to FIG. 1, the trunk trace routine comprises an executable file, resident of hard disk 62 of computer 59, and the routine communicates with the application program and the cellular switch.
FIG. 6 illustrates the simplified operation of the trunk trace routine. Referring now to FIG. 6, query 474 of the trunk trace routine determines whether the PIN solicited by the application program matches an entry in records of computer 59. If the PIN is valid, task 475 sets a flag accordingly and proceeds to task 476. The application program will subsequently use this flag in determining whether or not to report the results of the trunk trace to the telephone user. Otherwise, if query 474 finds an invalid PIN, the program advances directly to task 476.
Task 476 attempts to log-in to the switch, regardless of the validity of the received PIN. If query 477 finds that the log-in was unsuccessful, task 478 gives an error message and proceeds to task 479 which returns control to the application program.
On the other hand, if query 477 finds that the log-in was successful, task 480 issues a trunk trace command to the switch. Query 481 asks whether the trunk trace was successful. If the answer is negative, task 482 gives an error message and proceeds to task 483 which returns control to the application program.
However, if query 481 determines that the trunk trace has been successful, the software proceeds to task 484. Task 484 converts the hexadecimal digits of the ESN and decimal digits of the MID found by the trunk trace into card numbers (shown in Table IV), so as to be compatible with the application program. Task 484, in addition, stores the ESN and MID in the RAM registers B through I and K through 0, respectively.
If query 485 finds that a flag was set to store the results the trunk trace, then task 487 stores the call record accordingly and proceeds to task 486 where control is returned to the application program. Otherwise, if the result of query 485 was negative, the program proceeds to return to the application program in task 486.
FIGS. 7, 8, 9, 10, 11, 12, and 13, illustrate in more detail the operation of the trunk trace routine. In addition, Table V lists the individual statements of code which make up the trunk trace routine. This code is compatible with Microsoft™ QuickBASIC version 4.0 (part no. 00618). The code listed in Table V was designed for the Motorola EMX2500, but may be reconfigured for other Motorola switches without substantial difficulty and without exerting inventive effort by any member of ordinary skill in the art.
The trunk trace routine starts after being called by the application program in task 343 of FIG. 4. Referring now to FIG. 7, the detailed operation of the trunk trace routine will be shown. The starting position of the trunk trace routine is depicted by task 99. Next, task 100 initializes various internal variables. These variables and others employed in the trunk trace routine are described in Table VI.
Next, task 101 retrieves the address of a RAM location from parameters passed by the application program. This address corresponds to the beginning of a group of 2-byte RAM registers which are used in the exchange of data between the application program and the trunk trace routine. These RAM registers are shown in more detail in Table II (above).
Previously, when the telephone holder dialed the system, the application program executed task 31 (see FIG. 3) to prompt the telephone holder for a PIN. Tasks 317, 320, 323, 326, 339 and 342 (see FIGS. 3 and 4) then stored the digits of the PIN into RAM registers U through Z. In order to obtain this number, then, the trunk trace routine performs task 102 which retrieves the PIN from the RAM registers. Proceeding to task 103, the program opens the agent data file, retrieves various communications parameters, and attempts to find a match for the PIN submitted by the telephone holder.
Table III, presented below, represents a sample of the agent data file, which contains information that the trunk trace routine uses to check the validity of the PIN and to log-in to the cellular switch.
TABLE III______________________________________AGENT DATA FILELine Number Data______________________________________line 1 PASSWORD, USERNAMEline 2 TRUNK, FFFFFFSSTTTTTTBBBBBPDXline 3 PIN, Agent Nameline 4 PIN, Agent Nameline 5 PIN, Agent Nameline 6 PIN, Agent Nameline 7 PIN, Agent Nameline 8 PIN, Agent Nameline 9 PIN, Agent Nameline 10 PIN, Agent Name..last line EOFEOF (end of file indicator)______________________________________
Referring to Table III, presented above, the agent data file will be described. The trunk trace routine retrieves, then uses the "password" and "username" of line 1 of the agent data file in order to log-in to the switch. The trunk trace routine performs a trunk trace on the circuit designated by the "trunk" variable of line 2. The character string following "trunk" in line 2 represents a series of flags and communication parameters. "FFFFFF" represents six yes/no flag positions, collectively called "VFLAG$". "SS" represents a two digit switch number and "TTTTTT" represents a type of switch. For serial port card 60, "BBBBB" represents the baud rate, "P" represents the parity setting, "D" represents the number of data bits, and "X" represents the number of stop bits.
Referring again to FIG. 7, the communications parameters, then, that the trunk trace routine retrieves in task 103 from the agent data file include the password username, trunk, various flags, and several communications parameters.
Query 104 asks whether or not the PIN submitted by the telephone holder matched any PINs located in the agent data file. If query 104 found a matching PIN in the agent data file, then task 106 sets VPIN$ to "Y" (representing that yes, a valid PIN number was in fact entered) and fills the string variable ANAME$ with the agent name from the agent data file corresponding to the matched PIN.
If query 104 searched the agent data file finding no matching PIN for the user-submitted PIN, then task 106 allows VPIN$ to remain equal to "N". But, if query 107 determines that the flag 1 of VFLAG$ is not set to require a proper PIN entry, then task 108 sets VPIN$ to "X" (representing that the trunk trace routine is indifferent to whether a telephone holder enters a correct PIN).
After task 108, after a positive answer to query 107, or after task 105, query 109 asks if an invalid PIN was submitted. If the answer to query 109 is negative, task 110 program places "99" in register A, signalling that the PIN entry is acceptable.
Next, task 111 arranges communications related data from the agent data file into parameters which will be used to communicate with the switch. These parameters are used in task 112, which configures and opens serial port 60 of computer 59 as COMI, to communicate with switch port 55. The program treats port 60 as a BASIC file.
As part of the process of opening communications with switch port 55, task 113 sends an attention character via the serial port 60. Tasks 114 and 115 solicit two responses from the switch by calling upon subroutine 1000 (described later). Basically, subroutine 1000 gathers one line of data, character by character, from switch port 55 each time it is called upon.
If query 116 finds the greater-than character (">") in the response gathered by tasks 114 and 115, then task 117 proceeds to section 500 (described later), which will confirm the log-in and execute the trunk trace command. Receipt of ">" may indicate that computer 59 is already logged in to the switch, because the switch issues ">" to prompt logged-in users.
If query 116 did not find (">") in the response, query 118 searches the response for ". . . >", which would indicate a prompt for computer 59 to log in. If query 118 finds ". . . >" in the response gathered by tasks 114 and 115 then task 119 passes control to section 300, which performs a log-in sequence. If ". . . >" was not found in the response, then an error has been detected I and task 120 sends an error message to computer screen 70 and task 121 passes control to section 2000.
Since this concludes the description of the main program portion of the trunk trace routine, the various subroutines and sections will now be described.
Turning to FIG. 8, subroutine 1000 of the trunk trace routine is shown. Each time the main program of the trunk trace routine calls subroutine 1000, it gathers one line of input from switch port 55. Task 224 clears the two variables (SWCO$ and SWLO$) used to store output from switch port 55 and marks the current time. Query 225 then determines whether or not there are any characters waiting in the input buffer for the serial port card ("input buffer"). As long as there are no characters present, and the timer has not advanced more than ten units past the prior sampling, the query 225 continues to search the input buffer for characters. When query 226 detects a timeout condition and an empty input buffer, task 227 sends an error message to computer screen 70 and task 228 returns control to the main portion of the trunk trace routine.
On the other hand, when query 225 detects one or more characters in the input buffer, task 230 sets the string variable SWCO$ equal to an input character. If query 231 finds this character to be a null character, the end of a line has been detected and task 232 returns control to the main portion of the trunk trace routine.
However, if query 231 determined that the character was not a null, task 233 appends the character to the contents of string variable SWLO$. In this way, SWLO$ collects the characters that make up an entire line of output.
If query 234 finds "password" or "username" in string variable SWLO$, task 235 returns control to the main portion of the trunk trace routine. Otherwise, task 236 resets SWCO$ to null and marks the time before extracting another character from the input buffer in task 230.
Referring to FIG. 9, section 500 of the trunk trace routine will described. This algorithm begins at query 162 by searching for the character string ". . . >", which is an indicator of an unsuccessful log-in. If query 162 finds the string ". . . >", task 163 jumps to section 300 to begin a new log-in attempt.
Alternately, if query 162 did not find the string ". . . >", task 164 issues the trunk trace command to the switch via serial port 60 and switch port 55 (shown in FIG. 1). Task 165 gathers two lines of response from the switch, one line at a time, using subroutine 900 (described later).
Query 166 then asks whether or not "<<<<" is found in the lines of response from the switch. If the answer to query 166 was negative (indicating an unsuccessful trunk trace), task 168 sends a A (control-A) abort command to serial port 60. Then, tasks 169 and 170 retrieve two lines of response from the switch to clear the contents of switch port 55. Task 171 then prints an error message to the computer screen 70, and task 172 jumps to section 2000 (described later).
However, if query 166 finds the character string "<<<<" in the response procured by subroutine 900, then the trunk trace has been successfully completed, and task 182 places six calls to subroutine 900 in order to retrieve six response lines from the switch. Task 183 then retrieves the ESN and MID of the telephone that initially dialed *ESN, from the 'sixth response line. The ESN and MID are stored in the string variables SWESN$ and SWMID$, respectively (not shown). Then, task 184 sets the variable VFND$ to "Y", indicating that the telephone's ESN and MID have been found. Next, task 185 calls subroutine 900 eleven times to clear out the buffer of switch port 55, and task 186 jumps to section 2000.
Turning to FIG. 10, section 300 will now be described. Basically, this algorithm performs a log-in sequence in order to log computer 59 in to the switch. First, task 131 sends "LOGIN" to serial port 60, in order to initiate the log-in procedure with the switch. Task 132 retrieves one line of response, using subroutine 1000. Query 133 then examines this response line for the character string "USER". The "USER" string indicates that the switch has prompted computer 59 for a "USER NAME" as part of the log-in process. If query 133 does not locate "USER" in the response line, task 142 prints an error message to computer screen 70 and then task 143 jumps to section 2000.
However, if query 133 detected "USER" in the response from the switch, task 134 sends the proper user name (previously stored in SWUSER$) to serial port 60 After tasks 135 and 136 each retrieve a response line from the switch, query 137 searches the latter response line for the character string "PASSWORD:". This would indicate that the switch has prompted computer 59 for a password during the log-in process. If query 137 finds that the response line does not contain a password prompt, task 139 sends A (control-A) to serial port 60 in order to discontinue the log-in process, task 140 prints an error message to computer screen 70, and task 140 passes control to section 2000.
On the other hand, if query 137 found the character string "PASSWORD:" in the response line from the switch, control is passed to task 153 which sends the contents of SWPASS$ (the password from the agent data file) to serial port 60. Then, tasks 154 and 155 retrieve two lines of response from the switch by calling upon subroutine 1000. If query 156 does not find the character string "LOGIN COMPLETE" in the last response line, then task 157 sends and error message to computer screen 70 and then task 158 jumps to section 2000.
Otherwise, if query 156 finds "LOGIN COMPLETE" in the response from the switch, task 160 calls subroutine 1000 to procure a line of response from the switch. Then, task 161 jumps to section 500 (described earlier).
Referring now to FIG. 11, sections 2000 and 900 will be described. Basically, section 2000 serves to print the results of the trunk trace to computer screen 70, and to report these results to the application program.
First, task 199 assembles the switch status string (SWSTAT$) with information from the variable strings VFND$, VACT$, VMEC$, VDEN$, AND VPIN$ (described in Table VI). Next, task 200 outputs the values of SWSTAT$ to computer screen 70. If query 201 determines that the trunk trace did not yield the telephone holder's ESN and MID, then task 202 jumps to section 5000 to perform record keeping tasks and return control to the voice shell.
However, if query 201 determined that the trunk trace did yield an ESN and MID, task 203 sets a first pointer to RAM register A. Task 204 advances the first pointer once and sets a second pointer to the next ESN digit to be stored in RAM. Task 205 then calls upon subroutine 3000, which converts the retrieved hexadecimal digit into another number corresponding to one of the voice cards shown in Table IV. The main portion of the application program will later use the converted number to pronounce the original hexadecimal number to the telephone holder. After completion of task 205 (subroutine 3000), task 207 stores the converted ESN character to the proper RAM register.
If query 206 determines that the last ESN character has not been processed, task 204 repeats by advancing the first pointer to the next ESN digit and incrementing the second pointer to the next RAM register. In this manner, tasks 204, 205, and 207 and query 206 repeat until all of the characters of the ESN have been converted and stored in RAM registers.
When query 206 determines that all of the ESN digits have been processed, tasks 208, 209, 210, 212 and query 211 similarly cooperate to convert the digits of the retrieved MID and store them in RAM registers.
When query 211 determines that the last MID digit has been processed, task 213 jumps to section 5000 to perform record keeping tasks and return control to the voice shell.
Still referring to FIG. 11, subroutine 900 retrieves one line of input from switch port 55. First, task 191 clears the variable SWLO$ by setting it equal to null. Then, task 192 fills this variable with a line of input from the switch. Task 193 then prints this value to computer screen 70. Having completed the line input, task 194 returns.
Referring now to FIG. 12, section 5000 will be described. This algorithm outputs the results of the trunk trace to hard disk 62 and/or line printer 69 and returns control to the application program.
Query 294 determines if the fifth flag of VFLAG$ is set to "Y" If the answer is positive, task 295 saves the results of the trunk trace (or trunk trace attempt) to a call record on hard disk 62. Then, task 296 sends the trunk trace results to computer screen 70.
If query 297 finds that the fourth flag of VFLAG$ is not set to "Y", task 298 returns control to the application program. On the other hand, if query 297 finds that the fourth flag is set equal to "Y", task 299 checks the line printer's availability, and task 301 prints the results of the trunk trace (or attempt) to line printer 69 if available.
On the other hand, if task 299 finds line printer 69 was unavailable, task 303 generates an audible beep to signal this error condition. After task 301 or task 303, task 302 returns control to the application program.
Referring now to FIG. 13, subroutine 3000 will now be described. Each time this subroutine is called by the main program, it converts a single, original hexadecimal number into another number which the application program will later use to pronounce the original hexadecimal number to the telephone holder (see Table IV). The numbers to be converted represent ESNs (which comprises hexadecimal digits from 0 to F) and MIDs (which comprise decimal digits from 0 to 9).
First, task 246 fills the string variable TC$ with the character for which conversion is to be performed. Then, tasks 247-262 attempt to match TC$ to specific hexadecimal values. If a match is found, then one of tasks 263-279 performs a specific conversion, depending upon the value of TC$. After the program finds a match and accomplishes the appropriate conversion, task 280 returns control to the point in the trunk trace routine from where subroutine 3000 was called. | A method and apparatus for an authorized user of a cellular mobile radiotelephone to easily obtain data and performance evaluation of the telephone, such as the electronic serial number (ESN), the mobile telephone number (MID), and transmitted audio information that permits evaluation of the voice modulation performance of the telephone. By calling a dedicated telephone number, an authorized operator, such as a cellular agent, can contact a computer with voice response capability, which is associated with the electronic mobile exchange (cellular switch). The computer then transmits to the agent a voice prompt requesting a password. Upon correct entry of the password, the computer initiates a trunk trace of the incoming call. The trunk trace identifies the ESN and MID for the telephone used to make the call. The computer reports that data to the calling party, via the cellular network. Having supplied the telephone user or agent with the data, the computer then prompts the agent to record a voice sample on the system for subsequent re-transmittal to the telephne. By evaluating the re-transmitted voice sample, the agent can evaluate the voice modulation capability of the telephone. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of and claims priority to U.S. patent application Ser. No. 12/194,966, filed on Aug. 20, 2008 titled DOOR ASSIST SYSTEM CONTROLLER AND METHOD which application is incorporated by reference in this application in it entirety.
FIELD OF THE INVENTION
[0002] This invention relates to a door assist system to aid a user in opening doors by providing a power assist and controls to operate the power assist. In particular, the invention relates to a door assist system adapted for use in a motor vehicle, such as an armored motor vehicle used in military operations, to aid the user in opening doors by providing a power assist and controls to operate the power assist.
BACKGROUND
[0003] To protect military personnel during combat, military vehicles are provided with layers of armor. In some vehicles, the armor may be provided on the vehicle in the factory during manufacture of the vehicle. However, it has become increasingly common for armor to be applied to existing vehicles in the field.
[0004] The military started adding armor to its High Mobility Multipurpose Wheeled Vehicle, or “HMMWV” or “Humvee” well before Operation Iraqi Freedom, but attacks from small anus, rocket-propelled grenades and “improvised explosive devices,” or IEDs in military parlance, prompted the military to increase protection for vehicles already in the field. The “up-armored” HMMWV can weigh thousands of pounds more than the standard HMMWV and includes several hundred pound steel-plated doors. Such heavy armored doors make opening and closing the doors increasingly difficult for personnel.
[0005] There is a need for a mechanism to assist with moving heavy armored doors on military vehicles. There is also a need for such mechanisms to be able to retrofit to existing vehicles that are up-armored in the field.
SUMMARY
[0006] A system for motorizing movement of at least one door of a vehicle relative to a door frame of the vehicle is provided. Vehicle power is provided by a vehicle power supply. An electric drive system is coupled at least in part to the door frame and one of the doors of the vehicle and moves the door between a closed door position and an open door position. A local power source that is different from the vehicle power supply is coupled at least in part with the electric drive system to allow for movement of the door between the closed door position and the open door position independent of the vehicle power supply. The local power source has priority over the vehicle power supply to provide power to the electric drive system when moving the door between the closed door position and the open door position. A controller is coupled at least in part with the electric drive system and is also coupled at least in part with the local power source such that the controller manages the local power source.
[0007] A method of controlling operation of a vehicle door using a door assist system is further provided. The door assist system has a motor assist and an inner door switch and an outer door switch that respectively initiate opening of the vehicle door when actuated. The motor assist is activated to move the vehicle door between an open door position and a closed door position. A desirable current supply is maintained to the motor assist when moving the vehicle door between an open door position and a closed door position. A determination that a lockout switch is engaged is made. The outer door switch is overridden in favor of the inner door switch such that the vehicle door cannot be opened via the outer door switch when the lockout switch is engaged.
[0008] In another example, a method of controlling the operation of a door of a vehicle relative to a door frame of the vehicle is provided. The position of the door is sensed and a door open command or a door close command is received. Opening or closing of the door at preselected speeds is initiated based on the command received. The length of time that the open command or close command is continuously received is then determined. The door is moved at a relatively slow speed for a predetermined initial time period and after the predetermined initial time period has ended the door is moved at a relatively faster speed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a schematic diagram of a door assist system according to one embodiment.
[0010] FIG. 2 is a plan perspective view of a door of a vehicle adapted with a door assist system according to another embodiment.
[0011] FIG. 3 is a plan perspective view of a portion of the outer side of the door of FIG. 2 .
[0012] FIG. 4 illustrates a general schematic of an exemplary rack and pinion gear.
[0013] FIGS. 5-10 are logic sequence diagrams illustrating overviews of methodologies for controlling an exemplary door assist system.
[0014] FIG. 11 illustrates an exemplary control system for a door assist system.
[0015] FIG. 12 is a schematic illustrating an example controller according to yet another embodiment.
DETAILED DESCRIPTION
[0016] A door assist system is provided that relieves vehicle occupants of having to manually maneuver a vehicle's heavily armored entry/exit doors in a rapid and safe manner. While the description below is made with reference to armored military vehicles, it should be appreciated that the systems described may be applied to other types of doors.
[0017] It should be noted that the basic system components remain the same for all four doors of the vehicle. However, because of the differences in the manner that each of the vehicle doors open (i.e. left doors open to the left, right doors to the right, front doors are geometrically different from back doors) the implementation of the door assist system on each of the four doors is slightly different. All operating modes of the system can be implemented with various and alternative mechanical implementations.
[0018] FIG. 1 illustrates a general schematic illustration of a motorized door assist system 30 for moving a door relative to a door frame of a vehicle. The door assist system 30 is designed to assist a single door, and each door in a vehicle can be equipped with a separate one of door assist system 30 . A dashed line 32 indicates a division of the recited components that are inside (below line 32 ) and outside (above line 32 ) of the vehicle.
[0019] The motorized door assist system 30 includes a drive system 34 coupled to the door and the door frame of the vehicle. As used herein, “door frame” refers to any part of the vehicle adjacent the door or door opening, including without limitation the vehicle frame or vehicle roof. The drive system 34 , when activated, moves the door between a closed door position and an open door position. The drive system 34 includes a motor and an actuator device, such as a hydraulic piston or rack and pinion gear that extends between the door and the vehicle. The activated motor in turn moves the piston or gears which causes movement of the door relative to the vehicle frame. When retrofitted to an existing vehicle, the drive system 34 desirably includes the motor and any accompanying gearing attached to an upper side of the external side of the door. The actuator device extends from the motor to the vehicle, e.g., the vehicle frame or roof. The actuator device is connected to the vehicle by, for example, a bracket and clevis pin. In another embodiment, the motor is mounted on the vehicle and the actuator device extends from the motor to the door. As will be appreciated by those skilled in the art following the teachings herein provided, various and alternative configurations are available for the drive system, and components thereof, depending on, for example, the design of the vehicle.
[0020] The drive system 34 may selectively include a manual override actuator, illustrated in FIG. 1 as a manual override lever 36 . The manual override lever 36 is located on the top inside of the door and is connected with the external drive system 34 . Actuating (e.g., pulling or rotating) the lever disengages the drive system, e.g., disengages the drive system actuator from the drive motor or disengages a mechanical gear train of a motor/gear drive system, and allows the occupant to manually open and close the door.
[0021] A controller 40 is electrically connected to the drive system 34 . The controller 40 is the brain of the door assist system 30 , and can include a circuit board and memory component. All system stimuli (i.e., switches, sensors, power, etc.) are desirably fed to the controller 40 . Based on the values read from the various inputs discussed below, the controller 40 may or may not take action. For instance, should the door be closed and the controller 40 receives a signal to open the door, the controller 40 will supply power to the drive system 34 to open the door. The controller 40 monitors the various inputs to determine when to stop supplying power to the drive system 34 . In another example, if the controller 40 receives a signal to open the door, but is also receiving a signal input that the door is at maximum open, the controller 40 will not provide power to the drive system 34 .
[0022] The door assist system 30 may contain a separate rechargeable electrical power supply, such as local battery 42 , at each door, in combination with each controller 40 . In another embodiment, the local battery 42 and controller 40 can be mounted onto or integrated with the vehicle itself. No user interaction is required regarding the battery 42 during operations. The battery 42 or controller 40 can include a battery power level indicator, such as an LED panel, to indicate the remaining power supply. In the embodiment of FIG. 1 , the controller 40 is connected to or includes a battery charger 44 to recharge the battery from the vehicle's power system. The condition upon the battery 42 being recharged can vary. For example, the battery 42 can be recharged whenever the vehicle is in operation (i.e., when the alternator is in operation), every time the local battery 42 is used or cycled (e.g., the battery is recharged to full power after every door opening or closing), upon reaching a predetermined power level, or upon complete discharge. A trickle charge can be used to charge the battery 42 when the vehicle is of and if the battery 42 is in danger of being depleted. In one embodiment, the charge from the vehicle battery is dependent upon the vehicle battery having a sufficient, predetermined charge, so that the system does not deplete the vehicle battery and render the vehicle inoperable.
[0023] As will be appreciated by those skilled in the art following the teachings herein provided, various and alternative powering schemes can be used to power the door assist system. For example, in other embodiments, the door assist system 30 may pull primary power from the vehicle battery, and use the local battery 42 as a back-up power source.
[0024] The door assist system 30 includes an external close switch 46 mounted to an external side of the door, or otherwise outside the vehicle, and in communication with the controller 40 . When activated, the external close switch 46 signals the controller 40 to move the door toward the closed door position. In the example seen in FIG. 1 , the external close switch 46 is integrated in the same housing as the controller 40 , and is embodied as a button on the side of the housing of the controller 40 . The external close switch 46 , as with other switches of this invention, is not limited to any particular type of switch, and can be, for example, a spring loaded toggle switch.
[0025] The door assist system 30 further includes an internal close switch 50 mounted to an internal side of the door, or otherwise inside the vehicle, and in communication with the controller 40 . When activated, the internal close switch signals the controller 40 to move the door toward the closed door position. In the example seen in FIG. 1 , the internal close switch 50 is integrated with a junction box 52 , and is shown as a button on the side of the junction box 52 .
[0026] The junction box 52 is located on the inside of the vehicle, desirably approximately in the middle of the door. The junction box 52 desirably serves as a gathering point for the cabling from internal components. The junction box 52 also houses a door stop switch 54 . When the door stop switch 54 is depressed it deactivates any opening or closing operation, and will optionally open a stopped dosing door a moderate amount, such as to allow any obstruction to be removed. When the door stop switch 54 is released, no further movement will take place. If desired, the occupant must initiate a new door opening or closing action.
[0027] The door assist system 30 includes a door open sensor 58 in combination with the controller 40 and the door latch mechanism 60 . As shown in the example of FIG. 1 , the door latch mechanism 60 includes an internal latch actuator 62 and an external latch actuator 64 . In one embodiment, the door open sensor 58 is a magnetically activated switch, e.g., a Hall Effect sensor, that is triggered by the movement of a magnet embedded in the door latch mechanism 60 . When the door latch mechanism 60 is activated to open the door, the portion of the mechanism containing the embedded magnet is moved closer to the door open sensor 58 , activating the sensor. When the door latch mechanism 60 is released the embedded magnet will be moved away from the door open sensor, deactivating the door open sensor 58 . In up-armored M1114 HMMWV, a multi-point locking system is commonly employed. The latch actuators 62 and 64 are connected to a vertical component 65 connecting an upper and lower latching point. In such a latch mechanism, the magnet can be attached to the vertical component 65 , which moves vertically toward the door open sensor 58 upon actuation of either of actuators 62 and 64 .
[0028] A door position sensor 66 is mounted on the inside of the vehicle close to the door hinge. The door position sensor 66 is mounted so that one end or part of the sensor 66 is attached to the door assembly while the other end or part is attached to the door frame. The door position sensor 66 detects movement and position of the door and relays this information to the controller 40 , via junction box 52 in the example seen in FIG. 1 . In one embodiment, the door position sensor 66 includes a Hall Effect sensor. The controller 40 uses the provided information to determine the position of the door.
[0029] In one embodiment, the door assist system 30 includes a safety switch 68 . The safety switch 68 activates should the door assist system 30 be closing the door and any part of the switch 68 is depressed. When depressed the switch 68 will cause the door assist system 30 to immediately cease closing the door and, optionally, will moderately open the door. This safety mechanism is intended to prevent door closures while obstructions remain between the door and the door frame. The safety switch 68 can include one or more sensors strategically placed around at least portions of the outside perimeter of the door. In one embodiment, the safety switch 68 includes a multi-segmented, large surface area, single pole switch that is located around at least portions of the inside perimeter of the door.
[0030] As discussed above, military vehicles are often up-armored in the field, and a retrofit kit is contemplated for the door assist system provided herein. FIGS. 2 and 3 generally illustrate a representative HMMWV door 120 (not to scale or shown in full detailed) retrofitted with a door assist system 130 . The door 120 includes a door latch mechanism 160 coupled to the door. The door latch mechanism 160 includes an internal door latch actuator 162 . The door 120 is connected to a vehicle frame, generally illustrated as frame 122 , by a hinge (not shown).
[0031] In the embodiment shown in FIG. 2 , a drive system 134 is a hydraulic motor. The hydraulic motor includes a hydraulic piston 135 having a first end attached to the door 120 and a second end attached to the door frame 122 . As discussed above, alternative drive systems are available, such as linear actuators, pneumatic drive systems (either dynamic using an air source or static through a pressure cylinder), and geared drive systems, such as the rack and pinion drive system 134 shown in FIG. 4 .
[0032] The drive system 134 , a control box for controller 140 , and local electrical power supply (not shown) can be attached to the external side of the door by various means, such as, without limitation a welded or bolted on attachment plate. Desirably, the external components of the system are covered to protect them from battlefield damage. As shown in FIG. 3 , the control box for controller 140 includes a button operated external close switch 146 for initiating the closing of the door 120 from outside of the vehicle.
[0033] Referring back to FIG. 2 , a junction box 152 includes an internal close switch 150 and a door stop switch 154 . The junction box 152 is electrically connected to the controller 140 , as well as door position sensor 166 , vehicle battery 128 , and a safety switch 168 by electrical connectors 126 . The connector 126 extending between the controller 140 and the junction box 152 extends through an opening 125 in the door. It is generally preferred to limit the amount of holes drilled through the door 120 , so as to not compromise the armor applied to the door 120 .
[0034] The safety switch 168 extends around the inside perimeter of the door 120 . The safety switch 168 is a multi-segmented single pole switch. Sensor segments 17 Q of the safety switch 168 are strategically placed depending on need in areas where obstructions to the door closing likely will occur. The sensor segments 170 are connected to electrical connections (e.g., wires or cables) 172 . The segments 170 and the connectors 172 can be secured to the door 120 by any suitable means, such as adhesives or clips. When the door is closing and any one of the segments 170 are contacted, the safety switch 168 sends a door stop signal to the controller 140 to stop the dosing motion to allow the obstruction to be removed.
[0035] FIG. 3 shows a portion of the external side of the door. A door open sensor 158 is connected to the controller 140 for detecting whether the door latch mechanism 160 is in a latched state or an unlatched state. A magnet 159 is bolted to a vertical component 166 of the latch mechanism 160 . As discussed above, when the latch mechanism 160 is activated to open the door, the magnet 159 is moved closer to the door open sensor 158 , which signals the controller 140 to activate the drive system 134 to open the door 120 .
[0036] FIGS. 5-10 are flow charts illustrating the operation of an exemplary door assist system as described above in FIGS. 1-3 . Referring to FIG. 5 , to open the door from the inside, the vehicle occupant simply pulls back on the internal latch actuator. The door will immediately begin to open by the drive system. Should the occupant quickly release the internal latch actuator, the door will cease opening immediately. Should the occupant after initial pull back on the internal latch actuator maintain that position for a predetermined time, such as a minimum of 2 seconds, the door will be opened fully by the door assist system regardless of whether or not the occupant continues to pull back on the internal latch actuator. In one embodiment, the occupant can determine when the door assist system has achieved the “Auto” mode by a noticeable speed up of the door opening. The predetermined times may be user-programmable, such as in the field and/or at installation, depending on need.
[0037] Referring to FIG. 6 , to open the door from the outside, the occupant simply pulls back on the external latch actuator. The door will immediately begin to open. Should the occupant quickly release the external latch actuator, the door opening will cease immediately. Should the occupant after initial pull back on the external latch actuator maintain that position for a predetermined, and optionally user-programmable, time, such as a minimum of 2 seconds, the door will be opened fully by the door assist system regardless of whether or not the occupant continues to pull back on the external latch actuator. Again, the occupant can determine when the door assist system has achieved “Auto” mode by a noticeable speed up of the door opening.
[0038] Referring to FIG. 7 , to close and latch the door from the inside of the vehicle, the occupant simply presses the internal close switch button (located on the side of the junction box in FIGS. 1-3 ). The door will immediately begin closing. Should the occupant quickly release the close switch, the door will cease closing. If after initial depression of the internal close switch, the occupant continues to depress the internal close switch for a predetermined, and optionally programmable, time, such as a minimum of 2 seconds, the door will automatically fully close regardless of whether or not the occupant continues to depress the internal close switch. The occupant can detect when the door closing has entered into the “Auto” mode by the noticeable speed increase of the door closing.
[0039] Referring to FIG. 8 , to close and latch the door from the outside of the vehicle, the occupant simply presses the external close switch button located on the side of the control box located at the top of the door. The door will immediately begin closing. Should the occupant quickly release the switch, the door will cease closing. If after initial depression of the external close switch button, the occupant continues to depress the external close switch for a predetermined, and optionally user-programmable, time, such as a minimum of 2 seconds the door will automatically fully close regardless of whether or not the occupant continues to depress the external close switch button. The occupant can detect when the door closing has entered into the “Auto” mode by the noticeable speed increase of the door closing.
[0040] Referring to FIG. 9 , to open the door from the inside without the use of the door assist system, the occupant must first disengage the drive system by actuating (e.g., pulling or rotating) the manual override actuator located at the top inside of the door. Once the manual override has been activated, the occupant must pull on the internal actuator and manually push the door open. The door assist system may supply power to the drive system once the latch actuator is pulled, if the battery is charged, but the drive system will not operate due to the manual override. Manually closing the door from the inside also requires the disengagement of the drive system.
[0041] Referring to FIG. 10 , to open or close the door from the outside without the use of the door assist system, the drive system must be removed from the vehicle frame. For example, where the drive system is attached to the vehicle from by a Clovis pin, the Clevis pin can simply be removed. The occupant must pull on the external latch actuator to pull the door open.
[0042] The door assist system may be programmed to stop at a predetermined open position for the convenience of the occupant. In one embodiment, to program the door open position, the door must first be in the fully opened position. To do this the occupant should pull on either the internal or external latch actuator. The occupant must disengage the drive system by pulling on the manual override actuator located at the top inside of the door. The occupant then manually positions the door to the desired opening. Once the door is positioned to the desired maximum opening, the occupant pulls on and holds either the internal or external latch actuator for a minimum of 30 seconds. The occupant releases the latch actuator and reengages the drive system by releasing the manual override actuator. The door may now be operated normally. When opened, it will not open beyond the programmed maximum value. Should the occupant desire to change the maximum door opening, the procedure will need to be repeated.
[0043] The door assist system is desirably designed such that the battery for each door can support approximately 50 full openings or closings on a full charge. Exact capacity may vary due to battery life, temperature, and increased or decreased door loads. In one embodiment, the door assist system desirably does not draw power from the vehicle when the vehicle is not running. The door assist system batteries will only recharge once the engine of the vehicle is operational and its alternator output is, for example, greater than 27 volts. This is intended to prevent excessive door closures and openings from rendering a vehicle inoperative due to a discharged vehicle battery or batteries.
[0044] FIG. 11 illustrates a further embodiment of a control system for the door assist system. The vehicle illustrated in FIG. 11 is a two-door vehicle, such as Mine Resistant Ambush Protected (MRAP) vehicles, but the control system can be similarly applied and adapted for a four-door vehicle. In FIG. 11 , control system 230 includes a vehicle mounted internal switch box 232 . The switch box 232 , for example, may be centrally located between the two doors, such as on the dash or above the windshield. The switch box 232 includes two internal open/close switches 234 , one for each of two doors representatively shown in phantom. In the embodiment of FIG. 11 , each switch 234 has at least two positions, one for opening the corresponding door and the other for closing the corresponding door. In one embodiment, the switch box 232 can optionally include two additional lockout switches that, when activated, disable the corresponding external open/close switch 250 (i.e., the driver side lockout switch disables the driver side external open/close switch 250 , and the passenger side lockout switch disables the passenger side external open/close switch 250 ). These lockout switches desirably do not disable the interior internal open/close switches 234 , and are used to keep unwanted third parties from being able to open the door from the outside when an operator is inside.
[0045] The internal open/close switches 234 each communicate with a corresponding controller 240 . Each controller 240 is in communication with a corresponding drive system (not shown) as discussed above, and can be powered by a local battery 242 . A door stop switch 244 and a multi-segment sensor safety switch 246 for each door communicate with the corresponding controller 240 . The door stop switch 244 is a particularly beneficial safety feature in embodiments where the switches are simply actuated and stay in the actuated position without requiring the operator to hold the switch in the actuated position. In another embodiment, the switch must be maintained in the actuated position by the operator, or the switch will return to a non-actuated position and stop the movement of the door.
[0046] A notable difference in this embodiment is that the external open/close switch 250 is routed through the switch box 232 . In one embodiment, where the vehicle has additional armor added, and the armor prevents the operator from reaching the external switch 250 , an extension switch 250 ′ can be added to connect to the original switch 250 . In another embodiment, the external open/close switch may be integrated with the existing vehicle door handle or latch mechanism, without the need for a further added switch.
[0047] As described, the example door assist systems preferably include a controller (e.g., controllers 40 , 140 , 240 ) for controlling a motor assist, i.e., any system components that provide mechanical, electrical, hydraulic and/or pneumatic assistance, in actuating a door to move between an open position and closed position. The motor assist employed may be activated by the controller to actuate the door and may or may not necessarily include a motor. According to such embodiments as described, the controller operates in connection with an outer door switch (e.g., external close switch 46 / 146 , door open sensor 58 / 158 , external open/close switch 250 , or other suitable means) and an inner door switch (e.g., internal door switch 50 / 150 , internal open/close switch 234 , or other suitable means). FIG. 12 schematically illustrates a representative controller 260 according to one example embodiment. It is contemplated that controllers 40 , 140 , and 240 will operate in a similar manner as controller 260 , described hereinafter, however, each controller 40 , 140 , 240 may include more, less or variations of features to those described, depending on need and the design of the vehicle and/or door assist system.
[0048] As shown schematically in FIG. 12 , controller 260 , in this example, includes one or more circuits 310 , 320 , 330 , 340 , 350 , 360 for operation and control of the door 300 . As used herein, “circuit” refers to a complete wired or wireless communications channel for effecting a result between controller 260 and one or more additional components of the door assist system described herein.
[0049] In this embodiment, controller 260 includes charging circuit 310 for maintaining a desirable power level in a power supply. In this embodiment, the power supply may comprise local battery 428 connected between the motor 420 and the charging circuit 310 , wherein the local battery 428 is further connected to a primary energy supply, such as a vehicle battery 400 , desirably through the charging circuit 310 . The charging circuit 310 may further selectively draw power from the vehicle battery 400 to ensure that the vehicle battery 400 is not drained by charging the local battery 428 .
[0050] As further shown in FIG. 12 , controller 260 , in this example, includes a detection circuit 320 for stopping the motor 420 if movement of the door 300 is obstructed. For example, if the door 300 moves into a position where it is blocked by an obstacle for a preset period of time, then detection circuit 320 provides a signal to motor 420 to discontinue further motion and/or cut power to motor 420 . Following deactivation of the motor 420 , a user can either manually operate the door 120 or reverse the door under power assist.
[0051] Controller 260 may additionally include a cessation circuit 330 for stopping the motor 420 if door operation exceeds a maximum time threshold. For example, cessation circuit 330 may be operable to provide a signal to motor 420 to discontinue further motion and/or cut power to motor 420 should door operation exceed a preset time threshold, such as a time required to reach a desirable opening threshold of the door 300 .
[0052] Controller 260 may additionally include a position circuit 340 for determining a relative position of the door 300 . To facilitate operation of position circuit 340 as described, controller 240 may be connected relative to a door position sensor 366 connected with respect to the position circuit 340 , as shown schematically in FIG. 12 . Position circuit 340 is preferably utilized to set and maintain presets for door operation. That is, a user may program a desired position for the door 300 to arrive at a fully opened position.
[0053] In addition, controller 260 may further include an override circuit 350 permitting the inner door switch, or a dedicated lockout switch as described above, to override the outer door switch. Such operation may be particularly desirable in an emergency scenario whereby users inside the vehicle seek to prevent operation of the door 300 by a person or persons outside of the vehicle.
[0054] As briefly described above, controller 260 communicates with respect to one or more safety systems that are positioned in association with the door 120 . Accordingly, controller 260 may further include a safety circuit 360 for actuating or stopping the door following an emergency input. A safety switch, such as safety switch 246 described above, for example, may be connected or positioned along or relative to the door and electrically connected with respect to the safety circuit 360 . In addition, controller 260 may include a sleep mode wherein the controller 260 will only draw a minimal amount of power when the door is not being activated.
[0055] As shown schematically in FIG. 12 , the controller 260 may further include a status display 380 indicating at least one of battery capacity, battery charging, safety switch activation, door switch activation and door position. The status display 380 may comprise indicator LEDs, an external display, an integrated LCD display and/or any other suitable status display for conveying at least the listed information. Status display 380 is preferably multifunctional and may further be used as a debugging tool for the motorized door assist system. The status display 380 may indicate a battery capacity, particularly while the door is moving. For example, a series of bars may be lit to represent the battery capacity remaining and/or exhausted. The status display 380 may indicate battery charging status. For example, a series of upwardly cascading lights may represent charging status. The status display 380 may indicate safety switch operation; for example, one or more lights may flash rapidly. The status display 380 may indicate a door open or door closed condition. For instance, the lights may flash in a predetermined manner. In addition, the status display 380 may confirm programming steps. For instance, following programming of a preferred door stop increment, the lights may go blank for a predetermined amount of time and then reilluminate.
[0056] As described above, the door assist system may include programmable options for inputting one or more position presets of the door 30 . According to this embodiment, the controller 260 may include a memory for retaining one or more trainable stops of the door. The memory may comprise a fixed internal memory, an external memory, a replaceable magnetic memory device such as a diskette, a memory stick or a compact flash card and/or any other suitable memory for retaining such programmable options with the door assist system.
[0057] An external programmer may be used to program various features of controller 260 . Such features may include: a maximum forward speed; a maximum reverse speed; a minimum speed; a maximum forward acceleration; a maximum reverse acceleration; a maximum acceleration during direction change; a maximum reverse deceleration; a maximum deceleration during direction change; a motor compensation value; and/or an “indoor” mode for a second mode of operation. Additional programmable features may include: scaling for throttle types and values; deadband value around throttle neutral; failband above and below throttle maximum and minimum; setting for a non-linear throttle response; compensation values for load conditions; timing for application of mechanical brake; deceleration parameter for quickstep using key or switch; compensation value for power wire resistance; power down period for controller inactivity; lower current limit bound; upper current limit bound; and delay time before controller 260 drops from the upper current limit to the lower current limit.
[0058] The external programmer, for example, may be connected with respect to the controller 260 to permit programming of various functions and features described herein. In addition, various functions and/or presets such as door position presets may selectively be programmed by the user without use of the external programmer and yet such functions and/or presets may be retained by the controller 260 . To facilitate such programming at least one of the outer door switch and the inner door switch may be connected with respect to the controller 260 to permit actuation of such switch to establish the presets. In operation, a user may open and hold the outer door switch and/or the inner door switch to set a door position preset to a desired position.
[0059] As described, a method of operation of the controller 260 for actuating a door having a motor assist and an outer door switch and an inner door switch includes one or more of the following steps. As an initial matter, a user engages a switch, latch, or similarly described means for activating the motor assist. The controller 260 thereafter maintains a desirable current supply to the motor assist; determines a relative position of the door; determines whether movement of the door is obstructed; actuates the door to an appropriate position; determines whether door operation exceeds a maximum time threshold; and/or deactivates the motor assist once the door reaches the appropriate position or the door operation exceeds the maximum time threshold.
[0060] In addition, a lockout switch may be connected relative to the controller to override the outer door switch in favor of the inner door switch. The motor assist may be activated in response to a manual activation of an inside door handle. Additionally, should a safety switch be activated, the door may be reversed to a closed position or, preferably, a preset amount. Such reversal permits the safety hazard to be cleared and normal operation of the door may be resumed.
[0061] The outer door switch may be activated for a preset period of time thereby activating the motor assist until the door is in a fully open or fully closed position. More particularly, the controller 240 may sense a current position of the door and subsequently move the door to a position opposite the current position.
[0062] In another example, the controller 240 , 260 may determine a load required to move the door by sensing a current required to move the door. In doing so, the controller 240 , 260 may determine an approximate weight of the door during ordinary operation, that is, during operation under normal load conditions on a level surface. Such ordinary operation may determine a baseline or nominal load required to move the door. If subsequent operation requires an adjustment in the desired current for operation of the door, the controller 240 , 260 will deliver power to the door in a controlled manner to open or close the door in a controlled manner. As such, if the current is outside of a nominal threshold required to move the door, the controller 240 , 260 will not permit the door to quickly open or “fling” open if on a downhill side or to open slowly if on an uphill side. Such operation results in safe operation in that it permits an operator an expected response to an open or close activation.
[0063] The invention illustratively disclosed herein suitably may be practiced in the absence of any element, part, step, component, or ingredient which is not specifically disclosed herein.
[0064] While in the foregoing detailed description this invention has been described in relation to certain preferred embodiments thereof, and many details have been set forth for purposes of illustration, it will be apparent to those skilled in the art that the invention is susceptible to additional embodiments and that certain of the details described herein can be varied considerably without departing from the basic principles of the invention. | A method of controlling the operation of a door of a vehicle relative to a door frame of the vehicle is provided. The position of the door is sensed and a door open command or a door close command is received. Opening or closing of the door at preselected speeds is initiated based on the command received. The length of time that the open command or close command is continuously received is then determined. The door is moved at a relatively slow speed for a predetermined initial time period and after the predetermined initial time period has ended the door is moved at a relatively faster speed. | 7 |
The present application claims the benefit under Title 35, U.S.C. §119(e) of U.S. provisional application Ser. No. 60/013,946, filed Mar. 22, 1996.
The present invention relates to refrigerants generally, and more specifically to a mixture of refrigerants that may be substituted for 1,1,1,2-tetrafluoroethane (R-134a) refrigerant.
BACKGROUND OF THE INVENTION
In order to provide a more compact format for identifying mixtures of refrigerants in the following discussions, mixtures of refrigerants will be listed in the form of:
R-ABC/DEF/GHI N0/N1/N2
which represents a mixture of refrigerants (fluids) R-ABC, R-DEF, and R-GHI where N0, N1, and N2 are the weight percentages of each component refrigerant fluid, and N0+N1+N2=100 percent; or in the form of:
R-ABC/DEF/GHI N0--N0'/N1--N1'/N2--N2'
which is similar, but specifies ranges of the weight percentages each of the component refrigerant fluids, with the total of the weight percentages being 100 percent.
Zeotropic (nonazeotropic) mixtures of refrigerants will change composition if they are allowed to leak as vapor phase from a container containing all components of the refrigerant mixture in both vapor and liquid phases. Single component and azeotropic mixtures of refrigerants do not change composition appreciably from vapor leakage. Single component and azeotropic mixtures of refrigerants have only one boiling point temperature for a given pressure, provided the refrigerant exists as both liquid and vapor states in the container. Zeotropic mixtures of refrigerants will boil over a range of temperatures at a given pressure. As the temperature is raised, the point at which the first bubbles appear (constant pressure) in the liquid is known as the "bubble point," which is roughly analogous to the boiling point of a single component or an azeotropic mixture. Starting in a vapor phase and lowering the temperature (at a constant pressure) to the point where the first droplet of liquid forms defines what is known as the "dew point" of the mixture of refrigerants. The difference between the bubble point temperature and the dew point temperature is known as the temperature "glide". A pressure gauge connected to a cylinder containing a zeotropic mixture of refrigerants will read the bubble point pressure for the corresponding temperature of the refrigerant mixture.
Under the Montreal Protocol, as amended, United States laws (1990 Clean Air Act), and U.S. Environmental Protection Agency rules, the production and importing of dichlorodifluoromethane (CFC-12 or R-12) refrigerant ended on Dec. 31, 1995. Additionally, only 15% of the 1989 baseline amounts of chlorinated fluorocarbons (CFCs) was allowed to be produced or imported into the U.S. during the year 1995, adjusted on an ozone depletion factor basis. R-12 was the major share of that production.
With the effective date of the ban on U.S. R-12 production and importing having passed (Dec. 31, 1995), one industry option has been to retrofit R-12 refrigeration or air conditioning systems, both stationary and automotive, to R-134a (tetrafluoroethane). The mineral oils used in R-12 systems are completely immiscible in R-134a. The industry has therefore developed new oils, which are either polyalkylene glycol (PAG) based (for automotive) or polyol ester (POE) based (stationary refrigeration and some automotive retrofit).
While PAG oils are good lubricants, and are miscible in R-134a at typical evaporator temperatures, they have two main problems. First, most PAG oils cannot tolerate even minute traces of residual chlorides that remain in the R-12 refrigeration or air conditioning systems that have been purged of R-12. These chlorides are dissolved in the small amount of mineral oils which cannot be flushed out or are in coatings on the inside of aluminum piping (aluminum chloride from previous R-12) or are dissolved in rubber hoses. The presence of chlorides greatly accelerates the breakdown of most PAG oils.
It has been reported in the literature that test systems that were flushed with R-11 (trichlorofluoromethane) and then retrofitted to PAG oil and R-134a, sustained catastrophic compressor failures within one week due to oil breakdown. R-11 has a greater affect on PAG oil breakdown than does R-12. It was common practice in the automotive air conditioning service industry, into the early 1990s, to flush R-12 systems with R-11 to remove contaminates. The traces of R-11 remaining do not interfere with R-12 operation, but could cause premature failures if R-12 systems are ever retrofitted to R-134a and PAG oils.
Compressors manufactured for R-12 and mineral oil use were often constructed with a paraffin based wax coating on the motor windings as an aid to building the motor without breaking the wire during the motor winding phase of the construction. When retrofitted to R-134a and POE oils, the paraffin would sometimes come off the windings, and not dissolve in the R-134a refrigerant and POE oils, and circulate through the system as solids and plug up the refrigerant metering device, usually a capillary tube, causing the system to fail. R-12 (or a substitute with adequate mineral oil miscibility) and mineral oil just dissolve the pieces of paraffin wax that come off the motor windings and therefore do not clog the refrigerant metering device.
Finally, the low critical temperature of R-134a (214.07 degrees Fahrenheit) verses the critical temperature of R-12 (233.26 degrees Fahrenheit) can cause abnormally high head pressures in hot ambient conditions in systems designed for R-12. For automotive applications, stopped traffic or hot climates can cause a reduction in R-134a performance. Systems designed for R-134a often increase the size of the condenser about 50 percent over the size similarly designed R-12 system condenser. Stationary systems, such as vending machines, now retrofitted to R-134a, may see high head pressure and low performance problems when the condenser becomes slightly fouled by dirt and dust. R-12 systems can run much longer between cleanings to remove dust and dirt from the condenser than similar systems converted to R-134a.
R-406A is a known ternary mixture of refrigerants, consisting of isobutane (R-600a), chlorodifluoroethane (R-142b), and chlorodifluoromethane (R-22), that provides a "drop-in" substitute for dichlorodifluoromethane (R-12) refrigerant. R-406A is described in U.S. Pat. Nos. 5,151,207 and 5,214,929, the disclosures of which are incorporated herein by reference.
If one must convert an existing R-12 refrigeration or air conditioning system to another refrigerant due to the Montreal Protocol mandated phaseout of R-12 refrigerant, it is usually far preferable to use a refrigerant mixture with adequate miscibility with mineral oils used by R-12 systems, such as R-406A (R-600a/142b/22 4/41/55) or GHG-X4 (R-600a/124/142b/22 4/28.5/16.5/51) than to attempt to retrofit to R-134a. However, one may have followed the industry recommended choice and already retrofitted said systems to R-134a or purchased a new system that was manufactured for R-134a refrigerant, using lubricants that are miscible with R-134a such as POE or PAG oils.
To date, the oils used in new or retrofitted R-134a refrigeration and air conditioning systems (PAG and some POE) are adversely affected by chlorinated refrigerants (HCFCs), with the PAG oils being affected more than the POE oils. Once installed in a refrigeration or air conditioning system, PAG or POE oils are virtually impossible to completely remove from a system, especially from the compressor. If said systems where then recharged with chlorine containing refrigerants, such as R-406A or GHG-X4 and R-12 compatible mineral oils, some amount of the PAG or POE oils would remain and would be destroyed, creating contamination and system failures. A better performing refrigerant is needed that can be "drop-in" substituted for R-134a in R-134a refrigeration and air conditioning systems, and that is also compatible with oils used by R-134a refrigeration and air conditioning systems.
There are a few existing refrigerants that can be "drop-in" substituted for R-134a in R-134a refrigeration and airconditioning systems, such as OZ-12, HC-12a, and ES-12r. However, these mixtures are composed entirely of hydrocarbons (typically R-600a/290 40/60) and are extremely flammable. Hydocarbon mixtures are outlawed in many states and by US EPA as "unacceptable" for use as a replacement for R-12 in all but a few specialized uses. These hydrocarbon refrigerants contain no chlorinated compounds, so they do not destroy oils used in R-134a systems.
SUMMARY OF THE INVENTION
In summary, I have discovered a group of refrigerant fluids, which are listed in Table 1, that may be combined in novel ways to produce several excellent "drop-in" substitutes for R-134a refrigerant. Performance is increased by constructing a zeotropic mixture of refrigerants, such that a single boiling point (of R-134a) is replaced by a "temperature glide" between the mixture's "bubble point" and "dew point". The temperature glide causes the phase change area in the condenser to be larger than with a single component refrigerant such as R-134a, thereby increasing heat rejection of the condenser, which lowers head pressures, and increases capacities and efficiencies compared to R-134a. Components are also selected to attempt to reduce the overall critical temperature of the mixture of refrigerants, also increasing performance and lowering head pressures under hot conditions with undersized condensers. Finally, a small amount of a mineral oil miscibility improver may be added, not to return mineral oil from the evaporator as in R-12 systems, but to keep waxes, tars, and other contaminates in the system that may have arisen from the manufacturing process (such as wax coatings on the motor windings in a hermetic compressor, or "tar" from valve packing) soluble. In R-12 mineral oil systems, these contaminates readily dissolve in mineral oils, causing no problems. In R-134a systems, the waxes and tars may not be soluble in POE or PAG oils and may turn into solids, and plug up the refrigerant metering device. The addition of a very small amount of a mineral oil miscibility improver prevents these contaminates from becoming solid and plugging the system.
One embodiment of the present invention is the creation of "drop-in" substitutes for R-134a from novel mixtures of components from Table 1.
It is also an object of the present invention to provide a "drop-in" refrigerant substitute for R-134a that provides an acceptable level of cooling in low, medium, and high temperature applications where R-134a is now in use.
It is also an object of the present invention to provide a "drop-in" refrigerant substitute for R-134a that keeps a small amount of system contaminates, such as tars and waxes, soluble in the refrigerant/lubricant mixture, so said contaminates do not plug small openings, such as refrigerant metering devices
It is also an object of the present invention to provide a "drop-in" substitute refrigerant for R-134a that causes very little global warming damage.
It is also an object of the present invention to provide a "drop-in" substitute refrigerant for R-134a that causes zero stratospheric ozone damage.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments described below and specific language will be used to describe the same. It will neverless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the described embodiments, and such further applications of the principles of the invention as described therein being contemplated as would normally occur to one skilled in the art to which this invention relates.
Boiling points (BP), and critical temperatures (Crit) in Table 1 are in degrees Fahrenheit and are taken from the November 1993 "NIST Database 23: NIST REFPROP v4.0", available from U.S. Department of Commerce, Technology Administration, National Institute of Standards and Technology (NIST), Standard Reference Data Program, Gaithersburg Md. 20899, and the "January 1996 ARTI Refrigerant Database", available from Engineering Consultant, 10887 Woodleaf Lane, Great Falls Va. 22066-3003. Molecular weights (MW) are taken from the same sources.
TABLE 1__________________________________________________________________________R-numFormula Name BP Crit MW__________________________________________________________________________R-227eaCF3CHFCF3 1,1,1,2,3,3,3- 2.5 215.37 170.0 heptafluoropropane*R-134aCF3-CH2F 1,1,1,2-tetrafluoroethane -15.07 214.07 102.0R-143aCF3-CH3 1,1,1-trifluoroethane -53.23 163.58 84.04R-125C2HF5 pentafluoroethane -55.43 151.12 120.0R-E125CFH2-O-CF3 difluoromethyltri- -41.9 176.7 136.0 fluoromethyl etherR-E143aCH3-O-CF3 methyl trifluoromethyl ether -10.8 220.8 100.04R- CHF2-CF2-O- 1-(trifluoromethoxy)- 26.3 186.0 238.3E227ca2CF3 1,1,2,2-tetrafluoroethaneR-245cbCH3-CF2-CF3 1,1,1,2,2-pentafluoropropane 0.3 224.5 134.0R-600aC(CH3)3 isobutane 10.83 274.46 58.12R-290C3H8 propane -43.75 206.06 44.10R-E170CH3-O-CH3 dimethyl ether(DME) -12.7 263.8 46.07R-1270CH3CH = CH2 propylene -53.8 198.4 42.07R-1216CF2 = CFCF3 hexafluoropropene -20.2 unknown 150.0R-218C3F8 perfluoropropane -34.15 161.4 188.0R-C318C4F8 octafluorocyclobutane 19.42 239.6 200.4R-C270C3H6 cyclopropane -27.2 256.3 42.1R-152aCH3CHF2 1,1-difluoroethane -12.37 236.39 66.05R-600C4H10 n-butane 31.03 305.62 58.12R-32 CH2F2 difluoromethane -61.15 172.78 52.02R-134CHF2CHF2 1,1,2,2-tetrafluoroethane -3.66 246.11 102.03R-116CF3CF3 hexafluoroethane -108.7 67.8 138.012R-23 HCF3 trifluoromethane -115.65 78.71 70.01R-71468F6 sulfur hexafluoride -82.8 114.0 146.054R-CE216CF2-CF2-O-hexafluoro-oxetane -20.4 191.1 166.022CF2-R-C216CF2-CF2-hexafluorocyclopropane -24.7 unknown 150.023CF2-R-CF2-O-CF2-hexafluorodioxetane -7.8 194.0 182.022CE216ca1O-CF2-R-E218CF3-CF2-O- 1-(trifluoromethoxy)- unknown unknown 204.02CF3 1,1,2,2,2-pentafluoroethaneR- CF3-O-CF2- bis(trifluoromethoxy)- unknown unknown 220.019E218ca12O-CF3 difluoromethane__________________________________________________________________________ *At the present time, only the 1,1,1,2,3,3,3heptafluoropropane isomer is available in commercial quantities, however, all isomers of heptafluoropropane are within the scope of the present invention.
The refrigerant fluids in Table 1 may be grouped into four categories, GROUP-A, GROUP-B, GROUP-C, and GROUP-D as set forth in Table 2. GROUP-A contains refrigerant fluids with the higher boiling points, GROUP-B contains refrigerant fluids that improve oil miscibility with mineral oils, tars and waxes. GROUP-C contains refrigerant fluids with the lowest boiling points. GROUP-D refrigerant fluids may be used to dilute the other three groups. Some refrigerant fluids (e.g. R-143a) may be in more than one GROUP. Flammability is listed as "very" for very flammable refrigerant fluids, "weak" for weakly or mildly flammable refrigerant fluids and "none" for nonflammable refrigerant fluids. The term "unkn" means "unknown".
TABLE 2______________________________________GROUP-A Refrig Flam______________________________________ R-227ea none R-152a weak R-E218ca12 none R-E143a unkn R-E227ca2 none R-245cb unkn R-134 none R-C318 none R-CE216ca1 none R-E218 none______________________________________GROUP-B Refrig Flam______________________________________ R-E134 none R-600a very R-290 very R-E143a unkn R-E170 very R-1270 very R-600 very R-C270 very______________________________________GROUP-C Refrig Flam______________________________________ R-C216 none R-125 none R-143a weak R-E125 none R-218 none R-32 weak R-116 none R-23 none R-7146 none______________________________________GROUP-D Refrig Flam______________________________________ R-134a none R-1216 none R-CE216 none______________________________________
Preferred embodiments of the present invention include a mixture of refrigerant fluids with one or more components from GROUP-A, zero or more components from GROUP-B, one or more components from GROUP-C, and zero or more components from GROUP-D, subject to the three following conditions.
Condition 1
The resulting temperature versus pressure curve of a closed container containing said mixture of refrigerant fluids, such that all component refrigerant fluids coexist in both liquid and vapor states in the container, should approximate the temperature-pressure curve of a closed container of R-12 for the range of temperatures and pressures commonly used for R-134a refrigerant, about -40 degrees Fahrenheit to about 200 degrees Fahrenheit. The degree of approximation should be within about 15 percent to about 30 percent error. To account for the "glide" in the mixtures of refrigerant fluids, the "bubble point" pressure at a temperature of 70 degrees Fahrenheit should be around 10 percent higher than the pressure (gauge pressure, PSIG) of R-134a. Increasing the mass fraction of components from GROUP-C and decreasing the mass fraction of components from GROUP-A will cause the pressure versus temperature curve of the mixture of refrigerant fluids to increase and vice versa. Rarely, two or more refrigerant fluids may be combined and the resultant boiling/bubble point of the mixture may not lie in between the boiling points of the components. This is the result of a partial or complete azeotrope formation. If an azeotrope is formed, the resultant boiling/bubble point is often near or a few degrees lower than the component with the lowest boiling point. If an unwanted azeotrope forms, additional components can be added to further modify the temperature-pressure curve.
In order to achieve good performance, it is usually necessary to have roughly equal liquid volumes of low (GROUP-C) and higher boiling components (GROUP-A) in the final mixture. This results in better utilization of the evaporator and condenser surface areas.
If the object is to produce a "high performance" or "higher capacity" mixture of refrigerant fluids, which may only be usable under certain conditions, such as automotive air conditioning, where extra horsepower is available for compressor operation, or in low temperature situations where the compressor is under loaded, then the mass fraction of the components from GROUP-C may be further increased about 5 to about 20 weight percent. Conversely, to produce a "reduced capacity" mixture of refrigerant fluids, the mass fraction of GROUP-C components may be reduced by about 5 to about 15 weight percent. Reduced capacity refrigerant mixtures will often perform poorly (but still useable) in "normal" systems. Air conditioning systems which were oversized when installed, may use a reduced capacity refrigerant to obtain a better equipment load match to the heat load. Properly sized air conditioning systems provide far better humidity control (longer run times) than do oversized systems.
Condition 2.
Optionally, about 0.5 to about 2 weight percent of GROUP-B components may be added to the mixture to prevent system clogging from solidified waxes and tars that may be present in a refrigeration system, especially if said system had been retrofitted to R-134a refrigerant from R-12 refrigerant. There is no need to be miscibile with large amounts of mineral oils (as typically used in R-12 refrigeration systems), since the said systems will already contain oils which are miscibile with R-134a and probably HFCs (hydrofluorocarbons) in general.
Condition 3.
The resulting mixture of refrigerant fluids should be nonflammable or weakly flammable at worst. The maximum mass fraction of "very" flammable refrigerant fluid components will be limited to about 5 to about 10 percent. The maximum mass fraction of "weakly" flammable refrigerant fluid components will be limited to about 15 to about 60 percent. A test sample of the mixture of refrigerant fluids should be vapor leaked (fractionated) at several constant temperatures over the range of expected temperatures where the leaking may occur. Some temperatures for fractionation testing would typically be -20, 0, 40, 70, 120, 180 degrees Fahrenheit. Flammability tests should be conducted on the mass fractions of vapor and liquid phases and be analyzed with appropriate equipment (e.g. a gas chromatograph) at various points during each leak down to verify the mass fraction of flammable components does not become great enough to cause greater than "no" or "weak" flammability as desired. Flammability can also be reduced by placing the boiling point of a very or weakly flammable refrigerant fluid near a lesser flammable or nonflammable refrigerant fluid component with a similar boiling point. Total flammability may also be reduced by spreading out (by boiling point) the flammable components over the entire mixture instead of using just one flammable component.
For the purposes of making the mixture of refrigerants of the preferred embodiments of the present invention, one needs to procure the following equipment, or equivalents. A mixing cylinder, which can be a standard refrigeration industry "recovery" cylinder, or a small propane (20 pounds net weight propane) tank is needed. These are U.S. Department of Transportation (DOT) rated at 240 PSIG or higher. This tank (or cylinder) must be clean. Also needed is a refrigeration (or equivalent) vacuum pump, scales, and a refrigeration manifold set (hoses and gauges).
The air must be removed from the mixing cylinder with a vacuum pump, such as any used by refrigeration service technicians. A deep vacuum gauge is needed to verify that about a 200 micron vacuum is achieved on the mixing cylinder. Deep vacuum gauges that read to less than 25 microns are commonly available at refrigeration supply houses.
This mixing cylinder is placed on electronic charging scales, of the type commonly available to the refrigeration service technician. These scales often read in 1/2 ounce increments up to a total of 60 pounds or more total weight.
A refrigerant mixture is made by connecting up each component supply cylinder to the mixing cylinder on scales, and weighing in the appropriate weight percentage of each component. The mixing hoses or manifolds should be purged or evacuated first to remove air and moisture. Each component supply cylinder should have a "dip tube" or eductor tube to withdraw the component in liquid phase. If the supply component cylinder does not have a dip tube, it must be inverted to obtain the component in liquid phase.
Although the components can be mixed in any order, it is easier to add the high boiling components first. The vacuum on the cylinder will usually be sufficient to draw in the required amount of the first component.
Some sort of liquid pump will be required to transfer the remaining GROUP-A and GROUP-B components as the pressure on the mixing cylinder will rise to match the supply cylinder.
Instead of a liquid pump, the mixing cylinder may be chilled by any convenient means to 10-20 degrees Fahrenheit colder than the supply cylinders. Alternately, the component supply cylinder may be heated to 10-20 degrees Fahrenheit warmer than the mixing cylinder to facilitate the transfer. A hot water bath or cylinder heating blanket works nicely for this purpose.
When transferring GROUP-C components, no pump will be needed, as the higher pressures of GROUP-C components will (rapidly) transfer them to the mixing cylinder. Caution is advised, for after the relatively slow transfers for GROUP-A and GROUP-B components into the mixing cylinder, GROUP-C components will transfer very quickly, possibly surprising the person doing the mixing, and causing too much of a component to be transferred.
A refrigerant mixture, just completed, should be allowed to thermally stabilize for 12 hours or more before temperature and pressure measurements are taken, if needed. If static pressure and temperature measurements are not needed, a mixture may be charged into a refrigeration or air conditioning system and operated without the 12 hour or more delay. A refrigerant mixture should always be unloaded from the mixing cylinder in liquid phase when charging into an appliance or other refrigeration system. This prevents fractionation from changing the composition of the mixture during charging. The mixing cylinder may contain a "dip tube" to provide for unloading in liquid phase. If a mixing cylinder is used without a dip tube, the cylinder must be inverted to unload in liquid phase.
If a mixture contains significant mass fractions of components with high molecular mass, the molecular mass of the total refrigerant mixture will increase. This may be beneficial for operation in centrifugal chiller refrigeration systems.
The mixtures of refrigerants are zeotropic, which means the composition changes during evaporation and condensation phases of refrigeration or air conditioning system operation. Unlike a single component refrigerant, such as R-134a, zeotropic refrigerants do not evaporate or condense at a single temperature (for a given pressure), but they evaporate or condense over a small range or "glide" of temperatures. Depending on the temperature, the glides involved for the preferred embodiments of the present invention are in the order of 10 to 15 degrees Fahrenheit.
Some refrigeration systems should see performance improvements upwards of about 30 to about 40 percent due to the glide factor, especially during the initial cool down period. Other systems will exhibit similar performance to that of R-134a. Events taking place in the condenser are broken down into 3 rough areas. The hot gas upon entering the condenser is first desuperheated, no condensation takes place in this area, just a relatively low amount of heat is rejected in cooling the hot gas down to the point where it is ready to condense. The second area involves the actual condensation of the gas, where a phase change occurs to liquid state. A relatively high amount of heat is given off due to the phase change. Thirdly, the now liquid refrigerant is further cooled (called subcooling in the art), with a relatively low amount of heat rejected.
Zeotropic mixtures, such as those of the present invention, cause the condensation phase change area (and evaporation phase change area) to occupy more of the condenser (or evaporator), thus increasing the capacity of the condenser to reject or the evaporator to gain heat.
A stationary refrigeration system test stand was constructed from a conventional Copeland 3/4 horsepower, medium temperature, R-134a condensing unit, model FTAM-A075-IAA-201. The condensing unit consisted of a Copeland model RS54C1E-IAA-100 compressor, a small fan, a condenser, and a liquid receiver. The compressor was rated for 11.8 Amperes, 115 volts, 60 Hertz power. The compressor came factory charged with Polyol Ester (POE) oil, suitable for R-134a operation. The high side liquid line was connected to a Sporlan refrigeration drier, model C-053 followed by a liquid line sight glass. A Sporlan model BFF A C 43 FC (1/2-1 ton) internally equalized expansion valve was used as the refrigerant metering device. The evaporator consisted of about 30 feet of 3/8 inch refrigeration copper wound into a coil of 20 turns of diameter about 51/2 inches and about 11 1/2 inches in height. The evaporator was connected back to the compressor via 3/8 inch tubing that contained an additional sight glass to monitor any liquid refrigerant that might be returning to the compressor.
The evaporator coil was aligned with it's axis vertical and immersed in a Rubbermaid two gallon insulated thermal jug, filled with about 17/8 gallons (14.42 pounds) of distilled water. The test runs were all made under the same starting conditions: 75 degrees Fahrenheit condenser inlet air and the water was at 66 degrees Fahrenheit. The expansion valve was adjusted (visually) for about 0 degrees of suction line superheat (at the point of no liquid refrigerant returning to the compressor as monitored through the sight glass). R-134a was used as the baseline (control) refrigerant. Three degrees of condenser airflow restrictions were employed to simulate "dirt" buildup encountered in normal long term operation. The first degree was no airflow restriction, the second degree was about a 50% reduction in airflow accomplished by placing two pieces of porous 1/2 inch thick foam rubber over the air inlet side of the condenser. The third degree of reduction was achieved by taping cardboard to the air inlet side of the condenser, covering about 3/4 (top) of it's area. The bottom 1/4 was covered with the same foam as used to provide the second degree of restriction. About 90% of the airflow was blocked by the third degree of restriction. This is a highly abnormal condition (90% reduction) and probably will not occur often in practice. On the other hand, a 50% reduction in air flow could be expected to occur often in practice from dirt buildup. It was noted that the condenser on this R-134a condensing unit was sized about 50% larger than a condenser on the same capacity R-12 condensing unit. Thermocouples were attached to the compressor hot gas discharge line, and to the condenser liquid line out. Condenser outlet air, compressor current draw, and system low side and high side pressures were monitored at 1, 5, 10, 15, and 20 minutes after startup. At the 20 minute mark, the system was shut down, and the thermal jug on the evaporator was removed and weighed. Ice which was made during the run remained on the evaporator coils. The amount of ice made was determined by weighing the remaining water after each run.
The energy use was computed by doing a simple integration of the compressor amp draw. The average amp draw was used from each segment of the run to determine the energy use of that segment. For example, to compute the energy use for the first segment (minute 1 through minute 5), the amp draw at one minute was averaged with the amp draw at 5 minutes. The average amp draw was multiplied by 11 5 (volts) to obtain the average power for the segment and multiplied by the time used (in hours) to obtain the power (watt-hours) used for the segment. The energy used for a given run was the sum of the energy used in each of the four segments. Data (including amp draw) from minute 0 to minute 1 was ignored in each run, to allow the system to reach stability. The heat removed to cool down the 1.7 gallons of water from 66 degrees Fahrenheit to 32 degrees Fahrenheit, along with the evaporator coils, and the inside of the thermal jug is not accounted for in the amount of ice made, but it was the same for each run. Results are summarized in Table 3, below.
TABLE 3______________________________________ ICE MADE (in pounds)Refrigerant NONE PARTIAL VERY______________________________________R-134a 5.055 4.695 3.915Example 1 5.225 4.740 3.735Example 2 4.840 4.385______________________________________ Total Watt-hours usedRefrigerant NONE PARTIAL VERY______________________________________R-134a 429.24 434.32 445.24Example 1 422.72 430.96 428.38Example 2 423.68 423.68______________________________________ Watt-hours/lb of iceRefrigerant NONE PARTIAL VERY______________________________________R-134a 84.91 92.51 113.73Example 1 80.90 90.92 114.69Example 2 86.59 96.62______________________________________
Each refrigerant was tested with the condenser unrestricted (labeled NONE), the condenser partially restricted for about a 50% reduction in airflow (labeled PARTIAL), and very restricted for about a 90% reduction in air flow (labeled VERY).
EXAMPLE 1
Three pounds of R-227ea/152a/125 55/5/40, a "drop-in" substitute refrigerant mixture for an R-134a stationary refrigeration system were created in the manner set forth above. Although the temperature-pressure curve is a little higher than optimal, it performed well when charged into the test stand described above. The higher than normal temperature-pressure curve resulted from the necessity of having roughly equal liquid volume portions of the low and high boiling components. The refrigerant mixture of this example produced 3.4% more ice than R-134a while using 1.5% less energy for the case of unrestricted condenser airflow. For the partially blocked condenser (about 50% airflow reduction), this mixture still made 1% more ice than R-134a while using 0.8% less energy.
For the highly obstructed condenser (about 90% airflow reduction) case, R-134a faired better. R-134a produced 4.8% more ice than the mixture of this example, but R-134a also used 3.9% more energy. The extremely obstructed condenser is not often encountered in the field, as the system would most likely have failed before this state was reached.
EXAMPLE 2
Three pounds of R-227ea/152a/125 60/5/35, a "drop-in" substitute refrigerant mixture for an R-134a stationary refrigeration system were created in the manner set forth above. Although the temperature-pressure curve is a little higher than optimal, but closer to R-134a than the mixture of Example 1, it only produced more ice than R-134a in the case of the highly obstructed condenser (producing 12% more ice and using 4.8% less energy). R-134a outperformed the mixture of this example when the condenser was unrestricted. R-134a made 4.4% more ice while using 1.3% more energy. This mixture would be useful for continuous operation in high ambient temperatures and/or heavy dirt fouling of the condenser airflow (or water flow if water cooled).
EXAMPLE 3
3.2 pounds of the mixture of Example 1, a "drop-in" substitute refrigerant mixture for an R-134a automotive air conditioning system were created in the manner set forth above. 2.9 pounds of this mixture were charged into 1982 Chevy pickup truck air conditioning system. This system, based on the GM "R4" compressor, was originally designed for R-12 refrigerant, and had been retrofitted to R-134a during the previous year. Retrofitting including replacing the condenser with a larger one, and adding a second outboard condenser fan to provide more condenser airflow and changing the oil from mineral oil to PAG oil. The R-134a retrofit had performed poorer cooling (truck is owned by a Lafayette, Ind., air conditioning service shop and the R-134a retrofit was a "test" retrofit) than did the original R-12, even after numerous attempts at "tweaking" it's performance on R-134a. When operated with the mixture of this example, (ambient temperature was 81 degrees Fahrenheit), excellent cooling performance was obtained, although the head pressure was a little higher than normal, but still well within system design limits. The air conditioner controls were set on "MAX" (highest fan speed, recirculate). The low pressure cutout switch was set at (the standard setting) of 24 PSIG. The second condenser fan, added during the R-134a retrofit, was disconnected for this example, creating a tougher test.
______________________________________ Suction Head pressure pressure Duct TemperatureDriving Conditions (PSIG) (PSIG) (degrees Fahrenheit)______________________________________Not moving, engine idle 55 235 52In town, 35 MPH 32 220 42Highway, 55 MPH 25 190 39Highway, 65 MPH 24 175 38______________________________________
The owner of the truck in this example stated that the cooling performance of the mixture of this example significantly exceeded the cooling performance of R-134a, and somewhat exceeded the cooling performance of the original R-12 system.
EXAMPLE 4
25 pounds of the mixture of Example 1, a "drop-in" substitute refrigerant mixture for an R-134a automotive air conditioning system, were created in the manner set forth above. A 199X Cadillac vehicle, that was manufactured with a R-134a air conditioning system, had the original R-134a charge removed and was evacuated and recharged with 2 pounds of the mixture of this example. Head pressures ran about 10% higher than with R-134a, suction pressures were the same. Cooling performance (82 degrees Fahrenheit) was superior to the cooling performance of the original R-134a. Duct temperatures (MAX Fan, recirculate) were about 5 degrees Fahrenheit colder at idle and 10 to 14 degrees colder when doing normal "in town" driving. This vehicle was taken to Florida (winter), and has been performing well for four months in 80 to 90 degree Fahrenheit ambient conditions.
EXAMPLE 5
3.2 pounds of R-227ea/152a/125 62/8/30, a "drop-in" substitute refrigerant mixture for an R-134a automotive air conditioning system were created in the manner set forth above. All of this mixture was charged into the air conditioning system of the vehicle in Example 3. Ambient temperature was 87 degrees Fahrenheit. While driving 55MPH, the charge was adjusted by admitting liquid refrigerant back into the (metered) charging cylinder. Optimum performance was obtained with a system charge of 2.9 pounds. Performance similar to R-12 was obtained. Highway driving (55 MPH) produced duct temperatures of 42 degrees Fahrenheit on MAX fan speed (recirculate), and 39 degrees Fahrenheit on one fan speed slower. The head pressure ranged from 250 PSIG at idle down to 175 PSIG while driving 55 MPH. Although the cooling performance of this example's refrigerant mixture was not as good as Example 3 refrigerant mixture, it was none the less "acceptable", and comparable to R-12, which was somewhat better than R-134a would have been.
EXAMPLE 6
25 pounds of R-227ea/125 75/25, a "drop-in" substitute refrigerant mixture for an R-134a automotive air conditioning system were created in the manner set forth above. 3.2 pounds of this mixture were charged into the air conditioning system of the vehicle in Example 3. Air conditioner controls were set at MAX fan (recirculate). Ambient temperature was 78 degrees Fahrenheit. Head pressure was 200 PSIG at idle, which dropped to 130 PSIG at 30 MPH driving speeds. This is too much of a drop for the head pressure, and could cause refrigerant starvation in the evaporator. At idle, not moving, the suction pressure was 40 PSIG, which dropped to 24 PSIG at 30 MPH driving, causing the low pressure cutout switch to open, causing the compressor to cycle off. The cold air duct temperature at this point was about 42 degrees Fahrenheit. Later in the day, the ambient temperature warmed up 85 degrees Fahrenheit. Head pressure at idle was still about 200 PSIG, and the 30 MPH driving head pressure rose to 150 PSIG. Duct temperature remained the same at 42 degrees Fahrenheit, but the higher head pressure caused more refrigerant to be admitted to the evaporator resulting in a faster cool down compared to 78 degree Fahrenheit temperatures earlier in the day.
EXAMPLE 7
R-600a/227ea/125 1/75/24, a "drop-in" substitute refrigerant mixture for an R-134a automotive air conditioning system, is created in the manner set forth above. The mixture of this Example shows good results in computer simulation with NIST program REFPROP V5.10. The glide calculates to be 17.5 degrees Fahrenheit (bubble point-dew point) at 70 degrees Fahrenheit ambient. The glide is a little bit too high. The R-600a component keeps waxes and tars dissolved, if present.
EXAMPLE 8
R-600a/227ea/125/134a 1/67/22/10, a "drop-in" substitute refrigerant mixture for an R-134a automotive air conditioning system, is created in the manner set forth above. The mixture of this Example shows good results in computer simulation with NIST program REFPROP V5. 10. The glide calculates to be 15.8 degrees Fahrenheit at 70 degrees Fahrenheit ambient, which is about right. R-134a is used to "dilute" the glide. Tars and waxes are dissolved by the R-600a component in the mixture.
EXAMPLE 9
R-245cb/125/290 58/41/1, a "drop-in" substitute refrigerant mixture for an R-134a automotive air conditioning system, is created in the manner set forth above. The mixture of this Example shows good results in computer simulation with NIST program REFPROP V5.10. The glide calculates to be 19.5 degrees Fahrenheit at 70 degrees Fahrenheit ambient, which is too high, but usable. Protection from plugging from tars and waxes is provided by the R-290 component.
EXAMPLE 10
R-245cb/125/290/134a 59/20/1/20, a "drop-in" substitute refrigerant mixture for an R-134a automotive air conditioning system, is created in the manner set forth above. The mixture of this Example shows good results in computer simulation with NIST program REFPROP V5. 10. The glide calculates to be 16 degrees Fahrenheit at 70 degrees Fahrenheit ambient, which is about right. R-134a is used to "dilute" the glide. Tars and waxes are dissolved by the R-290 component of the mixture.
EXAMPLE 11
R-134/143a/290 78/21/1 (note: R-134, not R-134a), a "drop-in" substitute refrigerant mixture for an R-134a automotive air conditioning system, is created in the manner set forth above. The mixture of this Example showed good results in computer simulation with NIST program REFPROP V5.10. The glide calculates to be 14 degrees Fahrenheit at 70 degrees Fahrenheit ambient, which is about right. Tars and waxes are dissolved by the R-290 component in the mixture. The critical temperature of this mixture is calculated to be around 240 degrees Fahrenheit, which is excellent.
EXAMPLES 12-24
Most of the "drop-in" substitute refrigerant mixtures for R-134a of Examples 12-24, which are tabulated in Table 4, show good results in computer simulated with NIST program REFPROP V5.10. The refrigerant mixtures of Examples 1-15 are also included in Table 4 for completeness. General comment(s) are included for most entries in Table 4. The "Fig." column refers to which Figure of FIGS. 1-8 contains the temperature-pressure chart for the Example mixture. The "Crit" column refers to the estimated critical temperature calculated from computer program REFPROP V5.10.
TABLE 4______________________________________ General comments Composi- (all glidesExample Components tion Crit FIG. at 70° F.)______________________________________ 1 R-227ea/152a/125 55/5/40 207 1 2 R-227ea/152a/125 60/5/35 210 1 3 Same as Example 1 4 Same as Example 1 5 R-227ea/152a/125 62/8/30 215 2 6 R-227ea/125 75/25 214 2 7 R-600a/227ea/125 1/75/24 214 glide a little high (17.5° F.) 8 R-600a/227ea/ 1/67/22/10 216 3 good glide 125/134a (15.8° F.) 9 R-245cb/125/290 58/41/1 210 3 glide a little high (19.5° F.)10 R-245cb/125/ 59/20/1/20 223 4 good glide 290/134a (16° F.)11 R-134/143a/290 78/21/1 240 4 good glide (14° F.), good crit temp12 R-227ea/143a/290 82/17/1 215 5 glide a little high (18.5° F.)13 R-245cb/143a/ 73/26/1 221 5 glide OK 600 (17.1° F.)14 R-245cb/E125/ 65/34/1 60015 R-E143a/E125/ 90/9/1 60016 R-227ea/152a/ 61/15/23/1 222 6 glide a little 125/600 low (13.4° F.)17 R-600a/227ea/ 1/57/32/10 209 6 High perfor- 125/134a mance version of Ex818 R-245cb/125/290 48/51/1 203 7 High perfor- mance version of Ex919 R-245cb/125 58/42 210 Ex9 without an oil miscibility improver20 R-227ea/143a 82/18 215 Ex12 without an oil misci- bility improver21 R-245cb/143a 73/27 221 Ex13 without an oil misci- bility improver22 R-227ea/152a/125 50/10/40 210 7 higher crit temp, lower glide than Ex123 R-227ea/152a/125 45/15/40 213 higher crit temp, lower glide than Ex124 R-227ea/152a/125 45/20/35 218 higher crit temp, lower glide than Ex1______________________________________
There exist thousands of possible combinations and permutations from the refrigerant fluids listed in Table 1 that could produce a refrigerant substitute for R-134a. Many combinations can be ruled out under conditions 1,2, and 3 listed above. Other combinations may still provide a good refrigerant, but may not be currently environmentally acceptable, but they may become acceptable in the future as new evidence and understanding of the environment proceeds. Other combinations from Table 1 may produce R-134a "drop-in" substitutes that have low critical temperatures, below about 215 degrees Fahrenheit, and still provide satisfactory performance in the majority of climates, but prove unsatisfactory in extreme heat or very high humidity climates.
For any given combination of components from Table 1, above, that produce a useable "drop-in" substitute for R-134a, many permutations (ranges) of each component's weight percentage are possible. GROUP-C components (see discussion in Condition 1, above), may be varied over the range of about-10 to +15 weight percent from their "normal centerline" values used to create a normal temperature-pressure curve. This allows for special uses such as "low capacity" and "high capacity" refrigerant mixtures. Adjustment of weight percentages of GROUP-C components, must be accompanied by a corresponding opposite adjustment in GROUP-A components so that the total of all weight percentages remains at 100 percent | A group of refrigerant fluids that may be combined in novel ways to produce several excellent "drop-in" substitutes for R-134a refrigerant. Performance is increased by constructing a zeotropic mixture of refrigerants, such that a single boiling point (of R-134a) is replaced by a "temperature glide" between the mixture's "bubble point" and "dew point". The temperature glide causes the phase change area in the condenser to be larger than with a single component refrigerant such as R-134a, thereby increasing heat rejection of the condenser, which lowers head pressures, and increases capacities and efficiencies compared to R-134a. Components are also selected to attempt to reduce the overall critical temperature of the mixture of refrigerants, also increasing performance and lowering head pressures under hot conditions with undersized condensers. Finally, a small amount of a mineral oil miscibility improver may be added, not to return mineral oil from the evaporator as in R-12 systems, but to keep waxes, tars, and other contaminates in the system that may have arisen from the manufacturing process (such as wax coatings on the motor windings in a hermetic compressor, or "tar" from valve packing) soluble. | 2 |
FIELD OF THE INVENTION
[0001] The present invention relates to a method of recovering gold from waste sources thereof, in particular waste electrical goods. Also disclosed herein is an apparatus for recovering gold from said waste sources.
BACKGROUND TO THE INVENTION
[0002] The cost of precious metals, such as gold, makes recovery or recycling of these materials economically viable and desirable. Gold is typically recovered from ores and other impure sources using cyanide, aqua regia or smelting. Such methods suffer from inter alia, toxicity issues, disposal costs and high energy input.
[0003] Prior art patents addressing the problem of improving efficiency in gold extraction and recovery are numerous. For example, U.S. Pat. No. 3,834,896 describes a process for recovering gold involving injecting chlorine into an aqueous slurry of carbonaceous ore at high temperature in the presence of iron, aluminium or gallium promoters.
[0004] U.S. Pat. No. 4,723,998 discloses a two-step process for extracting gold from carbonaceous or metal oxide based ores. The process comprises using chlorine to dissolve the gold from the ores and subsequently absorbing the gold on to ion exchange resins.
[0005] U.S. Pat. No. 3,495,976 communicates a method of recovering gold that has been plated or coated on to non-ferrous metals such as tungsten, molybdenum, or copper. The gold plated material is treated with an aqueous solution of potassium iodide and dissolved iodine. The gold is recovered by adding conc. sulphuric acid and distilling of the iodine. When all the iodine has been removed, the gold is separated from the remaining solution as a powder.
[0006] U.S. Pat. No. 3,957,505 discloses a process for extracting gold from gold bearing material comprising: treating the gold bearing material in an aqueous solution consisting essentially of iodine and a water soluble iodide salt to dissolve gold from said gold bearing material; mixing a reducing agent with said aqueous solution to reduce dissolved gold iodide salts to gold metal and precipitate said gold metal in substantially pure form from said aqueous solution. The precipitated gold metal is removed from the aqueous solution. An oxidizing agent is subsequently added to the aqueous solution to restore the solution to substantially its original condition for dissolving gold from further gold bearing material.
[0007] G.B. Patent No. 20471 discloses a method of extracting gold from ores thereof. The method discloses utilising an undivided electrolytic cell to generate a leaching material. Once the gold has been leached from the ore it is subsequently electrodeposited on the cathode. This method suffers in that the cathode has to be removed from the electrochemical cell to recover the gold and the cell will have to be cleaned out regularly to remove unwanted sludge, salts and other contaminants.
[0008] Hoffmann, J O M, Springer New York, vol 44, no. 7 p43-48 describes methods for recovering precious metals from electronic scrap involving slurrying the scrap in water and sparging chlorine gas into the slurry. WO 01/83835 A2 describes a gold recovery process in which gold scrap is mixed with water and hydrocloric acid and chlorine gas is blown into the reactor, to dissolve the gold. Both methods use large amounts of water.
[0009] In gold leaching, using for example cyanide, it is essential to carry out the reaction in an aqueous system to facilitate ionisation of the sodium cyanide used to cyanide ions. Waste electronic scrap contains irregularly shaped pieces and will take up more volume than it would if compacted. But if compacted the leachant solution could not act on all the surfaces.
[0010] As an example, 382 grams of computer connector slots occupied a volume of 1000 cm 3 in a beaker. To fill the same beaker to the 1000 cm 3 mark required an additional volume of 770 cm 3 of water. Based on these figures, 1 tonne of waste electronic scrap would occupy a volume of approximately 2.6 m 3 and would require a volume of 2 m 3 leachant to fill the container. In practical terms a larger tank with a larger volume of leachant would be needed to allow for agitation.
[0011] In contrast, gaseous chlorine as used in the present invention can circulate freely and penetrate into small nooks and crannies of the electronic scrap to leach and dissolve the surface gold. Much smaller volumes of water can be used to merely moisten the surfaces to facilitate reaction.
[0012] Notwithstanding the state of the art there remains a need for alternative methods for recovering gold that mitigate some or all of the above mentioned problems.
OBJECTS OF THE INVENTION
[0013] It is an object of the present invention to provide for a method and apparatus for recovering gold from waste sources thereof, in particular, waste electronic materials.
[0014] It is further object of the present invention to allow for the recovery of gold in solutions of small volume. Consequently, consumption of resources, such as water is minimal.
[0015] A further object of the present invention is to provide for a gold recovery process that affords an aqueous solution of gold without environmentally unfriendly process or treatment chemicals, used to produce the leaching material.
[0016] Another object of the present invention further is to provide for a method and apparatus in which the chlorine gas is generated externally to a reactor vessel and subsequently pumped into the reactor vessel comprising the waste gold materials.
SUMMARY OF THE INVENTION
[0017] In a first aspect the present invention provides for a method of extracting gold from waste substrates or sources comprising gold, the method comprising the step of:
[0018] delivering chlorine gas to a vessel containing the substrate comprising gold, the vessel comprising a vessel inlet through which the chlorine gas is delivered and a vessel outlet,
[0019] delivering water vapour to the vessel, such that
[0020] the chlorine gas, substrate comprising gold and moisture present in the vessel interact to provide a gold solution which may be recovered from the vessel via the vessel outlet.
[0021] The gold solution may flow directly into the vessel outlet. Alternatively, the gold solution may be actively forced into the vessel outlet.
[0022] The substrate comprising gold is a waste source. In particular the waste source is decommissioned or scrap electrical goods or electrical goods which are being recycled.
[0023] The substrate comprising gold may be a substrate on to which the gold is plated or coated. For example, the substrate may be a metal, plastic or ceramic material on which gold has been plated or coated. For example, the substrate comprising gold may be a metal or metal alloy substrate on to which gold is plated or coated. Suitable metals include ferrous and non-ferrous metals. For example, the metal substrate on to which gold is plated or coated may be selected from the group consisting of nickel, copper, and alloys thereof.
[0024] In one particular embodiment, the substrate comprising gold comprises waste electronic materials, for example printed circuit boards. From an environmental perspective it is highly advantageous to efficiently recycle gold from waste electronic materials.
[0025] With reference to the method of the present invention, water vapour or moisture may be charged into the vessel by any means known to a person skilled in the art. For example, the substrate comprising gold may be sprayed with water prior to being placed in the vessel. In a preferred embodiment, moisture is pumped into the vessel as a fine water mist, spray or steam to create a moist atmosphere. Advantageously, the presence of steam may also speed up the gold extraction process. In order to pump moisture into the vessel it may further comprise a water inlet for pumping said spray, steam, or mist into the vessel.
[0026] Advantageously, by providing a source of chlorine that is external to the vessel and delivering the chlorine into the vessel, small volumes of water can be utilised to recover the gold. Where chlorine generation and gold recovery occur in the same vessel large volumes of water and additives are required.
[0027] Accordingly, using the method of the present invention gold can be recovered in a low volume solution free of any additives. Furthermore, once the gold has been recovered from the solution the resultant waste liquid that must be treated before final discharge is low in volume. Consequently, costs are reduced.
[0028] The absence of dissolved chemicals and additives in the water fed into the vessel also greatly reduces the costs associated with treating the water prior to discharge.
[0029] For example, approximately 2000 L of prior art cyanide leaching solution would be required to recover gold from a cubic metre of scrap printed circuit boards (PCBs). Using the method of the present invention, gold could be recovered from the same quantity of PCBs with 200 L of water.
[0030] Naturally, the costs associated with treating and handling 2000 L of cyanide solution prior to discharge are considerable. Such large volumes of a potentially toxic material are undesirable in any industrial process. Advantageously, the method of the present invention avoids toxic materials such as cyanide solutions.
[0031] Prior art processes for gold recovery are based on leaching and have utilised aqueous environments in which gold containing substrates are submerged in an aqueous solution in an aqueous leaching bath. Advantageously, the lower water volumes associated with the method of the present invention allow for vessels of smaller volume to be used than prior art gold recovery methods. The method of the present invention can be industrially scaled up without having to provide excessively large vessels to hold the waste gold materials, and water. The vessel must simply be large enough to hold the waste gold material. Thus, costs involved in setting up and maintaining the process are lower.
[0032] Since the process of the present invention uses much lower water volumes than prior art processes, effluent treatment costs are minimised. The lower water volumes also enables better control of the gold leaching process. Initially the gold concentration in the outlet stream would be high but would decrease towards zero when all the gold is leached. When it is apparent that all the gold has been leached off, either by visual inspection or by measurement of the gold content in the reactor outlet stream, it is easy to quench the reaction by purging the reactor vessel of chlorine gas by passing air or another gas through the vessel. This minimises leaching of other substrate metals such as copper, nickel etc. Such almost instant quenching is not possible with an aqueous leaching bath.
[0033] The method of the present invention also provides for gaseous inter-halogen compounds being delivered in to the vessel along with the chlorine gas through the vessel inlet. As used herein, the term inter-halogen compounds is used to refer to gaseous materials comprising two distinct halogen atoms. For example, compounds such as iodine chloride (ICl) and bromide chloride (BrCl). Advantageously, the presence of inter-halogen compounds has been shown to increase the efficiency of the leaching/recovery process relative to chlorine on its own. The inter-halogen compounds may be introduced by doping the chlorine gas with amounts of elemental iodine or bromine, or they may be produced electrolytically, vide infra.
[0034] With reference to the method of the present invention, the chlorine gas may be prepared in an electrolytic cell external to the vessel. For example, the chlorine can be prepared in the electrolytic cell and delivered into the vessel, upon preparation, to provide a constant stream of chlorine into the vessel. The electrolytic cell may be a divided electrolytic cell, i.e. the anode electrolyte and cathode electrolyte are separated from one another.
[0035] Advantageously, by separating the chlorine preparation step from the gold leaching step in the vessel, the electrolyte used for chlorine preparation can be of optimum purity and concentration. Moreover, the gold leaching step can be performed without the build-up of salts and contaminants from the electrolytic process.
[0036] The chlorine gas prepared by the electrolytic cell may be delivered along a conduit to the vessel inlet. Furthermore, the gaseous inter-halogen compounds may be prepared in the electrolytic cell and may be deliverable along the conduit to the vessel. Inter-halogen compounds may be generated by adding amounts of bromide salts, for example NaBr, and iodide salts, for example, NaI, to the electrolyte.
[0037] Suitably, the conduit is manufactured from a material that is incapable of being corroded by chlorine gas.
[0038] The method of the present invention may further comprise a quenching process such that when water exiting the vessel via the vessel outlet no longer comprises gold the process can be shut down quickly.
[0039] A sensor may be utilised to detect the presence of gold in water exiting the vessel via the vessel outlet.
[0040] The quenching process may comprise cutting off the supply of chlorine gas to the vessel and flushing the vessel with inert gas prior to discharge of the vessel. As used herein, the term inert gas is used to represent a non-toxic, non-reactive gas. For example, the inert gas may be selected from the group consisting of air, nitrogen, argon and combinations thereof.
[0041] For example, the current to the electrolytic cell can be switched off to halt the production of chlorine. The vessel can be flushed with air, or another non-reactive, inert gas such as nitrogen or argon to purge it of any residual chlorine gas. The scrap materials can be unloaded from the vessel, and the vessel can be charged with new waste materials to recommence the process again.
[0042] The gold solution which exits the vessel via the vessel outlet may be further treated to recover solid gold metal from the gold solution.
[0043] The skilled person will be familiar with a number of different methods of reducing the gold solution to gold metal. For example, the gold solution may be treated with reducing agents such as sulphur dioxide gas, hydroxylamine, hydrazine, hydrogen peroxide. Alternatively, the gold solution may be refined electrochemically, for example by electrowinning or electroplating. A number of different methods of reducing a gold solution to provide gold metal are disclosed in U.S. Pat. No. 3,957,505. Advantageously, the process of the invention operates at ambient or slightly above ambient temperatures whereas some prior art processes for gold recovery require temperatures of between 200 and 800° C. to volatilise gold chloride, thus requiring a high and therefore expensive energy input. The reaction of the invention will proceed more rapidly at higher temperatures. Temperatures from ambient to 70° C. give good results but the use of higher temperatures are not excluded, subject to practical problems involved with higher pressures at higher temperatures.
[0044] In a further aspect, the present invention provides for an apparatus for extracting gold from a substrate comprising gold, the apparatus comprising:
[0045] a reaction vessel configured to receive the substrate comprising gold, the reaction vessel comprising a vessel inlet, through which chlorine gas is delivered into the reaction vessel and a vessel outlet,
[0046] a water inlet adapted to deliver water spray, steam, or mist into the vessel; and
[0047] a source of chlorine gas in fluid communication with the vessel; such that
[0048] the substrate comprising gold, chlorine gas and moisture present in the vessel interact to provide a gold solution which may be recovered from the vessel via the vessel outlet.
[0049] In one embodiment a conduit may extend from the vessel inlet to the source of chlorine gas to establish fluid communication therebetween.
[0050] Suitably, the conduit is manufactured from a material that is incapable of being corroded by chlorine gas.
[0051] With reference to the apparatus of the present invention the substrate comprising gold may be a substrate on to which the gold is plated or coated. For example, the substrate may be a metal, plastic or ceramic material on which gold has been plated or coated. For example, the substrate comprising gold may be a metal or metal alloy substrate on to which gold is plated or coated. Suitable metals include ferrous and non-ferrous metals. For example, the metal substrate on to which gold is plated or coated may be selected from the group consisting of nickel, copper, and alloys thereof.
[0052] In one particular embodiment, the substrate comprising gold comprises waste electronic materials, for example printed circuit boards. From an environmental perspective it is highly advantageous to efficiently recycle gold from waste electronic materials.
[0053] With reference to the apparatus of the present invention, moisture may be charged into the vessel by any means known to a person skilled in the art. For example, the substrate comprising gold may be sprayed with water prior to being placed in the vessel. In a preferred embodiment, moisture is pumped into the vessel as a fine water mist, spray, or steam. The vessel may further comprise a water inlet for pumping said spray, steam, or mist into the vessel. Advantageously, the presence of steam may also speed up the gold extraction process
[0054] With reference to the apparatus of the present invention, the source of chlorine gas may be an electrolytic cell disposed external to the vessel. For example, the chlorine can be prepared in the electrolytic cell and delivered into the vessel, upon preparation, to provide a constant stream of chlorine into the vessel. The electrolytic cell may be a divided electrolytic cell, i.e. the anode electrolyte and cathode electrolyte are separated from one another.
[0055] The build-up of chlorine gas in the electrolytic cell may generate sufficient pressure to urge the chlorine gas from the electrolytic cell along the conduit and into the vessel.
[0056] The apparatus of the present invention may further comprise an urging means for urging chlorine gas from the source of chlorine gas along the conduit and in to the reaction vessel. The urging means may be a pump.
[0057] The source of chlorine in the apparatus of the present invention may further comprise a source of inter-halogen compounds. For example, compounds such as iodine chloride (ICl) and bromide chloride, BrCl. Advantageously, the presence of inter-halogen compounds has been shown to increase the efficiency of the process relative to chlorine on its own.
[0058] The gaseous inter-halogen compounds may be prepared in the electrolytic cell. Inter-halogen compounds may be generated by adding amounts of bromide salts, for example NaBr, and iodide salts, for example, NaI, to the electrolyte.
[0059] The vessel of the apparatus of the present invention may further comprise an inlet for flushing the vessel with an inert gas prior to discharge of the vessel. The inert gas may be selected from the group consisting of air, nitrogen, argon and combinations thereof.
[0060] The apparatus of the present invention may further comprise a collector for the gold solution.
[0061] Where suitable, it will be appreciated that all optional and/or preferred features of one embodiment of the invention may be combined with optional and/or preferred features of another/other embodiment(s) of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0062] Additional features and advantages of the present invention are described in, and will be apparent from, the detailed description of the invention and from the drawings in which:
[0063] FIG. 1 illustrates an apparatus for carrying out the gold recovery method of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0064] It should be readily apparent to one of ordinary skill in the art that the examples disclosed herein below represent generalised examples only, and that other arrangements and methods capable of reproducing the invention are possible and are embraced by the present invention.
[0065] FIG. 1 illustrates an embodiment of the present invention. An electrolytic cell 101 is disposed external to a (reactor) vessel 102 , the latter being charged with substrates comprising gold 103 . By way of example, the substrates comprising gold 103 may be waste electrical goods, for example printed circuit boards, in which gold is plated or coated onto another material such as copper or nickel. A conduit 104 allows for fluid communication between the vessel 102 and the electrolytic cell 101 . Naturally, the conduit 104 will be manufactured from a material that is incapable of being corroded by chlorine gas.
[0066] The electrolytic cell 101 is a divided cell having an anode chamber 105 and cathode chamber 106 . A membrane 107 divides the anode 108 and cathode 109 . A pump 110 feeds the anode electrolyte or anolyte 111 to the anode 108 . The anode electrolyte 111 primarily consists of chloride salts, such as NaCl or KCl. However, the anode electrolyte 109 may also comprise small amounts of bromide and iodide salts, e.g. NaBr, NaI, KBr or KI to provide a source of inter-halogen compounds. A flow meter 112 regulates the flow of chlorine gas produced at the anode away from the anode 108 .
[0067] A second pump 113 feeds the cathode electrolyte or catholyte 114 to the cathode 109 . Typically, the cathode electrolyte 114 is a NaOH or KOH solution. A flow meter 115 regulates the flow of hydrogen gas produced at the cathode away from the cathode 109 . An outlet 116 provides an exhaust for hydrogen gas generated during the electrolytic process.
[0068] In the embodiment shown, the vessel 102 has a chlorine gas inlet 117 and a water inlet 118 . Water is fed to the water inlet 118 through conduit 119 . An outlet 120 provides an exit for an aqueous solution of recovered gold. The gold solution travels along conduit 121 to a collection flask or container (not shown).
[0069] Conduit 122 provides an outlet for any excess chlorine gas.
[0070] In use, the NaCl electrolyte 111 delivered to the anode 108 is oxidised to yield chlorine gas:
[0000] 2NaCl→Cl 2 +2Na + +2 e −
[0071] As indicated supra, the presence of chloride and bromide salts, such as NaBr and NaI can result in the formation of gaseous inter-halogen compounds BrCl and ICl. The presence of these compounds improves the efficiency of the chlorine leaching process. The inter-halogen compounds may be formed by reaction of halogens in elemental form as follows:
[0000] 2NaBr→Br 2 +2Na + +2 e −
[0000] 2NaI→I 2 +2Na + +2 e −
[0000] I 2 +Cl 2 →2ICl
[0000] Br 2 +Cl 2 →2BrCl
[0072] At the cathode 109 , hydrogen gas is generated from the electrolyte 114 according to the following equation:
[0000] 2H 2 O+2 e − →H 2 +2OH −
[0073] The membrane 107 prevents the anolyte and the catholyte mixing, and it stops the chlorine forming at the anode 108 from mixing with the sodium hydroxide and the hydrogen formed at the cathode. The hydrogen gas generated as a by-product of the electrolytic process exits the cell via outlet 116 .
[0074] Chlorine gas generated at the anode 108 flows into the conduit 104 and into the vessel 102 via vessel inlet 117 . Water is introduced into the vessel 102 through water inlet 118 from water conduit 119 . Water inlet 118 may comprise a nozzle to pump the water in as a fine mist, spray, or steam. By using a fine water mist, spray or steam the final volume of the gold solution is vastly reduced compared to prior art methods of gold recovery. Advantageously, a low volume solution is cheaper to treat prior to discharging it as effluent.
[0075] Upon contact with the waste electrical materials comprising gold, the chlorine gas (and any inter-halogen compounds present), gold and water react to afford an aqueous solution of gold recovered from the waste materials. The aqueous gold solution exits the vessel through outlet 120 and passes along conduit 121 to a collection flask/container.
[0076] The gold solution which exits the vessel via the vessel outlet 120 may be further treated to recover solid gold metal from the gold solution. The skilled person will be familiar with a number of different methods of reducing the gold solution to gold metal. For example, the gold solution may be treated with reducing agents such as sulphur dioxide gas, hydroxylamine, hydrazine, hydrogen peroxide. Alternatively, the gold solution may be refined electrochemically, for example by electrowinning or electroplating. A number of different methods of reducing a gold solution to provide gold metal are disclosed in U.S. Pat. No. 3,957,505.
[0077] Conduit 121 may internally house a gold sensor or detector. When solution exiting the vessel 102 through outlet 120 no longer contains any gold, current to the electrolytic cell 101 can be stopped to halt chlorine production. The vessel 102 can be flushed with a non-reactive gas such as air, nitrogen or argon to expel any residual chlorine gas and the now gold depleted waste electronic materials 103 can be discharged from the vessel 102 to be replaced by new materials.
[0078] A reiteration of the process can be easily commenced by recharging the vessel 102 with new waste electronic materials 103 .
[0079] The words “comprises/comprising” and the words “having/including” when used herein with reference to the present invention are used to specify the presence of stated features, integers, steps or components but do not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof.
[0080] It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination. | The cost of precious metals, such as gold, makes recovery or recycling of these materials economically viable and desirable. Disclosed herein is a method of recovering gold from waste sources thereof, in particular waste electrical goods. Also disclosed herein is an apparatus for recovering gold from said waste sources. In particular, disclosed herein is a method and apparatus in which gold leaching chlorine gas is generated externally to a reactor vessel and subsequently pumped into the reactor vessel comprising the waste gold materials. | 2 |
TECHNICAL FIELD
[0001] The present invention generally relates to asphalt paving machines, and more particularly to a control for a tamping mechanism on an asphalt paving machine.
BACKGROUND
[0002] Asphalt paving machines are used to spread asphalt relatively evenly over a desired surface. These machines are regularly used in the construction of roads, parking lots and other areas where a smooth durable surface is required for cars, trucks and other vehicles to travel. An asphalt paving machine generally includes a hopper for receiving asphalt material from a truck and a conveyor system for transferring the asphalt from the hopper for discharge on the roadbed. Screw augers spread the asphalt transversely across the road bed in front of a floating screed, which is connected to the paving machine by pivoting tow arms or draft arms. The screed smoothes and somewhat compacts the asphalt material and ideally leaves a roadbed of uniform depth and smoothness. The screed is sometimes equipped with an eccentric bar that rotates and thereby causes the screed to vibrate, which assists with the compaction. Although the screed compacts the asphalt material to some degree, it is often desirable to exert greater compaction force on the asphalt. To do so, some screeds include a tamping mechanism which often includes a tamping bar, located in front of the screed, relative to the direction of travel of the paving machine, and transversely to the direction of travel. The tamping bar moves up and down, striking the asphalt on each downward stroke thereby imparting increased compaction force on the asphalt. The speed with which the tamping bar moves upward and downward is generally controlled by an operator input device such as a control knob.
[0003] It is desirable to have the asphalt on the roadbed compacted uniformly so that the density of the roadbed is consistent from one place to another. Prior art tamping systems control only the frequency of the up and down motion of the tamping bar thereby causing the screed to tamp at a fixed rate. If the asphalt paving machine is moving at a constant speed the tamping bar will strike the asphalt the same number of times per unit distance traveled. Because the tamping bar strikes the asphalt the same number of times for every foot traveled, it is more likely to produce a uniformly dense roadbed. However, if the operator changes the speed of the asphalt paving machine the number of times the tamping bar strikes the asphalt per foot traveled will change, thereby increasing the likelihood that the density of the roadbed will be inconsistent.
[0004] It would be preferable to have an automatic tamping control that would deliver a uniform number compaction strokes for each unit distance traveled, irrespective of the speed of the asphalt paving machine.
SUMMARY OF THE INVENTION
[0005] The present invention includes a control system for use with a tamping mechanism on an asphalt paver. The control system preferably includes an electronic control module that is connected with an operator input device for inputting a desired tamping frequency. The electronic control module is also connected to a speed sensor that produces a signal indicative of the speed of the asphalt paver. The electronic control module controls the speed of the tamping mechanism as a function of the operator input and the asphalt paver speed.
[0006] These and other advantages of the present invention will be apparent upon reading the detailed description in connection with the drawings and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The drawings are provided to assist in the understanding of the present invention and represent a preferred embodiment of practicing the invention. Other embodiments could be created that will fall within the scope of the present invention as defined by the appended claims.
[0008] [0008]FIG. 1 is a side view of an asphalt paving machine;
[0009] [0009]FIG. 2 is a side view of a screed including a tamping mechanism associated with the asphalt paving machine of FIG. 1;
[0010] [0010]FIG. 3 is a block diagram of a control system of preferred embodiment of the present invention; and
[0011] [0011]FIG. 4 is a flowchart of preferred software control of the control system of the present invention.
DETAILED DESCRIPTION
[0012] A preferred embodiment of the best mode of practicing the present invention is described herein. Referring first to FIG. 1, a typical form of track-laying, floating screed asphalt paver 30 is shown. In accordance with well known practice, the paver is provided with push rollers 31 at the front, for engaging and pushing forwardly on the wheels of a truck loaded with asphalt paving material. The paving material is arranged to be discharged progressively from the truck into a hopper 32 at the front of the paver. Conveyor means (not shown) controllably transport the paving material to the rear of the paver and deposit it in a mass 33 on the prepared paving bed 34 . Screw augers 35 distribute the paving material laterally in front of a screed, generally designated by the numeral 36 . The screed is towed behind the paver and connected thereto by a pair of elongated, forwardly extending tow bars 37 connected at their front ends to the chassis of the paver. In accordance with known practice, by controlling the elevation of the tow points 38 and the angle of attack of the bottom surface of the screed 36 , a level, uniform paving mat 39 is laid behind the paver as it advances forwardly.
[0013] Referring now to FIG. 2, a screed 36 of the type used in connection with the asphalt paver 30 is shown. The screed 36 comprises a baseplate 100 which is configured to float on paving material 33 laid upon a prepared paving bed 34 and to “smooth” or level and compact the paving material on the base surface, such as for example a roadway or roadbed. The base plate 100 is connected, preferably by means of a carrier 105 , to a vibrating shaft 110 coupled to a vibratory drive (not depicted). As is known to those skilled in the art, the vibratory shaft 110 generally includes weights placed eccentrically so that when the vibratory drive rotates the vibrating shaft 110 , the shaft 110 causes the screed 36 to vibrate. The vibrating screed 36 to some degree improves compaction and quality of the asphalt mat being laid on the prepared paving bed 34 .
[0014] The screed also includes a tamping mechanism 111 which includes a tamping bar 115 arranged in front of the baseplate 100 and extending generally transversely to the paving direction over substantially the entire width of the baseplate 100 . The tamping bar 115 is configured to be driven so as to move alternately in upward and downward directions (i.e., generally toward and away from the base surface). Preferably, the tamping bar 115 is driven by an eccentric drive 120 and is configured to be adjustably displaceable by the amount of an adjustable stroke of the eccentric drive 120 . A speed sensor 290 is preferably located adjacent the eccentric drive and produces a speed signal on an electrical connector 300 that is an input to an electronic control module 210 , described in more detail below with reference to FIGS. 3 and 4. Further, the tamping bar 115 has a lead-in slope 125 located at the front edge of the bar 115 . The angle of the lead-in slope 125 is preferably between 30 degrees and 70 degrees, so as to ensure an optimum feed of the paving material.
[0015] The screed 36 has preferably includes a front wall 130 disposed proximal to the screw auger 35 (shown in FIG. 1), the screw auger 35 functioning to spread paving material falling off the end of a conveyor mounted on the paver 30 The front wall 130 includes a lower guide portion 135 which is preferably inclined relative to the tamping bar 115 and which terminates adjacent to the bar 115 , such that the guide portion 135 directs paving material from the auger 35 to the tamping bar 115 . The angle of inclination of the guide portion 135 preferably corresponds approximately to the angle of the lead-in slope 125 of the tamper bar 115 .
[0016] Referring now to FIG. 3, a block diagram of a preferred embodiment of an electronic control system 200 for use with the tamping mechanism 111 is shown. The electronic control system preferably includes an electronic control module (“ECM”) 210 connected with the various system components shown. A tamper bar mode selector 230 is connected with the ECM 210 . In the drawing, the tamper bar mode selector is shown as a three position toggle switch 240 . Those skilled in the art will recognize that other devices, including rotary switches, depressible button switches and the like could readily and easily be substituted for the three position switch. As described in more detail below with reference to FIG. 4, the mode selector 230 preferably includes three positions corresponding to an off mode, a manual mode and an automatic mode. The operator of the asphalt paving machine preferably places the mode selector 230 in a position corresponding to the desired mode. The mode selector then produces a mode signal on electrical connectors 250 indicative of the selected mode.
[0017] A tamper bar desired speed input 260 is connected with the ECM 210 by connector 270 . Although this input is described herein as a desired speed input, it also controls the desired number of tamps per unit distance when the system is in the automatic mode. As shown in the drawing, the tamper bar desired speed selector is shown as a rotary dial 280 . Preferably there are markings on the dial indicating to the operator a general desired tamping bar rotational velocity (when in manual mode) or a desired number of tamps per foot (when in automatic mode). The operator of the asphalt paving machine moves the dial to a position corresponding to the desired rotational speed of the tamping bar or number of tamps per foot and the rotary dial 280 produces a signal on connector 270 indicative of the desired tamping bar speed or tamps per foot.
[0018] A tamping bar speed sensor 290 is associated with the eccentric drive 120 of the tamping mechanism 111 and produces a tamping bar speed signal on connector 300 indicative of the rotational velocity of the eccentric drive 120 . Preferably, the tamping bar speed sensor is a passive sensor, such as a magneto restrictive type sensor. However, other types of speed sensors can be used without deviating from the scope of the present invention.
[0019] The ECM 210 produces a tamper bar control signal 310 to control the rotational speed of the shaft eccentric drive 120 . As shown in the drawing, the tamper bar control signal 310 is received by a solenoid 320 connected with a hydraulic pump 330 associated with the hydraulic motor 125 . The tamper bar control signal 310 controls the flow of hydraulic fluid through conduits 340 , 350 and thereby controls the rotational speed of the hydraulic motor 125 and eccentric drive 120 of the tamper bar. Although the preferred embodiment shows the use of a hydraulic pump 330 and motor 125 to control the rotational speed of the eccentric drive 120 , other power sources could readily and easily be substituted for the hydraulic motor without deviating from the scope of the present invention. For example, in some applications it might be preferable to replace the hydraulic motor with an electric motor and controllably power the motor with electric power through associated power circuitry.
[0020] Also connected with the ECM 210 is a asphalt paving machine speed sensor 360 that produces a signal on connector 370 indicative of the speed that the asphalt paving machine is travelling. The speed sensor is preferably associated with a driveline on the asphalt paving machine, which connects the engine to the tracks, or other ground engaging device. The speed sensor produces a signal indicative of the speed of the track, or other ground engaging device, which can be readily converted by the ECM 210 to ground speed. Any of a variety of well known speed sensors could be used in connection with the present invention.
[0021] Referring now to FIG. 4, a block diagram of a preferred embodiment of the software control associated with the ECM 210 of the present invention is shown. Software control begins in block 400 and passes to block 410 .
[0022] In block 410 the ECM 210 reads the signal on connectors 250 and determines whether the operator has placed the tamper bar mode selector 230 in the position corresponding to off mode. If the mode selected is the off mode then software control returns to block 400 . Otherwise, program control continues to block 420 .
[0023] In block 420 , software control determines whether the operator has placed the tamper bar mode selector 230 in the position corresponding to manual mode. If the mode selected is the manual mode then software control passes to block 430 . Otherwise, software control passes to block 440 .
[0024] In block 430 , the ECM 210 reads the desired tamping speed signal on connector 270 produced by the tamping bar desired speed input 260 . Program control then passes to block 470 . In block 470 , the ECM produces a tamper bar control signal as a function of the desired connector 270 . In a preferred embodiment of the invention the speed of the tamper bar shaft 122 is controlled open loop. However, as will be apparent to those skilled in the art, the ECM 210 could readily and easily use the electrical connector 300 as feedback to implement a closed loop tamper bar speed control. From block 470 program control returns to block 400 .
[0025] Returning to block 420 , as described above if the position of the mode selector 230 does not correspond to the manual position, then software control passes to block 440 and the control system is in automatic mode.
[0026] Software control passes from block 440 to block 450 .
[0027] In block 450 , the ECM 210 reads the signal on connector 270 , which in the automatic mode corresponds to a desired number of tamps per foot (or other unit distance) that the asphalt paving machine travels. Program control then passes to block 460 where the ECM determines a corresponding desired tamping speed. To do this, the ECM preferably reads the asphalt paving machine speed signal on connector 370 and calculates the desired tamping bar speed. In a preferred embodiment, the control system of the present invention uses two asphalt paving speed sensors 360 and averages the signals of those two sensors. Program control then passes to 470 .
[0028] As described above, in block 470 , the ECM produces a tamper bar control signal as a function of the desired connector 270 . In a preferred embodiment of the invention the speed of the tamper bar shaft 122 is controlled open loop. However, as will be apparent to those skilled in the art, the control could readily and easily use the electrical connector 300 as feedback to implement a closed loop tamper bar speed control. From block 470 program control returns to block 400 .
INDUSTRIAL APPLICABILITY
[0029] The control described in the present application permits the operator of the asphalt paving machine to select between three modes of tamping: an off mode; a manual mode; and an automatic mode. In the off mode, the screed will not tamp the asphalt material. In the manual mode the operator can select a desired tamping speed which produces a desired tamping rate (i.e., a desired number of tamps per unit time). In the automatic mode the operator can select a desired number of tamps per unit distance. In the automatic mode the control will automatically adjust the tamping speed as a function of the speed that the asphalt paving machine is moving. This will allow the operator to better achieve consistent compaction from the tamper bar with minimum operator action. | A control system for use with an asphalt paving machine receives inputs from an operator interface for inputting a desired tamping frequency or a desired tamping rate (tamps/ft) and a speed sensor that produces a signal indicative of the speed of the asphalt paver. The control system includes an automatic mode and when in automatic mode the system modifies the tamping frequency to better achieve a desired number of tamps per foot traveled irrespective of speed. | 4 |
BACKGROUND
[0001] 1. Field of the Invention
[0002] The present invention generally relates to an in-line resonator for an air induction system.
[0003] 2. Description of Related Art
[0004] Resonators for attenuating acoustic pressure pulsations in automotive applications are well known. The air induction systems of internal combustion engines produce undesirable noise in the form of acoustic pressure pulsations. This induction noise varies based on the engine configuration and engine speed. The induction noise is caused by a pressure wave that travels from the inlet valve towards the inlet of the air induction system. Further, the induction noise may be reduced by reflecting a wave toward the inlet valve 180° out of phase with the noise wave. As such, Helmholtz type resonators have been used to attenuate the noise wave generated from the inlet valve-opening event. In addition and more recently, resonators have been developed that change the volume of the resonator to adjust for varying frequencies of the noise wave, as engine speed changes. Previous designs, however, have not provided the control of multiple frequencies at the same engine speed, which is required for some applications.
[0005] To meet order based air induction noise targets, it is generally necessary to incorporate a tuning device, such as a resonator, into the air induction system. Traditional static resonators are tuned to a fixed frequency that will not change with engine speed. These resonators provide notch-type attenuation at their designated frequency, but introduce undesirable side band resonances at higher and lower frequencies. Even after the addition of multiple static devices, it may still not be possible to match the desired order based targets due to the notch-type attenuation and side band amplification caused by such devices. Resonators have been developed that change the volume of the resonator to adjust for the varying frequencies of the noise wave as engine speed changes. However, the acoustic pressure pulsations may be composed of several frequencies of significant amplitude that occur simultaneously at any given engine speed.
[0006] In view of the above, it is apparent that there exists a need for an improved resonator having broader flexibility to attenuate the various noise frequencies of the engine.
SUMMARY
[0007] In satisfying the above need, as well as overcoming the drawbacks and other limitations of the related art, the present invention provides an in-line resonator with multiple chambers for an air induction system of an internal combustion engine.
[0008] The system includes a resonator housing, an upstream duct, a downstream duct, a conduit, a partition, an upstream sleeve, and a downstream sleeve. The upstream duct and downstream duct are connected to opposite ends of the housing. The upstream duct connects the resonator to the air intake, and the downstream duct connects the resonator to the internal combustion engine. The conduit extends through the resonator housing providing an airflow path between the upstream duct and downstream duct. The partition divides the housing into an upstream chamber and a downstream chamber. Additionally, the partition, downstream sleeve, and upstream sleeve are fixed to each other so that these components always maintain the same relative position with respect to each other. The partition, downstream sleeve, and upstream sleeve are collectively referred to as the sliding unit of the resonator assembly. The downstream and upstream sleeves slide along the outside of the conduit while the airflow from the upstream duct to the downstream duct is bounded by the inner surface of the conduit. The downstream chamber, conduit, and downstream sleeve cooperate to form a downstream Helmholtz resonator that is in fluid communication with the downstream duct. The properties of the Helmholtz resonator are characterized by the volume of the downstream chamber and the length and cross-sectional area of the passage connecting the downstream duct to the downstream chamber.
[0009] In another aspect of the present invention, the conduit and the upstream sleeve may include overlapping openings that form a fluid communication path from the interior of the conduit to the upstream chamber. The upstream chamber and the overlapping openings of the upstream sleeve and conduit form an upstream Helmholtz resonator. The overlapping openings of the conduit and upstream sleeve may have a variety of shapes thereby varying the frequency of the second Helmholtz resonator as a function of the relative positions of the upstream duct and conduit.
[0010] In another aspect of the present invention, the downstream sleeve may be composed of an outer downstream sleeve and an inner downstream sleeve. The outer downstream sleeve is spaced apart from the inner downstream sleeve. The inner downstream sleeve slides about the conduit, and the outer downstream sleeve slides within the downstream duct. The gap between the inner and outer downstream sleeves defines the area of the passage connecting the downstream duct and the downstream chamber.
[0011] In a further aspect of the present invention, the outer downstream sleeve has an end that extends into the downstream chamber. The distance from the end of the conduit that terminates within the downstream duct and the end of the outer downstream sleeve that terminates within the downstream chamber defines the length of the passage between the downstream duct and the downstream chamber.
[0012] In another aspect of the present invention, the means for axially moving the sliding unit includes a motor mounted on the resonator housing and an actuator connecting the motor to the sliding unit.
[0013] In yet another aspect of the present invention, the conduit may contain a plurality of perforations. As a function of the position of the upstream sleeve, the upstream sleeve will act to cover or uncover a portion of the perforations in the conduit. The uncovered perforations form a fluid communication path to the upstream chamber. The upstream chamber and the uncovered perforations in the conduit form an upstream Helmholtz resonator.
[0014] Further objects, features and advantages of this invention will become readily apparent to persons skilled in the art after a review of the following description, with reference to the drawings and claims that are appended to and form a part of this specification.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a longitudinal sectional view of an in-line resonator embodying the principles of the present invention;
[0016] FIG. 2 is a chart depicting various hole configurations used to vary the frequency attenuation of the upstream chamber;
[0017] FIG. 3 is a graph showing the frequency attenuated by the upstream chamber for various conduit hole configurations as varied by the partition being moved across the resonator;
[0018] FIG. 4 is a sectional side view of another embodiment of a in-line resonator having perforations in the conduit;
[0019] FIG. 5 is a sectional side view of another embodiment of an in-line resonator having an extension of the downstream duct protruding into the downstream chamber; and
[0020] FIG. 6 is a sectional side view of yet another embodiment of an in-line resonator where the upstream and downstream ducts have extensions that protrude into the upstream and downstream chambers.
DETAILED DESCRIPTION
[0021] Referring now to FIG. 1 , an in-line resonator embodying the principles of the present invention is illustrated therein and designated at 10 . As its primary components, the in-line resonator 10 includes a resonator housing 12 , a conduit 20 , a partition 24 , a downstream sleeve 30 , and an upstream sleeve 31 .
[0022] The housing 12 of the in-line resonator 10 forms a compartment 13 having a fixed volume. Extending from the ends of the housing 12 are an upstream duct 16 and a downstream duct 18 . Positioned axially within the in-line resonator 10 and providing an airflow passage from the upstream duct 16 to the downstream duct 18 is the conduit 20 . The conduit 20 is centered on the axis 14 of the resonator housing 12 and air flows generally into the upstream duct 16 , through the conduit 20 , into the downstream duct 18 , and to the internal combustion engine (not shown). Acoustic pressure pulsations created by the air induction process travel from the engine into the downstream duct 18 .
[0023] Located axially around the conduit 20 and attached to the partition 24 for sliding therewith are a downstream sleeve 30 and an upstream sleeve 31 . The downstream sleeve 30 , the upstream sleeve 31 , the partition 24 , and the resonator housing 12 cooperate to form a first or downstream chamber 28 and second or upstream chamber 26 . The downstream sleeve 30 includes an outer downstream sleeve 46 that is spaced apart from the conduit 20 and that defines an outer downstream sleeve end 32 extending into the downstream duct 18 and downstream chamber 28 . The outer downstream sleeve end 32 in cooperation with the conduit end 22 defines an annular connector passage 48 . Further, a length 36 is defined from the conduit end 22 to the outer downstream sleeve end 32 .
[0024] To attenuate the acoustic pressure pulsations, the first chamber 28 , and the annular connector passage 48 form a first or downstream Helmholtz resonator 38 . As the acoustic pressure pulsations enter the downstream resonator 38 , the location of the partition 24 , the downstream sleeve 30 , and outer downstream sleeve 46 within the housing 12 are adjusted by the actuator 40 to create the necessary internal dimensions that will reflect the acoustic pressure pulsations back into the downstream duct with a 180° phase shift at the desired frequency, thereby attenuating the acoustic pressure pulsations.
[0025] To further attenuate the acoustic pressure pulsations, the second chamber 26 , the opening 42 in the conduit, and the opening 44 in the upstream sleeve cooperate to form a second or upstream Helmholtz resonator 39 . As the acoustic pressure pulsations travel through the conduit 20 , they enter the second chamber 26 through the overlapping areas of the conduit opening 42 and the upstream sleeve opening 44 . Both of the openings 42 and 44 are further defined below. The frequency attenuated by the upstream resonator 39 is controlled by the position of the partition 24 , the size and shape of the opening formed by the overlapping or relative positions of the conduit opening 42 and the sleeve opening 44 , and the wall thickness of the conduit 20 and upstream sleeve 31 .
[0026] The upstream resonator 39 offers greater flexibility to address additional frequencies in need of attenuation, while the first resonator 38 addresses a single dominant order. If the intake manifold is acoustically symmetric, then an acoustic pressure pulsation signature composed of the engine firing order and its harmonics will dominate the induction noise. As a result the downstream resonator 38 can address the dominant engine order, and the upstream resonator 39 can be tailored to address additional problematic frequencies, as described in the paragraphs below.
[0027] Controller 41 monitors engine parameters, such as engine speed, engine acceleration, throttle position, and pedal position. The controller 41 calculates the optimal position of the partition 24 based on the engine parameters. In doing this, controller 41 can utilize a lookup table of the partition position relative to both engine speed and performance characteristics. The lookup table could be developed from a series of induction noise tests to determine the optimal position for the partition at every engine speed. In addition, a position sensor 49 may be used to monitor the position of the partition 24 and provide feedback to the controller 41 . Based on the feedback from the position sensor 49 and the engine's operating conditions, the controller commands the actuator 40 to move the partition 24 to the predetermined optimal position.
[0028] Now referring to FIG. 2 and FIG. 3 , examples of various shaped conduit holes are provided along with graphs of the resulting frequency of attenuation achieved by each conduit hole as the upstream sleeve 31 slides along the conduit 20 . For reference, the attenuation provided by downstream resonator is designated by reference numeral 51 . Further, it is to be noted, that the opening formed by the cooperation of the conduit opening 42 together with the upstream sleeve opening 44 significantly varies the frequency attenuated by the second resonator 39 . Accordingly, either the conduit opening 42 , the upstream sleeve opening 44 , or both may be altered in size and shape along the length of the opening to obtain desired attenuation characteristics. Utilizing the oval shape of the upstream sleeve opening 44 , as shown in FIG. 1 , a first wedge-shaped conduit opening 52 with the apex pointing towards the downstream duct 18 allows the attenuated frequency decrease while the volume of the second chamber 26 increases, as defined by the position of the partition 24 . The angle along the length of the first wedge shape 52 can be modified to vary the rate at which the frequency decreases as the volume of he second chamber 26 increases.
[0029] Utilizing a second wedge shape 54 , with the apex pointing towards the upstream duct 16 , the angle of the apex can be chosen to attenuate a constant frequency as the upstream sleeve 30 moves along the conduit 20 . The second wedge shape 54 essentially compensates for the increase in the volume of the second chamber 26 by changing the size and shape of the conduit opening, as shown by second wedge shape 54 and its corresponding graph.
[0030] In addition, non-linear transfer functions between the position of the partition 24 and the attenuated frequency can be created by changing the angle of the apex and shape of the sides in a non-linear manner. One example is provided in the violin-shaped wedge 56 .
[0031] In contrast to the first wedge shape 52 , the frequency may be increased using a third wedge shape 58 as the sleeve 30 moves along the conduit 32 . The third wedge shape 58 has an apex pointing towards the upstream duct 16 , however, the apex angle is wider than the second wedge shape 54 .
[0032] Referring now to FIG. 4 , another embodiment of in-line resonator according to the principles of the present invention is illustrated therein and designated at 60 . It is noted that common components with the previously described exponent are referenced with common element numbers.
[0033] As its primary components, the in-line resonator 60 includes a resonator housing 12 , a conduit 20 , a partition 24 , a downstream sleeve 30 , and an upstream sleeve 65 . The housing 12 of the in-line resonator 60 forms a compartment 13 having a fixed volume. Extending from the ends of the housing 12 are an upstream duct 16 and a downstream duct 18 . Positioned axially within the in-line resonator 60 and providing a passage from the upstream duct 16 to the downstream duct 18 is the conduit 20 . Generally, air flows into the upstream duct 16 , through the conduit 20 , and out the downstream duct 18 to the internal combustion engine (not shown). Acoustic pressure pulsations created by the air induction process travel from the engine into the downstream duct 18 .
[0034] Located axially around the conduit 20 and attached to the partition 24 , for sliding therewith, are a downstream sleeve 30 and an upstream sleeve 65 . The downstream sleeve 30 , the upstream sleeve 65 , the partition 24 , and the resonator housing 12 cooperate to form a first or downstream chamber 28 and a second or upstream chamber 26 . The downstream sleeve 30 includes an outer downstream sleeve 46 that is spaced apart from the conduit 20 that defines an outer downstream sleeve end 32 extending into the downstream duct 18 and downstream chamber 28 . The outer downstream sleeve end 32 in cooperation with the conduit end 22 defines an annular connector passage 48 . Further, a length 36 is defined from the conduit end 22 to the outer downstream sleeve end 32 .
[0035] To attenuate the acoustic pressure pulsations, the first chamber 28 , and the annular connector passage 48 form a first or downstream Helmholtz resonator 38 . As the acoustic pressure pulsations enter the resonator 38 , the location of the partition 24 , the downstream sleeve 30 , and outer downstream sleeve 46 within the housing 12 are adjusted by the actuator 40 to create the necessary internal dimensions that will reflect the acoustic pressure pulsations back into the downstream duct with a 180° phase shift at the desired frequency, thereby attenuating the acoustic pressure pulsations.
[0036] To further attenuate the acoustic pressure pulsations, a second chamber 26 , the perforated openings 61 in the conduit 20 , and the position of the upstream sleeve 65 cooperate to form a second or upstream Helmholtz resonator 39 . As the acoustic pressure pulsations travel through the conduit 20 , perforations 61 in the conduit 20 allow the acoustic pressure pulsation to enter the second chamber 26 . The frequency attenuated by the upstream resonator 39 is controlled by the position of the partition 24 , the wall thickness of the conduit 20 , as well as the amount of perforations 61 not covered by the upstream sleeve 30 based on the position of the upstream sleeve 30 .
[0037] Controller 41 monitors engine parameters, such as engine speed, engine acceleration, throttle position, and pedal position. The controller 41 calculates the optimal position of the partition 24 based on the engine parameters. In doing this, controller 41 can utilize a lookup table of the partition position relative to both engine speed and performance characteristics. The lookup table could be developed from a series of induction noise tests to determine the optimal position for the partition at every engine speed. In addition, a position sensor 49 may be used to monitor the position of the partition 24 and provide feedback to the controller 41 . Based on the feedback from the position sensor 49 and the engine's operating conditions, the controller commands the actuator 40 to move the partition 24 to the predetermined optimal position.
[0038] Referring now to FIG. 5 , another embodiment of in-line resonator according to the principles of the present invention is illustrated therein and designated at 62 . Again, common components to those of the preceding embodiments one designated with like reference numbers. As its primary components, the in-line resonator 62 includes a resonator housing 12 , a conduit 20 , a partition 24 , a downstream sleeve 30 , and an upstream sleeve 65 .
[0039] The housing 12 of the in-line resonator 62 forms a compartment 13 having a fixed volume. Extending from the ends of the housing 12 are an upstream duct 16 and a downstream duct 18 . Positioned axially within the in-line resonator 62 providing a passage from the upstream duct 16 to the downstream duct 18 is the conduit 20 . Generally, air flows into the upstream duct 16 , through the conduit 20 , and out the downstream duct 18 to the internal combustion engine (not shown). Acoustic pressure pulsations created by the air induction process travel from the engine into the downstream duct 18 .
[0040] Located axially around the conduit 20 and attached to the partition 24 for sliding therewith are a downstream sleeve 30 and an upstream sleeve 31 . The downstream sleeve 30 , the upstream sleeve 65 , the partition 24 , and the resonator housing 12 cooperate to form a first or downstream chamber 28 and second or upstream chamber 26 . The downstream sleeve 30 includes an outer downstream sleeve 64 that is spaced apart from the conduit 20 and that defines an outer downstream sleeve end 32 extending into the downstream chamber 28 . In addition, the downstream duct has an extension 63 that extends into the downstream chamber 28 around which the outer downstream sleeve 64 slides. The conduit end 22 , the downstream duct extension 63 , and the outer downstream sleeve 64 cooperate to define an annular passage 66 . Further, a length 36 is defined from the conduit end 22 to the outer downstream sleeve end 32 .
[0041] To attenuate the acoustic pressure pulsations, the downstream chamber 28 and the annular passage 66 cooperate to form a first or downstream Helmholtz resonator 38 . As the acoustic pressure pulsations enter the downstream resonator 38 , the location of the partition 24 , the downstream sleeve 30 , and outer downstream sleeve 46 within the housing 12 are adjusted by the actuator 40 to create the necessary internal dimensions that will reflect the acoustic pressure pulsations back into the downstream duct with a 180° phase shift at the desired frequency, thereby attenuating the acoustic pressure pulsations.
[0042] To further attenuate the acoustic pressure pulsations, a second chamber 26 , the perforated openings 61 in the conduit 20 , and the position of the upstream sleeve 65 cooperate to form a second or upstream Helmholtz resonator 39 . As the acoustic pressure pulsations travel through the conduit 20 , perforations 61 in the conduit 20 allow the acoustic pressure pulsation to enter the second chamber 26 . The frequency attenuated by the upstream resonator 39 is controlled by the position of the partition 24 , the wall thickness of the conduit 20 , as well as the amount of perforations 61 not covered by the upstream sleeve 30 based on the position of the upstream sleeve 30 .
[0043] Controller 41 monitors engine parameters, such as engine speed, engine acceleration, throttle position, and pedal position. The controller 41 calculates the optimal position of the partition 24 based on the engine parameters. In doing this, controller 41 can utilize a lookup table of the partition position relative to both engine speed and performance characteristics. The lookup table could be developed from a series of induction noise tests to determine the optimal position for the partition at every engine speed. In addition, a position sensor 49 may be used to monitor the position of the partition 24 and provide feedback to the controller 41 . Based on the feedback from the position sensor 49 and the engine's operating conditions, the controller commands the actuator 40 to move the partition 24 to the predetermined optimal position.
[0044] Referring now to FIG. 6 , another embodiment of in-line resonator according to the principles of the present invention is illustrated therein and designated at 68 . Again, common components to those of the preceding embodiments one designated with like reference numbers. As its primary components, the in-line resonator 68 includes a resonator housing 12 , a conduit 20 , a partition 24 , a downstream sleeve 30 , and an upstream sleeve 71 .
[0045] The housing 12 of the in-line resonator 68 forms a compartment 13 having a fixed volume. Extending from the ends of the housing 12 are an upstream duct 16 and a downstream duct 18 . The conduit 20 is positioned axially within the in-line resonator 68 providing a passage from the upstream duct 16 to the downstream duct 18 . Generally, air flows into the upstream duct 16 , through the conduit 20 , and out the downstream duct 18 to the internal combustion engine (not shown). Acoustic pressure pulsations created by the air induction process travel from the engine into the downstream duct 18 .
[0046] Located axially around the conduit 20 and attached to the partition 24 for sliding therewith are a downstream sleeve 30 and an upstream sleeve 71 . The downstream sleeve 30 , the upstream sleeve 71 , the partition 24 , and the resonator housing 12 cooperate to form a first or downstream chamber 28 and second or upstream chamber 26 . The downstream sleeve 30 includes an outer downstream sleeve 64 that is spaced apart from the conduit 20 and that defines an outer downstream sleeve end 32 extending into the downstream chamber 28 . The downstream duct has an extension 63 that extends into the downstream chamber 28 around which the outer downstream sleeve 64 slides. The conduit end 22 , the downstream duct extension 63 , and the outer downstream sleeve 64 cooperate to define an annular passage 66 . Further, a length 36 is defined from the conduit end 22 to the outer downstream sleeve end 32 .
[0047] In addition, the upstream sleeve 71 includes an outer upstream sleeve 70 that is spaced apart from the conduit 20 and that defines an outer upstream sleeve end 74 extending into the upstream chamber 26 . The upstream duct has an extension 69 that extends into the downstream chamber 26 around which the outer upstream sleeve 70 slides. The conduit end 76 , the upstream duct extension 69 , and the outer upstream sleeve 70 cooperate to define an annular passage 72 . Further, a length 78 is defined from the conduit end 76 to the outer upstream sleeve end 74 .
[0048] To attenuate the acoustic pressure pulsations, the downstream chamber 28 and the annular passage 66 cooperate to form a first or downstream Helmholtz resonator 38 . As the acoustic pressure pulsations enter the downstream resonator 38 , the location of the partition 24 , the downstream sleeve 30 , and outer downstream sleeve 46 within the housing 12 are adjusted by the actuator 40 to create the necessary internal dimensions that will reflect the acoustic pressure pulsations back into the downstream duct with a 180° phase shift at the desired frequency, thereby attenuating the acoustic pressure pulsations.
[0049] To further attenuate the acoustic pressure pulsations, the upstream chamber 26 and the annular passage 72 cooperate to form a second or upstream Helmholtz resonator 39 . As the acoustic pressure pulsations enter the upstream resonator 39 , the location of the partition 24 , the upstream sleeve 71 , and outer upstream sleeve 70 within the housing 12 are adjusted by the actuator 40 to create the necessary internal dimensions that will reflect the acoustic pressure pulsations back into the upstream duct with a 180° phase shift at the desired frequency, thereby attenuating the acoustic pressure pulsations.
[0050] Controller 41 monitors engine parameters, such as engine speed, engine acceleration, throttle position, and pedal position. The controller 41 calculates the optimal position of the partition 24 based on the engine parameters. In doing this, controller 41 can utilize a lookup table of the partition position relative to both engine speed and performance characteristics. The lookup table could be developed from a series of induction noise tests to determine the optimal position for the partition at every engine speed. In addition, a position sensor 49 may be used to monitor the position of the partition 24 and provide feedback to the controller 41 . Based on the feedback from the position sensor 49 and the engine's operating conditions, the controller commands the actuator 40 to move the partition 24 to the predetermined optimal position.
[0051] As a person skilled in the art will readily appreciate, the above description is meant as an illustration of the principles of this invention. This description is not intended to limit the scope or application of this invention in that the invention is susceptible to modification, variation and change, without departing from spirit of this invention, as defined in the following claims. | An in-line resonator for an air induction system of an internal combustion engine is provided. The system includes a resonator housing, an upstream duct, a downstream duct, a conduit, a partition, and a sleeve. The conduit extends through the resonator housing connecting the upstream duct and the downstream duct. The partition is moveable within the resonator housing and divides the housing into an upstream chamber and a downstream chamber. The downstream chamber, the conduit, and the downstream sleeve cooperate to form a first Helmholtz resonator that is in fluid communication with the downstream duct. The upstream chamber, the conduit, and the upstream sleeve cooperate to form a second Helmholtz resonator that is in fluid communication with the upstream duct. Further, a means is provided to axially move the partition to vary the volume of the chambers concurrently with the length and/or area of the passages. | 5 |
FIELD OF THE INVENTION
This invention relates to a quick connect connector for a grooved pipe, which has the ability to inhibit rotation of the pipe relative to the connector, and, in turn, to inhibit rotation of a fitting relative to the grooved pipe, or, rotation of a further length of grooved pipe relative to the commencing length of grooved pipe.
By this invention, lengths of grooved pipe and appropriately grooved fittings can be secured to one another in a minimum of time, with a minimum of effort, and, by a workman having minimal skill.
Grooved pipe is well-known in the art, and is comprised of a length of metal or plastics pipe which has been cut or roll grooved in its outer circumference at a position adjacent an end of the pipe, to provide an annular groove extending circumferentially of the pipe.
The connector of the present invention finds utility in the joining of two lengths of grooved pipe in end-to-end relation, or, in connecting a grooved pipe to a fitting or fixture that also has been appropriately grooved for it to simulate an end of a grooved pipe.
The connector itself can be an axially straight connector for connecting two lengths of grooved pipe in end-to-end relation, or, it can be in the form of an elbow for connecting two lengths of grooved pipe in end-to-end right angled relation, or, it can be in the form of a T or cross adapted to connect multiple lengths of grooved pipe to a supply main of grooved pipe, or, it can be in the form of an adapter for receiving a sprinkler head, tap, pressure gauge, or other fitting.
While in its simplest form, the connector is in the form of a tube of substantially constant diameter throughout its length, the connector can be appropriately configured for it to connect a grooved pipe of one diameter to one or more grooved pipes of a different diameter.
The connector of the present invention finds particular utility in the quick assembly of water supply lines for non-permanent municipal, armed forces, refugee and other camp grounds, for use in field hospitals, field kitchens, showers, and the like, in which the supply lines must be assembled with minimum time and effort, and, similarly disassembled with minimum time and effort for transportation and re-assembly at a different site.
The connector of the present invention also finds particular utility in the quick assembly of water supply lines in mining operations, and in particular coal mines, in which the terrain to be traversed progressively is changed as the mining operation proceeds. Also, in such operations, it is required that the pipe lines must accommodate themselves to uneven terrain, slopes and angles and bends, that occur randomly as the mining corridors are developed.
The quick connector also evidences utility in the assembly of horticultural irrigation systems, that will be disassembled after a growing season to permit preparation of the ground for a subsequent growing season.
Such horticultural irrigation systems commonly are comprised of a main supply pipe line which is connected to secondary distribution pipe lines, the distribution pipe lines being employed to feed spray nozzles and the like, or, perforate drip irrigation lines.
BACKGROUND OF THE INVENTION
Quick connectors for pipe lines are well-known in the art, and, commonly are employed for connecting lengths of horticultural flexible plastic hose to one another.
Additionally, numerous devices have been prior proposed that are received in clamping engagement with the ends of un-grooved or plain-ended pipe, such devices commonly employing band clamps which are employed to compress a sleeve of a resilient material, such as rubber, into frictional gripping and sealing relation with the outer surface of plain-ended pipe.
Such installations are relatively weak and insubstantial, in that they rely exclusively on the frictional gripping of the pipes by the connecting sleeve, and, are subject to separation and water loss in the event that one of the pipes is angled relative to the other, or, is subjected to a tensile stress. Typical of such clamp-type connectors are those disclosed in U.S. Pat. No. 3,586,354 to Boscacci, and 5,193,859 to McKinnon.
More substantial types of connectors are disclosed in U.S. Pat. No. 2,980,143 to Harris, 4,146,252 to Bunda and 4,630,647 to Thompson, each of which is cumbersome and laborious to assemble, and each of which requires a wrench or other tool for its assembly.
These problems have been previously given consideration, and have been successfully met by the teachings of U.S. Pat. No. 5,498,042, issued Mar. 12, 1996 in the name of Douglas R. Dole, and assigned to the common Assignee.
U.S. Pat. No. 5,498,042 discloses and claims a quick connect connector for grooved pipe that will facilitate the quick assembly of pipe lines employing grooved pipe, with extreme rapidity, and in the absence of tools, and, which will provide a pipe line assembly having substantial strength and resistance against axial, lateral, or bending stressing of the pipes, thus to provide a predictability stable and leak-proof pipe line assembly, which, when required, can be disassembled with equal speed and facility, again, in the absence of tools.
Those advantages are accomplished by providing a connector in the form of a hollow cylinder that is sized for it to be slid easily over the end of a grooved pipe, the connector providing a housing for an O-ring for sealing engagement with the outer surface of the grooved pipe. Preferably, the O-ring is positioned within the connector at a location in which it is not required to pass over the cut or rolled groove in the pipe, thereby minimizing the chances of cutting or abrasion of the O-ring during the assembly of the coupling onto the pipe.
Preferably, the coupling includes an internal abutment for engagement with the end of the grooved pipe, in order that the connector can be quickly positioned over the grooved pipe in a required positional relationship relative to the grooved pipe, by merely stabbing the coupling onto the pipe end, or conversely, stabbing the pipe end into the coupling.
Interiorly of the coupling, there is provided an annular groove, which opens circumferentially into an access port which extends radially through the coupling, and which is open at the radially outer side of the coupling.
Positioned within the groove is a circlip, which can be manually contracted and locked in a condition in which the diameter of its inner periphery is less than the outer diameter of the pipe, and its outer periphery is of a diameter greater than the outer diameter of the pipe, and also greater than the inner diameter of the coupling. This provides a positive abutment for the side walls of the groove in the pipe, and also the side walls of the annular groove in the coupling member, thus to preclude unrestrained relative axial movement between the and the coupling member.
When it is desired to disassemble the pipe line, the locking device of the circlip is manually released, this permitting the circlip to expand to a larger diameter in which the circlip is contained entirely within the groove in the coupling the inner diameter of the circlip having been expanded to a diameter greater than the outer diameter of the pipe and greater than the inner diameter of the coupling, in this way removing the circlip in its entirety in its capacity of providing an abutment for the side wall of the groove in the pipe, and, permitting easy removal of the coupling from the pipe, or vice versa.
The grooved pipe can be cut-grooved metal or plastics pipe, or, it can be roll-grooved plastics pipe or thin-walled metal pipe. The coupling member can be formed of any suitable material including metals and plastics materials that are of sufficient rigidity to resist bending of the coupling member out of axial linearity. The circlip conveniently is formed from a hard but resilient plastics material, but also, if desired, could be fabricated from a suitable metal.
While the quick connect coupling of the issued patent performs admirably in its capability of enabling rapid assembly of pipe lines and fixtures, and the subsequent rapid disassembly of such pipe lines and fixtures, it is encumbered with a disadvantage, that is overcome by the teachings of the present invention.
In particular, while the prior art coupling is imminently successful in preventing separation of the pipes under axial and bending loadings, it does not necessarily inhibit rotation of one of the pipes relative to the next connecting pipe, or, rotation of a fitting that has been connected to an end of a pipe or between adjacent ends of pipes.
SUMMARY OF THE INVENTION
It is an object of this invention to eliminate the disadvantage appearing in the disclosure of U.S. Pat. No. 5,498,042 of permitting relative rotation between the pipe and the coupling, or, such angular rotation of a fitting attached to the coupling.
According to the present invention, the inner circumference of the circlip is provided with axially-extending serrations, and similarly the groove provided in the pipe end or in the fitting is provided with complementary axially extending serrations.
Thus, upon contraction and locking of the circlip, the respective axially-extending serrations are inter-engaged and interfit, thus inhibiting rotational movement of the circlip relative to the pipe or fitting.
The circlip is located within the connector in a manner inhibiting angular or rotational movement of the circlip within the connector by providing an abutment on the radially outer circumference of the circlip that is entrapped within a corresponding radially extending aperture in the connector.
The abutment can be a radially extending abutment located at a position intermediate the ends of the circlip, or, it can be provided on one end of the circlip, in this manner permitting the circumferential contraction of the circlip, while at the same time inhibiting the relative rotation between the circlip and the connector, and, ultimately, when the circlip is contracted into securing engagement in the pipe groove with the respective serrations inter-engaged, then inhibiting relative rotation between the connector and the pipe or fitting.
The interference in locking engagement of the circlip within the groove of the pipe or fitting and the elimination of relative rotational movements of the pipe, connector, or fitting, permits the rapid assembly and disassembly of rigid pipelines, and the rigid attachment of fittings to the rigid pipeline.
The axially-extending serrations in the groove of the pipe or fitting readily can be provided by means of a rolling operation by the use of an axially serrated pressure roll, which can be either be at ambient temperature for roll grooving the serrations in metal pipe or in pipe formed from plastics materials that are conducive to cold rolling, or, in the event that the plastics material is a heat deformable material, then, the pressure roll can be heated to an appropriate temperature prior to effecting the serrating operation.
The serrations on the inner circumference of the circlip readily can be provided during the molding of the circlips, or, can be effected by a broaching or stamping operation.
DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention will now be described with reference to the accompanying drawing, in which:
FIG. 1 is a perspective view of a prior art basic form of connector to be employed in joining to lengths of grooved pipe to each other in axial alignment;
FIG. 2 is a longitudinal cross-section to the prior art connector showing the connector in an unlocked condition;
FIG. 3 is a longitudinal cross-section to the prior art connector similar to that shown in FIG. 2, but showing the connector in locked condition.
FIG. 4 is a transverse cross-section taken on the line IV--IV in FIG. 1, showing a connector according to the present invention when in an unlocked condition;
FIG. 5 is a transverse cross-section along the line V--V in FIG. 1, and showing a connector according to the present invention when in a locked condition;
FIG. 6-11 illustrate diagrammatically various configurations that the connector may provide in order to meet varying requirements in a piping system;
FIG. 12 is a perspective view of an alternative form of connector according to the present invention when in an unlocked condition; and
FIG. 13 is a perspective view showing the connector of FIG. 12 when in a locked condition.
FIG. 14 is a view corresponding with FIG. 4, but showing an alternative construction of the connector.
FIGS. 15, 16 and 21 are views corresponding with FIGS. 2 and 3, when modified to incorporate the teachings of the present invention.
FIG. 17 is a view corresponding with FIG. 15, and illustrating a further embodiment of the invention; and
FIGS. 18 and 19 are views corresponding with FIGS. 15 and 16 and showing a still further embodiment of the present invention.
FIG. 20 illustrates a further alternative embodiment of the present invention.
DESCRIPTION OF THE PRIOR ART
FIG. 1 illustrates a basic form of connector according to the prior art, which is specifically intended to connect the axially aligned ends of two grooved pipes.
The connector, which is indicated generally at 10, comprises a cylindrical body 12 having a central bore 13, for the reception of the pipe ends, one of which is shown at 14.
Located within the body 12, as later fully described, are two circlips 16 and 18, the circlip 16 being shown in an open position in readiness for the reception of a pipe end, the circlip 18 being shown in a closed and secured position in which it is operative to prohibit removal of the connector 10 from the pipe 14, or, in the alternative, removal of the pipe 14 from the connector 10.
Referring now to FIGS. 2 and 3, the cylindrical body 12 is provided with a central abutment 20, which is provided to limit the extent to which a grooved pipe 22 can be inserted into the central bore 13 of the body, in this way accurately positioning the groove 24 in the pipe periphery in correct relation to the juxtaposed circlip 16 or 18.
In FIG. 2, both of the circlips 16 and 18 are shown in an expanded condition in which an inner periphery 30 of the respective circlips 16 and 18 are of a diameter at least equal to, and preferably slightly greater than the diameter of the pipe 22. In this condition, the pipe 22 can be stabbed into the body 12, or in the alternative, the body 12 can be stabbed onto the pipe 22, to bring the free end of the pipe 22 into contact with the abutment 20.
The circlip 16 is then contracted in diameter as shown in FIG. 3 for its inner diameter 30 to become less than the outer diameter of the pipe 22, the outer periphery 32 of the circlip 16 being of a diameter greater than the outer diameter of the pipe 22. In this condition, and as shown in FIG. 3, the end walls of the circlip 16 provide a positive abutment for the side walls of the groove 24 of the pipe 22, and also provides positive abutments for the side walls of the annular groove 28.
The pipe 22 is in this manner locked against axial movement relative to the body 12, the O-ring 27 providing a liquid-tight seal between the end of the pipe 22 and the body 12.
A second pipe (not shown) can then be stabbed into the opposite end of the connector in an identical manner to the pipe 22, subsequent to which the circlip 18 is contracted in an identical manner to the circlip 16 for it to secure that pipe within the body in an identical manner to that described with reference to the pipe 22.
At that point, the two pipes become locked within the body 12 in axial alignment with each other, leakage being prevented by the respective O-rings 27, which are located in grooves 26 formed in the body 12.
In the prior art constructions, the bottom wall 24a of the groove 24 cut into the exterior of the pipe 22 is cylindrical and axially straight.
Thus, and as is illustrated in FIG. 3, at the time the circlip 16 is contracted into the groove 24, while the circlip 30 is operative to inhibit relative axial movement between the connector 12 and the pipe 22, it cannot inhibit relative rotation between the connector 12 and the pipe 22. All that will occur, and this assumes that circlip has been contracted into clamping engagement with the bottom wall 24a of the groove 24, is that a minor frictional restraint will be provided acting against such rotational movement between the connector 12 and the pipe 22.
In the prior art arrangement, a locking device is provided for locking the circlip in the contracted position, and, which is releasable to enable the circlip to return to return under its own inherent memory to its original expanded condition.
The locking device is comprised by interfitting members provided at the respect ends of the circlip, and which include a locking member 34 which is received within a locking member 36 provided at the opposite end of the circlip 16 or 18.
The locking member 34 is arcuate in form and is provided with serrated teeth 38 on its outer surface. The complementary locking member 36 is provided with arcuate extensions 40 and 42, the arcuate extension 42 being provided with serrated teeth 44 on its inner arcuate surface.
The respective locking member 34 and 36 extend radially outwardly of an access port 46 that interconnects with an associated annular groove 28, such that the locking members 34 and 36 can be gripped exteriorly of the body 12, and then, be moved towards each other and interlocked with each other as illustrated in FIG. 5.
When moved towards each other to the position shown in FIG. 5, the locking member 34 enters the arcuate extensions 40 and 42 of the locking member 36 for the locking member 34 to be entrapped within and securely held by the arcuate extensions 40 and 42 of the locking member 36, movement of the arcuate extension 42 being permitted by resilience of the circlip 16 or 18, the circlips being formed from a relatively hard but resilient plastics material, or of a spring metal material.
During that movement the circlip becomes contracted in diameter, such that inner periphery of the circlip, which initially was of a diameter greater than that of the pipe 22 becomes of lesser diameter than the pipe 22, and is moved radially inwardly of the groove 24 from the position shown in FIG. 4 to the position shown in FIG. 5.
The outer diameter of the circlips similarly decreases, the radial width of the respective circlips being such that in the contracted position shown in FIG. 5, the outer diameter 32 of the circlip remains entrapped within the annular groove 28, the diameter of the outer periphery of the circlip in that condition being greater than the diameter of the pipe 22.
DESCRIPTION OF THE INVENTION
In contra-distinction to the prior art construction in which the radially periphery of the circlip 16 or 18 is smoothly continuous, and, the bottom wall of the groove 24 is smooth and uninterrupted, such as will permit rotation of the sleeve and pipe relative to each other, according to the present invention, the inner diameter 30 of the circlips 16 and 18 is provided with axially extending serrations 30A, and, the bottom wall of the pipe groove 24 is provided with complementary axially extending serrations.
Thus, in the released condition of the circlip 16 or 18, relative rotation between the connector and the pipe is readily available, to enable the seating of the pipe end within the connector, subsequent to which the circlip 16 or 18 is then contracted and locked in the contracted condition with the serrations of the circlip and those of the bottom wall of the pipe groove interfitted, in this manner prohibiting relative rotation between the circlip 16 or 18 and the associated pipe 22.
In order to eliminate relative rotation between the circlip and the connector, the circlip 16 or 18 is provided with a radially extending projection 50, which is a slidable fit within an aperture 52 formed in the body in the connector 12, and which intersects the groove 28 formed in the body of the connector.
While a straight line connector so for has been described, as will be apparent from FIGS. 6-11 the connector can take a multitude of forms. For example, the basic in-line connector of FIG. 6 can be provided as an elbow, as illustrated in FIG. 7, or as a T, as illustrated in FIG. 8, or, as a cross, as illustrated in FIG. 9, FIG. 9 also illustrating the option of one arm of the connector being formed to accommodate a pipe of larger diameter than the pipes accommodated by other arms of the connector. Similarly, as illustrated in FIG. 10, the connector can provide a step-down between a pipe of large diameter and a pipe of smaller diameter. As illustrated in FIG. 11, the connector can provided a termination of pipeline, which conveniently can have a tap, shower head, sprinkler head, or similar device attached thereto, thus facilitating the construction of washing facilities, showers, irrigation systems and the like of any desired lay-out and configuration.
By virtue of the rigid interconnection of the connector and the associated pipe or fitting, an entirely rigid pipeline assembly can be assembled, the fittings incorporated into the pipeline assembly themselves being settable at any desired angle, and, upon locking down of the connector being held immovably in that selected position.
An alternative construction of the body of the connector and the circlip is illustrated in FIGS. 12 and 13.
In this alternative embodiment, one end of the circlip 16 or 18 is provided with a radial projection 54, which extends through an aperture in the body 12, and is held captive therein.
The opposite end of the circlip is provided with a radial projection 56, which carries a locking member 58, and which is slidable circumferentially of the pipe within a circumferential slot 60, thus to permit locking of the circlip in a contracted condition by moving the projection 54 in a direction circumferentially of the connector 12, to insert a latch member 62 of the locking member 58 through an aperture 64 provided in the radial extension 54.
As will be readily apparent to persons skilled in the art, various other configurations of locking members can be employed in conjunction with the circlip, that are operative to latch the circlip in a contracted condition, and, which are releasable to permit expansion of the circlip to its original condition at the time it is desired to disassemble the pipeline assembly.
As also will be readily apparent, various other configurations of pipe groove circlip are possible, that will accomplish the basic object of the present invention, which is that of preventing rotation of the pipe relative to the coupling when the circlip is in a locked position.
Examples of such alternatives constructions are now discussed with respect to FIGS. 14-20.
Referring now to FIG. 14, in the event that the coupling is to be employed with pipes formed of plastics material, the circlip 16-18 can be formed of a material considerably harder than the material from which the pipes are formed so that the teeth on the circlip can become embedded in the bottom wall of the pipe groove upon closure of the circlip. In this event, the need to provide serrations on the bottom wall of the pipe groove is eliminated.
FIGS. 15 and 16 illustrate a further alternative, in which the groove 24b in the pipe wall is trapesoidal and formed with sloping side walls, and, the inner periphery of circlip 16 or 18 is correspondingly configured, the side walls of the circlip and the engaged side walls of the groove acting as further frictional restraint against relative movement between the pipe 22 and the coupling 12. In FIGS. 15 and 16 the bottom wall of the groove can be serrated, as previously described with reference to FIGS. 4 and 5, and, as illustrated in FIG. 17, the side walls of the groove also can be serrated, as can the side walls of inner periphery of the circlip, thus to provide a positive locking interengagement between the side walls of the groove and the side walls the clip, which, when the clip is locked, provides a further positive engagement between the clip and the pipe groove, to further inhibit relative rotation between the pipe and the coupling. FIG. 21 further illustrates the trapezoidal radial cross-section of the circlip and the pipe groove.
Other configurations interengageable surfaces can be employed to in order to inhibit relative rotation between the pipe and the coupling. For example, and as shown in FIGS. 18 and 19, the inner periphery of the circlip 16-18 can be formed with semi-spherical projections 56 that are receivable within semi-sperical indentations 58 that have been formed in the outer circumference of the pipe, the main objective being that projections are provided on the inner circumference of the circlip that will interfit with corresponding recesses formed in the outer periphery of the pipe, this including the formation of the inner circumference of the circlip as a regular polygon, and, the forming the groove in the outer periphery of the pipe as a complimentary polygon, as illustrated in FIG. 20.
In the event that the circlip and pipe groove are configured as illustrated in FIG. 20, a minor initial rotation of the pipe will be required as the circlip is closed, in the event that closure of the circlip does not itself automatically produce that rotation. | A quick connector for joining pipes having grooved ends has a circlip which is contracted circumferentially and locked in the contracted condition, the inner diameter of the circlip, when in the contracted condition, being less than the outer diameter of the pipe, the inner diameter of circlip and the bottom wall of the pipe groove including surface configurations that are interfitted in the contracted condition of the circlip, and which inhibit relative rotation between the quick connector and the pipe in addition to locking the connector against axial removable from the pipe. | 5 |
TECHNICAL FIELD
This invention relates to electrical switches and circuit breakers, and more particularly, to a combination switch and circuit breaker.
BACKGROUND ART
Circuit breakers are used in a wide variety of electronic systems in which components must be protected from large currents such as those that accompany circuit malfunctions or external power surges. A circuit breaker is connected between the source of power and the components to be protected, and contains a component that trips when excessive current flows through it, opening the circuit through the circuit breaker and disconnecting the source of power from the components to be protected. Electronic systems frequently include on and off switches connected in series with the circuit breaker for turning on or off the electronic system. Frequently, separate switches and circuit breakers are used in electronic systems. Since two units are used, a relatively large amount of space is required to accommodate both units.
A combined switch and circuit breaker unit is disclosed in U.S. Pat. No. 4,528,538 to Andersen. This is a single unit and is adapted so that after interruption of the current flow by the circuit breaker, opening the switch circuit resets the circuit breaker. In Andersen, however, the switch and circuit breaker are electrically separate units and are not unitary. The Andersen device is not very compact since the switch and circuit breaker are electrically separate units. The Andersen device is also relatively expensive to manufacture since it is relatively complex, and comprises numerous parts.
OBJECTS AND SUMMARY OF THE INVENTION
It is thus an object of the present invention to overcome the aforesaid defects of the prior art.
It is another object of the present invention to provide a unitary switch and circuit breaker.
It is also an object of the present invention to provide a unitary switch and circuit breaker that reduces the number of components used to perform both the switching function and the circuit breaker function.
It is still a further object of the present invention to provide a unitary switch and circuit breaker in which the two functions are performed in a single unit.
It is yet another object of the present invention to provide a unitary switch and circuit breaker that is small in size and relatively compact.
It is still a further object of the present invention to provide a unitary switch and circuit breaker that indicates when the circuit breaker function has been actuated.
It is yet a further object of the present invention to provide a unitary switch and circuit breaker in which the circuit breaker places the switch in the off position when the circuit breaker is actuated.
It is an even further object of the present invention to provide a unitary switch and circuit breaker in which placing the switch in the "on" condition simultaneously resets the circuit breaker function.
In accord with the present invention, a unitary switch and circuit breaker includes switch means having first and second contact means, the switch means actuable to assume a first condition in which the contact means are open and a second condition in which the contact means are closed, and breaker means integral with the switch means for actuating the contact means to interrupt current flow through the contact means in response to the current flow exceeding a predetermined level and for subsequently preventing the resumption of current flow through the contact means until reset.
As preferably embodied, one set of electrical contacts are operated by both the switch means and the breaker means.
The above, and other objects, features and advantages of the present invention will be apparent from the following detailed description of illustrative embodiments thereof which is to be read in connection with accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an embodiment of a unitary switch and circuit breaker in accord with the present invention;
FIG. 2 is an exploded, perspective view illustrating the component parts of the embodiment of FIG. 1;
FIG. 3 is a plan view of a terminal lug of the embodiment of FIG. 1 illustrating a thermally sensitive bimetallic strip;
FIG. 4 is a cutaway plan view of the reverse side of the embodiment of FIG. 1 showing the contacts in the open condition;
FIG. 5 is a cutaway plan view of the reverse side of the embodiment of FIG. 1 showing the contacts in the closed condition;
FIG. 6 is a side view of the embodiment of FIG. 1 showing the switch function in the off condition and the circuit breaker function in the open condition;
FIG. 7 is a side view of the embodiment of FIG. 1 illustrating the switch function in the on condition and the circuit breaker function in the closed condition;
FIG. 8 is a side view of the embodiment of FIG. 1 illustrating the switch function in the on condition and the circuit breaker function in the open condition;
FIG. 9 is a view taken along the line 9--9 of FIG. 1;
FIG. 10 is a cutaway side view of an alternate embodiment of the present invention;
FIG. 11 is a partial, plan view of a rocker arm and tab in an embodiment of the present invention;
FIG. 12 is a partial, perspective view of the tab of FIG. 11;
FIG. 13 is a partial, plan view of another rocker arm and tab in an embodiment of the present invention;
FIG. 14 is a partial, perspective view of the tab of FIG. 13;
FIG. 15 is an exploded, perspective view illustrating the component parts of another embodiment of the present invention;
FIG. 16 is a cutaway view of the reverse side of the embodiment of FIG. 15 showing the contacts in the open condition;
FIG. 17 is a cutaway side view of the embodiment of FIG. 15;
FIG. 18 is a perspective view of a cam element of the embodiment of FIG. 15;
FIG. 19 is a detailed view of the housing of the embodiment of FIG. 15 illustrating the pivoting action of the cam element of FIG. 18;
FIG. 20 is a plan view of the cradle of the embodiment of FIG. 15; and
FIG. 21 is a detailed view of a slot in the housing of the embodiment of FIG. 15.
DETAILED DESCRIPTION
Referring to the drawings, and initially to FIGS. 1 through 3 thereof, an embodiment of a unitary switch and circuit breaker 10 is disclosed. Device 10 includes a housing 12 for containing the electrical contacts and other elements of the device, as more fully discussed hereinbelow. A rocker arm 14 is pivotally mounted on pivot 16 in housing 12. As will be apparent from the following description, device 10 has at least two functions: a switching function and a circuit breaker function. When the switching function of device 10 is utilized, rocker arm 14 pivots between an "on" and an "off" position in which electricity flows or does not flow, respectively, through device 10. When the circuit breaker function is utilized, device 10 can assume a circuit "open" or a circuit "closed" condition in which electricity does not flow or does flow, respectively, through device 10. The two functions are integral to device 10, and the parts or elements of the illustrated embodiments cooperate to perform the described functions.
A facing 18 surrounds rocker arm 14 and provides a portion of the mounting structure for device 10. A pair of retaining arms 20 extend from the lateral edges of housing 12 for elastically cooperating with a mounting surface to retain device 10 therein. For example, device 10 might be inserted through an opening formed in a flat plate or the like (not shown), with retaining arms 20 flexed to retain device 10 in the opening.
Referring to FIG. 2, device 10 includes an upper terminal lug 22, and a pair of lower terminal lugs 24, 26. As is evident to those of skill in the art, lugs 22, 24, 26 provide electrical connections for device 10. Lower lugs 24, 26 have associated therewith first and second electrical contacts 28, 30, respectively. As discussed more fully hereinbelow, first and second contacts 28, 30 provide electrical switching contacts for the switching function of device 10. A reset element 32 is provided for resetting the circuit breaker function of device 10. Reset element 32 has as an integral part thereof a projecting arm 34 with a tab 36 formed on the end. Reset element 32 also includes a non-conducting area or portion 38 that blocks the flow of current between contacts 28, 30, as will be discussed more fully hereinbelow. Reset element 32 also includes a toothed-portion 40 for cooperating with a spring 42. Spring 42 cooperates with a back wall of device 10 to bias reset element 32 to block the flow of current between contacts 28, 30. Apertures (not shown) are formed in the back wall so that lugs 22, 24 and 26 can project therefrom in the form of male contact blades. The back wall includes a projecting portion 44 to receive spring 42 and reset element 32. Lug 22 provides an electrical connection for a pilot lamp 48. Lamp 48 is positioned in a cradle 46 that fits within rocker arm 14. In the preferred embodiment, rocker arm 14 is made of a transparent or translucent material, such as plastic, whereby lamp 48 is visible. Also in the preferred embodiment, lamp 48 is illuminated when rocker arm 14 is placed in the switch "on" condition, and is not illuminated when rocker arm 14 is placed in the switch "off" condition, or if the circuit breaker function has been actuated (even if rocker arm 14 is in the "on" condition).
FIG. 3 illustrates a bimetallic strip 56 associated with lug 26. Bimetallic strip 56 is a thermally sensitive bimetallic strip with a tongue 57 coupled to lug 26 for mounting contact 30. Such a bimetallic strip can be, for example, a so-called Taylor-type bimetallic strip such as disclosed in U.S. Pat. No. 4,379,278 to Kuczynski et al. Strip 56 is made of a flexible, spring-like material in which a U-shaped cut-out is made from tongue 57 which carries contact 30. As is evident to those with skill in the art, when an overload occurs, strip 56 heats up until tongue 57 snaps back to buckle over the switch center resulting in an instantaneous displacement of the tongue 57 to separate contact 28 on lug 24 from contact 30 on tongue 57.
FIG. 4 illustrates an embodiment of the device of the present invention in which rocker arm 14 has been pivoted so that contacts 28, 30 are in the open condition. Referring briefly to FIG. 2, rocker arm 14 includes an actuating arm 58 projecting therefrom. Arm 58 projects through a hole or an aperture in cradle 46 to engage bimetallic strip 56. The pivotal action of rocker arm 14 causes bimetallic strip 56 to move rightward in the illustrated embodiment to open contacts 28, 30.
In the embodiment of FIG. 4, lug 24 is positioned in slots or grooves 60, 62 formed in housing 12. Lug 22 is disposed in a groove or slot 64 in housing 12. Lug 26 is disposed in a groove or slot 66 in housing 12.
In FIG. 5, reset element 32 is not positioned between contacts 28, 30, as rocker arm 14 is placed in the "on" condition.
The operation of the circuit breaker feature of the illustrated embodiment is next to be described.
When a current surge occurs, and the current supplied to device 10 exceeds a predetermined threshold, bimetallic strip 56 is actuated to separate contacts 28, 30. When the surge occurs, tongue 57 bends enough to buckle over and move contact 30 to the right, as seen in FIGS. 4 and 5, whereby non-conducting portion 38 of reset element 32 is urged into a blocking position between contacts 28, 30 by the biasing action of spring 42.
Assuming that the external power surge is no longer present, displacement of reset element 32 will displace non-conducting portion 38 from a position between contacts 28, 30 whereby current can again flow through contacts 28, 30. Non-conducting portion 38 is returned to its abutting position with contacts 28, 30.
The operation of the switching feature of device 10 is next to be described.
As illustrated in FIG. 4, when rocker arm 14 is placed in the "off" condition, projecting arm 58 engages tongue 57 and laterally displaces it to the right. The lateral displacement of tongue 57 separates contacts 28, 30, thus breaking the flow of current therethrough. Spring 42 biases non-conducting portion 38 of reset element 32 between contacts 28, 30.
Pivotal movement of rocker arm 14 to the "on" condition causes projecting arm 58 to disengage from cam element 59, so that the spring action of tongue 57 returns tongue 57 to its prior position. At this point, non-conducting portion 38 of reset element 32 is still between contacts 28, 30. Tab 36 must next be depressed to displace non-conducting portion 38 from between contacts 28, 30. Tongue 57 then bends over whereby contacts 28, 30 meet. FIG. 5 illustrates device 10 with rocker arm 14, and hence device 10, in the "on" condition. In FIG. 5, reset element 32, and arm 58 have been omitted for ease of illustration.
FIGS. 6 through 9 illustrate the indicator function of an embodiment of the present invention wherein tab 36 extends outwardly from housing 12 through a slot or groove 68 formed on a lateral edge of rocker arm 14. As illustrated most clearly in FIG. 6, when the circuit breaker function of the device 10 has been actuated, and contacts 28, 30 are in the open position, so that no current flows through device 10, tab 36 extends beyond housing 12 visually to indicate that the circuit breaker function of the device is in the "open" condition. In FIG. 6, the switching function of device 10 is in the "off" condition, that is, contacts 28, 30 are separated by a gap or space so that no current can flow therethrough.
In FIG. 7, tab 36 does not extend from housing 12 since the circuit breaker function is in the "closed" condition. Rocker arm 14 of device 10 is in the "on" condition.
In FIG. 8, the circuit breaker function is in the "open" condition, but rocker arm 14 is in the "on" condition. In the illustrated embodiment, tab 36 extends beyond housing 12, visually indicating that the circuit breaker function of device 10 has been actuated and contacts 28, 30 are open. It is to be noted that in the embodiment of FIG. 8, contacts 28, 30 are open, even though rocker arm 14 is in an "on" condition, whereby contacts 28, 30 would be closed. In the illustrated embodiment, non-conducting portion 38 of reset element 32 is disposed between contacts 28, 30, effectively preventing the flow of current therethrough.
FIG. 9 illustrates slot or groove 68 in rocker arm 14 through which tab 36 projects from housing 12.
FIG. 10 illustrates an alternate embodiment of the present invention in which tab 36 is not included as a portion of reset element 32. Rather, projecting arm 34 of reset element 32 engages the lower edge of rocker arm 14. In the illustrated embodiment, when the circuit breaker function of device 10 has been tripped, and is in the "open" condition, displacement of reset element 32 will pivot rocker arm 14 into the "off" position. Conversely, pivotal movement of rocker arm 14 will displace reset element 32 and non-conducting portion 38 from its blocking position between contacts 28, 30. Thus, turning "on" device 10 automatically resets the circuit breaker function of the device. Conversely, operation of the circuit breaker function of device 10 provides a visual indication of such actuation because rocker arm 14 is moved to the "off" position. However, it is to be noted that, in the embodiment of FIG. 10, an operator cannot determine whether device 10 is in the "off" position because the circuit breaker function of the device has been actuated, or because the device 10 has simply been placed in the "off" position.
In the embodiment of FIGS. 1 through 9, tab 36 has a substantially rectangular cross-section that cooperates with a similarly shaped groove 68 in rocker arm 14. Other cross-sectional shapes of tab 36 are possible. For example, as illustrated in FIGS. 11 and 12, tab 36a can have a straight dove-tail shape. Dove-tail tab 36a of FIGS. 11 and 12 comprises a substantially rectangular-shaped central portion 70 with shoulder-shaped portions 72, 74 extending laterally therefrom. In tab 36a of FIGS. 11 and 12, substantially rectangular shoulder portions 72, 74, along with substantially rectangular central portion 70, are dimensioned to give tab 36a a substantially "flattened" appearance.
FIGS. 13 and 14 illustrate a tab 36b with an angular dove-tail shape. Tab 36b cooperates with a similarly shaped groove 68b in rocker arm 14. As illustrated most clearly in FIG. 14, tab 36b has an upper flat surface 76, a lower, flat, plane surface 78, and two slanted faces 80, 82. In tab 36b, faces 76, 78 are substantially larger than faces 80, 82, thus giving tab 36b a "flattened" shape.
It is to be appreciated that, with tabs 36a, 36b configured as in FIGS. 11 through 14, tabs 36a, 36b are held more securely in slots 68a, 68b, than is the case in the embodiment of FIGS. 1 through 9. More particularly, tab 36 is free to be displaced from slot 68 (see FIG. 9) while tabs 36a, 36b are constrained within slots 68a, 68b due to the shape of tabs 36a, 36b and the cooperating shapes of slots 68a, 68b. Thus, tabs 36a, 36b follow the arc of travel of rocker arm 14 when switch 10 is placed in the switch "off" condition. This assures a one-motion reset of the circuit breaker function when rocker arm 14 is placed in the "on" condition.
FIGS. 15-21 illustrate another preferred embodiment of the present invention. This embodiment is particularly advantageous in ensuring that the condition of the switch fully corresponds to the "on ", "off" indication provided by the rocker arm 14 and that the switch is always in the "off" condition when the rocker arm is in the "off" position. To this end, the embodiment of FIG. 15 includes a spring 49 disposed between cradle 46' and rocker arm 14 to bias rocker arm 14 into the full "on" position. A user can thus readily ascertain that the switch is "on" if the flag 36 remains withdrawn or "off" if the flag is projecting upwardly through the slot formed at the end of the rocker.
This embodiment further advantageously includes a cam element (indicated at 59) within housing 10 in operative association with arm 58 and tongue 57 of bimetallic strip 56 for "tripping" the switch in response to movement of rocker arm 14. (It will be understood that in FIG. 15, cam element 59 becomes positioned between slot 94 and arm 57). In the embodiment of FIG. 15, cam element 59 is preferably made of a heat resistant material such as a thermoset resin or other plastic of high temperature deformation characteristics, as can be reset element 36. By making cam element 59 (and reset element 32) of such a heat-resistant plastic, damage to any of the operative elements from heat generated during, e.g., a short circuit can be avoided. At the same time the remaining parts (such as rocker arm 14 and arm 58) can be economically fabricated from other materials since high heat resistence is not necessarily essential.
FIG. 18 illustrates cam element 59 in greater detail. Cam element 59 includes a substantially planar body portion 84 with a foot 86. As illustrated most clearly in FIGS. 19 and 21, foot 86 engages slot 88 in housing 12 to form a floating pivot mounting within the housing for allowing the cam to pivot in response to movement of arm 58 against its canted surfaces 89. (The floating pivot mounting facilitates the assembly operation by avoiding the need for, e.g., close tolerances in aligning pins.) Cam element 59 also includes a projecting portion 90 that extends slightly beyond planar body portion 84. Projecting portion 90 will engage tongue 57 of bimetallic strip 56 to "trip" the circuit.
FIG. 19 illustrates the pivoting action of cam element 59 in response to movement of rocker arm 14 and arm 58. Movement of arm 58 against canted surface 89 causes cam element 59 to rotate in pivotal fashion from the "on" position, indicated in full lines, to the "off" position, indicated in phantom lines.
FIG. 20 illustrates cradle 46' used in the embodiment of FIG. 15. Cradle 46 (FIGS., 1-14), it will be recalled, is used to provide a pivot point for cam element 59 and a fixed point for spring 49. Cradle 46 is provided with an aperture 94 for arm 58. In the embodiment of FIG. 15, aperture 94 is displaced from the left side to the right side of cradle 46', as compared with the location of the aperture in cradle 46 of the embodiment of FIG. 1. This displacement permits the addition of cam element 59 and acts to accommodate arm 58 which must likewise be displaced on rocker 14 to allow the location of the operative association with the cam element 59. Lamp 48 is disposed in rectangular compartment 96.
It is to be appreciated from the above description of the preferred embodiments that a unitary switch and circuit breaker in accord with the present invention is particularly compact, especially because only a single pair of contacts are included therein and are used for both the switching function and the circuit breaker function.
Although illustrative embodiments of the present invention have been described in detail herein with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments, and that various changes and modifications may be effected therein by one skilled in the art without departing from the spirit and scope of the invention as defined in the appended claims. | A unitary switch and circuit breaker (10) includes a switch circuit (14, 16, 22, 24, 26, 56, 57, 58) with first and second contacts (28, 30), the switch circuit (14, 16, 22, 24, 26, 56, 57, 58) being actuable to assume a first condition (FIG. 4) in which the contacts (28, 30) are open and a second condition (FIG. 5) in which the contacts (28, 30) are closed, and a circuit breaker (24, 26, 32, 42, 56, 57) integrally formed with the switch circuit (14, 16, 22, 24, 26, 56, 57, 58) for actuating the contacts (28, 30) to interrupt current flow through the contacts (28, 30) in response to the current flow exceeding a predetermined level and for subsequently preventing the resumption of current flow through the contacts (28, 30) until reset. | 7 |
FIELD OF THE INVENTION AND RELATED ART
[0001] The present invention relates to an image forming apparatus, such as a laser beam printer, an LED printer, a copying machine, etc., which employs a developer supply container, which is removably installable in an image forming apparatus, to supply the image forming apparatus with developer.
[0002] An electrophotographic image forming apparatus such as an electrophotographic printer uses developer made up of microscopic particles. Developer is consumed for image formation. Thus, as an electrophotographic image forming apparatus runs out of developer, it has to be replenished with developer with the use of a developer supply container.
[0003] It has been widely known that a developer supply container is equipped with such a member as a screw which is for conveying the developer in the container while stirring the developer.
[0004] In recent years, however, it has come to be desired to simplify a developing device in structure to reduce a developing device in cost, and/or make a developer supply container recyclable.
[0005] There is disclosed in Japanese Laid-open Patent Application S60-232578, for example, a developer supply container which is substantially smaller in component count than any conventional developer supply container. According to this patent application, the developer storing portion of the developer supply container is formed of an elastic substance, being enabled to expand or contract so that the developer in the main section can be discharged with the utilization f the resiliency of the elastic substance. Structuring a developer supply container like the one disclosed in the abovementioned patent application makes it unnecessary to equip a developer supply container with a screw or the like member for conveying developer while stirring the developer. Therefore, it can reduce a developer supply container in component count.
[0006] By the way, a developer supply container for an image forming apparatus is required to stir the developer therein, and discharge the developer as necessary to supply or replenish the image forming apparatus with developer. In the case of the image forming apparatus disclosed in the abovementioned patent application, its developer passage, through which the developer is discharged, is provided with a valve in order to control the discharging of the developer in the developer supply container by the resiliency of the elastic substance of which the developer supply container is made. Thus, the developer in the developer supply container can be discharged as necessary from the developer supply container while being stirred.
[0007] In the case of the developer supply container disclosed in Japanese Laid-open Patent Application S60-232578, the abovementioned valve always remains under the pressure generated by the resiliency of the elastic substance in the direction to cause the developer supply container to discharge the developer therein. Therefore, the moment the valve begins to be opened, the pressurized air in the developer supply container begins to be released, and therefore, the developer begins to be discharged from the developer supply container by the released pressurized air. This creates a problem. That is, the developer begins to be discharged from the developer supply container before the valve is fully opened. Thus, the portion of the valve, which is still in the developer passage, increases the developer passage in the developer flow resistance preventing thereby the developer from being properly discharged from the developer supply container.
[0008] As the developer flow is partially blocked by the portion of the developer discharge passage, which is higher in developer flow resistance, it occurs sometimes that the toner particles in the block portion of the developer flow developer agglomerates into larger particles, which reduce the developing device (image forming apparatus) in image quality.
[0009] Further, in the case of a developer supply container structured to utilize temporary force, such as the resiliency of the elastic substance of which the developer storing portion of the developer supply container is made to discharge the developer in the developer storing portion, if the positive pressure in the developer storing portion is lost before the valve is fully opened, the pressure difference between the internal air pressure of the developer storing portion and the atmospheric pressure is sometimes lost before the developer in the developer storing portion is fully discharged. Therefore, the amount by which the developer in the developer supply container fails to be discharged is affected by the speed with which the valve is opened. Thus, it sometimes occurred that a substantial mount of developer in the developer supply container fail to be discharged from the container.
SUMMARY OF THE INVENTION
[0010] The present invention is made in consideration of the above-described issues. Thus, the primary object of the present invention is to provide a developer supply container which is significantly less in the amount of developer flow resistance to which the developer in the developer supply container is subjected as the developer is discharged from the developer supply container, and also, to provide an image forming apparatus which is compatible with such a developer supply container.
[0011] According to an aspect of the present invention, there is provided a developer supply container for use with an image forming apparatus, comprising a container shell; a developer accommodation bag accommodating a developer, said developer accommodation bag being contained in said container shell; a developer discharging path for discharging the developer accommodated in said developer accommodation bag to an outside of said developer supply container; an air fluid communication path for fluid communication between inside and outside of said container shell; and a maintaining portion sealing said air fluid communication path to maintain a pressure inside said container shell in a negative pressure state which is lower than a pressure outside said container shell, wherein said developer accommodation bag deforms to discharge the developer, by said maintaining portion opening said air fluid communication path to permit air to enter said container shell through said air fluid communication path.
[0012] Further features of the present invention will become apparent from the following description of exemplary embodiments (with reference to the attached drawings).
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a schematic sectional view of a typical image forming apparatus to which the present invention is applicable.
[0014] FIG. 2 is a schematic sectional view of a typical process cartridge which is removably installable in an image forming apparatus in accordance with the present invention, and is for describing the structure of the cartridge.
[0015] FIG. 3 is a schematic sectional view of a typical toner cartridge which is removably installable in an image forming apparatus in accordance with the present invention.
[0016] FIG. 4 is a schematic external perspective view of the toner cartridge in the first embodiment of the present invention.
[0017] FIG. 5 is a schematic external perspective view of the image forming apparatus in the first embodiment, when the apparatus is ready for the replacement of the toner cartridges therein, or after the replacement of the toner cartridges in the apparatus.
[0018] FIGS. 6( a ) and 6 ( b ) are schematic sectional views of the toner cartridge, and the portion of the image forming apparatus, with which the toner cartridge is coupled, in the first embodiment, after the installation of the cartridge into the apparatus, and is for showing the state of the toner cartridge in the apparatus.
[0019] FIG. 7 is a schematic sectional view of the toner cartridge in the second embodiment of the present invention, and is for showing the structure of the toner cartridge.
[0020] FIG. 8 is a schematic sectional view of the third embodiment of the present invention, and is for showing the structure of the toner cartridge.
[0021] FIG. 9 is a schematic perspective view of the toner cartridge shown in FIG. 8 , and is for showing the structure of the toner cartridge.
[0022] FIGS. 10( a ) and 10 ( b ) are schematic sectional views of the toner cartridge in FIG. 8 , and the portion of the image forming apparatus, with which the toner cartridge is coupled, and is for showing the state of the toner cartridge and the portion of the image forming apparatus, with which the toner cartridge is coupled, after the proper installation of the cartridge into the image forming apparatus.
[0023] FIGS. 11( a ) and 11 ( b ) are drawings for showing the mechanism for re-inflating the toner storage pouch of the toner cartridge in the image forming apparatus, and the operational modes in which the image forming apparatus is operated to re-inflate the toner storage pouch.
[0024] FIGS. 12 ( a ) and 12 ( b ) are drawings for showing another mechanism for re-inflating the toner storage pouch of the toner cartridge in the image forming apparatus, and the operational modes in which the image forming apparatus is operated to re-inflate the toner storage pouch.
[0025] FIGS. 13( a ) and 13 ( b ) are drawings showing yet another mechanism for re-inflating the toner storage pouch of the toner cartridge in the image forming apparatus, and the operational modes in which the image forming apparatus is operated to re-inflate the toner storage pouch.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] Hereinafter, some of the embodiments of the present invention are described in detail with reference with appended drawings.
[0027] In the following description of the embodiments of the present invention, the terms such as “upward, downward, vertical and horizontal” indicate the directions when an image forming apparatus is in normal usage, that is, when a development unit or a process cartridge has been properly installed in an image forming apparatus, and is ready for image formation.
Embodiment 1
(General Structure of Image Forming Apparatus)
[0028] To being with, referring to FIGS. 1 and 2 , the image forming apparatus in this embodiment is described.
[0029] FIG. 1 is a schematic sectional view of the image forming apparatus in this embodiment. FIG. 2 is a process cartridge, which is installable in the image forming apparatus shown in FIG. 1 . It shows the general structure of the process cartridge.
[0030] The image forming apparatus 100 is a full-color laser printer of the so-called inline type, and also, of the so-called intermediary transfer type. The image forming apparatus 100 forms a full-color image on a sheet 12 of recording medium such as ordinary paper, plastic, fabric, etc., according to the information of an image to be formed.
[0031] The information about an image to be formed is inputted into the main assembly 101 of the image forming apparatus 100 from an image reading apparatus which is in connection to the main assembly 101 , or a host device such as a personal computer which is in connection to the main assembly 101 so that electrical signals can be exchanged between the host device and the main assembly 101 .
[0032] The image forming apparatus 100 has multiple image forming portions, more specifically, image forming portions SY, SM, SC and SK for forming yellow (Y), magenta (M), cyan (C) and black (K) images, respectively. In this embodiment, the image forming portions SY, SM, SC and SK are horizontally aligned in parallel (tandem).
[0033] The image forming portions SY, SM, SC and SK are practically the same in structure and operation, although they are different in the color of the images they form. Thus, in the following description of the image forming apparatus, the suffixes Y, M, S and K which are for indicating color are not shown. That is, in terms of structural components, the four image forming portions are described together, unless they need to be differentiated.
[0034] The image forming apparatus 100 has multiple image bearing members, more specifically, four photosensitive drums 1 which are aligned in parallel (tandem) in the direction perpendicular to the vertical direction. Each photosensitive drum 1 is rotationally driven by an unshown driving means in the direction indicated by an arrow mark A in FIG. 2 . The image forming apparatus 100 has also a charge roller 2 and a scanner unit 3 , which are in the adjacencies of the peripheral surface of the photosensitive drum 1 . The charge roller 2 is for uniformly charging the peripheral surface of the photosensitive drum 1 . The scanner unit 3 is an exposing means. It forms an electrostatic latent image on the peripheral surface of the photosensitive drum 1 , by emitting a beam of laser light while modulating the beam of laser light according to the information of the image to be formed.
[0035] The image forming apparatus 100 has also development unit 4 and a cleaning member 6 , which also are disposed in the adjacencies of the peripheral surface of the photosensitive drum 1 . The development unit 4 is a developing means for developing the electrostatic image into a toner image. The cleaning member 6 is for removing the transfer residual toner, that is, the toner remaining on the peripheral surface of the photosensitive drum 1 after the transfer of a toner image from the photosensitive drum 1 . Further, the image forming apparatus 100 has an intermediary transfer belt 5 , as an intermediary transferring member, which is for transferring the toner image on the photosensitive drum 1 , onto the sheet 12 of recording medium. The intermediary transfer belt 5 is positioned so that it directly faces the four photosensitive drums 1 . In terms of the rotational direction of the photosensitive drum 1 , the point at which the peripheral surface of the photosensitive drum 1 is charged by the charge roller 2 , is the point at which the peripheral surface of the photosensitive drum 1 is exposed, the point at which the electrostatic latent image on the peripheral surface of the photosensitive drum 1 is developed, the point at which the toner image is transferred onto the intermediary transfer belt 5 , and the point at which the peripheral surface of the photosensitive drum 1 is cleaned by the cleaning member 6 , are positioned in the listed order.
[0036] The development unit 4 reversely develops the electrostatic latent image on the peripheral surface of the photosensitive drum 1 , by placing the development roller 17 , as a developer bearing member, in contact with the photosensitive drum 1 . That is, the development unit 4 develops the electrostatic image, by adhering toner charged to the same polarity (negative in this embodiment) as the photosensitive drum 1 , to the various points of the peripheral surface of the photosensitive drum 1 , which have just been made to attenuate in the amount of charge, by the exposure.
[0037] The intermediary transfer belt 5 is an endless belt. It is placed in contact with the peripheral surface of the photosensitive drum 1 , and circularly moves in the direction indicated by an arrow mark B in FIG. 1 . It is suspended, and kept tensioned, by multiple belt supporting members, more specifically, an idler roller 51 , a belt backing roller 52 (which opposes primary transfer roller), and a driver roller 53 .
[0038] On the inward side of the loop (belt loop) which the intermediary transfer belt 5 forms, four primary transfer rollers 8 are disposed in parallel in such a manner that they oppose the photosensitive drums 1 one for one. Each primary transfer roller 8 forms a primary transfer portion N 1 , which is the area of contact between the intermediary transfer belt 5 and photosensitive drum 1 , by pressing the intermediary transfer belt 5 upon the peripheral surface of the photosensitive drum 1 . To the primary transfer roller 8 , bias which is opposite in polarity from the normal toner polarity is applied from a first transfer bias power source (unshown). Thus, the toner image on the photosensitive drum 1 is transferred (primary transfer) onto the intermediary transfer belt 5 .
[0039] On the outward side of the loop which the intermediary transfer belt 5 forms, there is a secondary transfer roller 9 , which is positioned so that it opposes the belt backing roller 52 . The secondary transfer roller 9 forms a secondary transfer portion N 2 , that is, the area of contact between itself and intermediary transfer belt 5 , by being pressed against the belt backing roller 52 , with the presence of the intermediary transfer belt 5 between itself and belt backing roller 52 . To the secondary transfer roller 9 , bias which is opposite in polarity from the normal toner polarity is applied from an unshown secondary transfer bias power source. Thus, the toner image on the intermediary transfer belt 5 is transferred (secondary transfer) onto the sheet 12 of recording medium.
(General Operation of Image Forming Apparatus)
[0040] When an image is formed by the image forming apparatus 100 in this embodiment, first, the peripheral surface of the photosensitive drum 1 is uniformly charged by the charge roller 2 . Then, the uniformly charged portion of the peripheral surface of the photosensitive drum 1 is scanned by (exposed to) the beam of laser light projected by the scanner unit 3 while being modulated according to the information of the image to be formed. Consequently, an electrostatic latent image which is in accordance with the information is effected on the peripheral surface of the photosensitive drum 1 . This electrostatic latent image on the peripheral surface of the photosensitive drum 1 is developed into a toner image, by the development unit 4 .
[0041] Then, the toner image on the photosensitive drum 1 is transferred (primary transfer) onto the intermediary transfer belt 5 by the function of the primary transfer roller 8 . During the formation of a full-color image, the above-described process is carried out in the listed sequence in the image forming portions SY, SM, SC and SK. As a result, four monochromatic toner images, different in color, are transferred (primary transfer) in layers onto the intermediary transfer belt 5 .
[0042] Meanwhile, the sheet 12 of recording medium is conveyed to the secondary transfer portion N 2 in synchronism with the circular movement of the intermediary transfer belt 5 , and is conveyed through the secondary transfer portion N 2 . While the sheet 12 of recording medium is conveyed through the secondary transfer portion N 2 , the four monochromatic toner images, different in color, on the intermediary transfer belt 5 are transferred together (secondary transfer) onto the sheet 12 of recording medium by the function of the secondary transfer roller 9 .
[0043] After the toner image transfer onto the sheet P of recording medium, the sheet 12 is conveyed to a fixing device 10 , in which the sheet 12 and the toner images thereon are subjected to heat and pressure. Thus, the toner images become fixed to the sheet 12 .
[0044] The primary transfer toner, that is, the toner remaining on the peripheral surface of the photosensitive drum 1 after the primary transfer, is removed and recovered by the cleaning member 6 . As for the secondary transfer residual toner, that is, the toner remaining on the intermediary transfer belt 5 after the secondary transfer, is removed by an intermediary transfer belt cleaning device 11 ; the intermediary transfer belt 5 is cleaned by the device 11 .
(Structure of Process Cartridge)
[0045] Next, the process cartridge which is removably installable in the image forming apparatus 100 is described about its structure.
[0046] Referring to FIG. 2 , the photosensitive drum 1 , charge roller 2 , development unit 4 , and cleaning member 6 make up a process cartridge 7 by being integrally placed in a cartridge. The process cartridge 7 is removably installable in the main assembly 101 of the image forming apparatus 100 , by being guided by such means as a cartridge installation guide, a cartridge positioning member, etc., of the main assembly 101 of the image forming apparatus 100 . In this embodiment, the four process cartridges 7 which correspond to four primary colors, one for one, of which the multicolor image to be formed is made up, are the same in structure. The four process cartridges 7 contain yellow (Y), magenta (M), cyan (C) and black (K) toners, one for one.
[0047] The process cartridge 7 is an integral combination of a photosensitive member unit 13 having the photosensitive drum 1 , and the development unit 4 having the development roller 17 , etc.
[0048] The photosensitive drum unit 13 has a cleaning means frame 14 as a frame for supporting various components of the photosensitive drum unit 13 . That is, the cleaning means frame 14 supports the charge roller 2 , cleaning member 6 , etc., in addition to the photosensitive drum 1 .
[0049] As for the development unit 4 , it has a developing means frame as a frame for supporting various components of the development unit 4 . The development unit 4 has the development roller 17 which rotates in the direction indicated by an arrow mark in FIG. 2 , in contact with the photosensitive drum 1 .
[0050] The development unit 4 has also a toner supply roller 20 , which rotates in the direction indicated by an arrow mark E in FIG. 2 , virtually in contact with the peripheral surface of the development roller 17 to supply the development roller 17 with toner.
[0051] The developing means frame 18 has a development blade 21 for regulating in thickness the toner layer on the peripheral surface of the development roller 17 . The development blade 21 is a piece of springy metallic plate. It is kept pressed upon the peripheral surface of the development roller 17 so that a preset amount of contact pressure is maintained between the development blade 21 and development roller 17 . Thus, a thin layer of toner is formed on the peripheral surface of the development roller 17 , and is supplied to the peripheral surface of the photosensitive drum 1 .
[0052] Further, the developing means frame 18 has a toner storage chamber 18 a for temporarily storing toner, and a development chamber 18 b in which the development roller 17 , toner supply roller 29 , etc., are held. The toner storage chamber 18 a is provided with a toner entrance 22 , through which the toner storage chamber 18 a receives toner.
[0053] The toner storage chamber 18 a and development chamber 18 b are in connection to each other through an opening 18 c as a toner passage. Thus, the toner with which the toner storage chamber 18 a is supplied is conveyed to the development chamber 18 b by a stirring member 19 with which the toner storage chamber 18 a is provided.
[0054] In the development unit 4 structured as described above, as toner enters the toner storage chamber 18 a through the toner entrance 22 , it is temporarily stored in the toner storage chamber 18 a . However, the development unit 4 may be structured so that toner directly enters the development chamber 18 b through the toner entrance 22 .
(Structure of Toner Cartridge)
[0055] Next, the toner cartridge (developer supply container) which supplies the development unit 4 with toner is described.
[0056] FIG. 3 is a sectional view of the toner cartridge, and FIG. 4 is an external perspective view of the toner cartridge.
[0057] The toner cartridge 15 has a toner storage pouch 41 (developer storage pouch), which has elasticity (resiliency) and is expandable (inflatable) to store toner 140 . It has also an external shell 40 which internally holds the toner storage pouch 41 . The external shell 40 functions as a frame for supporting the internal components of the toner cartridge 15 other than the toner storage pouch 41 , in addition to the toner storage pouch 40 .
[0058] The external shell 40 is provided with a toner discharge nozzle 42 (developer discharge passage), an air passage 43 , and a cartridge installation guide 48 . The toner discharge nozzle 42 is in connection to the toner storage pouch 41 , in the external shell 40 . Thus, it is through the toner discharge nozzle that the toner 140 in the toner storage pouch 41 is discharged from the external shell 40 . The toner storage pouch 41 is supported by the external shell 40 by being in connection to the toner discharge nozzle 42 .
[0059] The toner discharge nozzle 42 is a cylindrical tube, and protrudes from the external shell 40 in such a direction that its axial line is parallel to the direction in which the toner cartridge 15 is installed into the apparatus main assembly 101 .
[0060] The air passage 43 connects an airtight chamber 44 , which is the space between the external shell 40 and toner storage pouch 41 , with the ambient air (atmospheric air). It allows air to move between the airtight chamber 44 and the outside of the external shell 40 .
[0061] As for the material for the external shell 40 , it is desired to be such a substance that can provide the external shell 40 with such an amount of rigidity that can prevent the external shell 40 from being severely deformed by the change in the internal pressure of the external shell 40 . In this embodiment, polystyrene is used as the material for the external shell 40 . Also regarding the material for the external shell 40 , it may be practically any substance as long as it can enable the external shell 40 to withstand a certain amount of pressure. For example, it may be ABS, polyester, polyethylene, polypropylene, or the like resin. It may be also a metallic substance.
[0062] As the material for the toner storage pouch 41 , various resins can be used. For example, polyamide, polyurethane, polyamide elastomer, polyester elastomer, polyurethane elastomer, polystyrene elastomer, fluorinated elastomer, silicone rubber, latex rubber, or the like elastomer, may be used. Further, the material for the toner storage pouch 41 may be a combination of two or more among the above listed substances. In particular, from the standpoint of providing the toner storage pouch 41 with a large amount of internal pressure for discharging the toner, it is desired that a substance which is substantially stretchable and great in resiliency is used as the material for the toner storage pouch 41 . In this embodiment, among the above listed substances, latex rubber was used as a preferable material for the toner storage pouch 41 , from the standpoint of stretchability and flexibility.
[0063] In consideration of the amount of resistance which the toner discharge nozzle 42 generates against the toner flow as the toner 140 is discharged through the toner discharge passage 14 , the internal diameter of the toner discharge passage 41 is desired to be no less than 4 mm. In comparison, the air passage 43 is a passage through which only air moves into, or out of, the airtight chamber 44 . Therefore, the amount of resistance which the air passage 43 generates when air moves through the air passage 43 is does not matter. Therefore, the air passage 43 may be smaller in internal diameter than the toner discharge nozzle 42 . However, the internal diameter of the air passage 43 is desired to be no less than 2 mm.
[0064] Concretely, in this embodiment, the toner discharge nozzle 42 and air passage 43 are 6 mm and 4 mm, respectively, in internal diameter. Setting the internal diameter of the air passage 43 to be smaller than that of the toner discharge nozzle 42 makes it possible to reduce the toner cartridge 15 and image forming apparatus 100 in size.
[0065] According to the gist of the present invention, this embodiment is not intended to limit the present invention in scope in terms of the specification, in particular, dimension, of the toner cartridge 15 .
[0000] (Filling of Toner Cartridge with Toner)
[0066] Next, the procedure for filling the toner cartridge 15 with toner 140 is described.
[0067] The toner storage pouch 41 for storing toner 140 is filled with a preset amount of toner 140 , and also, a certain amount of air. The toner storage pouch 41 is elastic. Thus, as air is injected into the toner storage pouch 41 , the toner storage pouch 41 expands (inflates) in the external shell 40 , causing thereby the air in the airtight chamber 44 to discharge out of the external shell 40 through the air passage 43 .
[0068] After the filling of the toner storage pouch 41 with the preset amount of toner 140 , and the certain amount of air, the air passage 43 is airtightly sealed with a thin film seal 47 (means for keeping airtight chamber negative in internal pressure) for preventing air from entering into, or exiting from, the airtight chamber 44 through the air passage 43 . Thus, unless the thin film seal 47 is removed, it does not occur that the atmospheric air flows into the airtight chamber 44 , or the air in the airtight chamber 44 flows out of the external shell 40 (airtight chamber 44 ).
[0069] In other words, it is after the air in the airtight chamber 44 is pushed out of the external shell 40 by the expansion (inflation) of the toner storage pouch 41 that the air passage 4 is blocked by the thin film seal 47 to prevent the atmospheric air from flowing into the interior (airtight chamber 44 ) of the external shell 40 .
[0070] On the other hand, the toner storage pouch 41 tends to contract (deflate) because of its resiliency provided by the elasticity of the substance of which it is made. However, the ambient air is prevented by the thin film seal 47 from flowing into the airtight chamber 44 . Therefore, as the toner storage pouch 41 begins contract (deflate), the air in the airtight chamber 44 begins to be reduced in internal pressure. Thus, the air in the airtight chamber 44 begins to become low in pressure than the ambient air pressure (it becomes negative in pressure relative to atmospheric pressure). Consequently, the toner storage pouch 41 is made to remain expanded (inflated) in the external shell 40 , with the amount of the force which causes the toner storage pouch 41 filled with the ambient air, to contract, being equal to the amount of the force generated by the negative air pressure in the airtight chamber 44 . That is, the thin film seal 47 keeps the interior (airtight chamber 44 ) negative in pressure.
[0071] Therefore, even when the interior of the toner storage pouch 41 is open to the atmospheric air through the toner discharge nozzle 42 , it is possible to prevent the toner 140 and air in the toner storage pouch 41 from being discharged out of the toner storage pouch 41 by the resiliency of the toner storage pouch 41 .
[0072] Further, the toner discharge nozzle 42 is sealed with a seal 46 for the toner discharge nozzle 42 , during the manufacturing of the toner cartridge 15 , in order to prevent the toner 140 and air in the toner storage pouch 41 from being discharged while the toner cartridge 15 is shipped.
[0073] After the toner storage pouch 41 in which a preset amount of toner 140 , and a certain amount of air, was present, was expended (inflated) in the external shell 40 , which is 250 cc in capacity, to a size of 200 cc, the air pressure in the airtight chamber 44 was roughly −10 kPa relative to the atmospheric pressure. That is, the airtight chamber 44 remained negative in air pressure relative to the atmospheric air.
(Installation of Toner Cartridge)
[0074] Next, the procedure for installing the toner cartridge 15 into the image forming apparatus 100 , and the procedure for discharging the toner 140 in the toner storage pouch 41 , into the toner storage chamber 18 a (supplying toner storage chamber with toner), are described.
[0075] FIG. 5 is an external perspective view of the image forming apparatus 100 during the installation of the toner cartridge 15 into the image forming apparatus 100 .
[0076] Referring to FIG. 5 , as an operator opens the front door 70 of the image forming apparatus 100 , an opening 71 for installing the toner cartridge 15 appears. The main assembly 101 of the image forming apparatus 100 is provided with toner cartridge installation ribs 72 . Thus, the toner cartridge 15 is to be slid (inserted) into the main assembly 101 , with the installation ribs 72 being fitted in the installation guide 48 of the external shell 40 .
[0077] FIG. 6 is a schematic sectional view of the toner cartridge 15 , and the portion of the image forming apparatus 100 , with which the toner cartridge 15 is in connection. More specifically, FIG. 6( a ) is a schematic sectional view of the toner cartridge 15 , and the portion of the image forming apparatus 10 , with which the toner cartridge 15 is in connection, right after the completion of the installation of the toner cartridge 15 . FIG. 6( b ) is practically the same as FIG. 16( a ), except that in FIG. 6( b ), the thin film seal 47 has just been peeled away.
[0078] The first step for installing the toner cartridge 15 into the image forming apparatus 100 is to peel the toner discharge passage seal 46 . Then, the toner cartridge 15 is to be slid into the toner cartridge chamber of the apparatus main assembly 101 . As the toner cartridge 15 is inserted, the toner discharge nozzle 42 enters the toner discharge nozzle receptacle 80 (developer discharge passage connector) of the image forming apparatus 100 .
[0079] The toner discharge nozzle 42 is in the form of a piece of cylindrical tube, and its axial line is parallel to the direction in which the toner cartridge 15 is inserted into the apparatus main assembly 101 . Further, the apparatus main assembly 101 is structured so that as the toner cartridge 15 is slid into the apparatus main assembly 101 , the toner discharge nozzle 42 becomes connected to the toner discharge nozzle receptacle 80 of the apparatus main assembly 101 .
[0080] The toner discharge nozzle receptacle 80 is in connection to the toner entrance 22 of the toner storage chamber 18 a , enabling the toner storage chamber 18 a to be supplied with toner 140 from the toner cartridge 15 . Further, the toner discharge nozzle receptacle 80 is provided with a seal 81 , which engages with the toner discharge nozzle 42 (toner discharge passage is inserted into seal 81 ) to prevent the toner 140 from scattering while the toner storage chamber 18 a is supplied with the toner 140 .
[0081] In this embodiment, an oil seal was employed as the seal 81 . However, the seal 81 may be made of felt or sponge so that it is compressible by a preset amount.
[0082] Next, referring to FIG. 6( b ), after the installation of the toner cartridge 15 into the image forming apparatus 100 , a user is to remove the thin film seal 47 which is blocking the air passage 43 . Prior to the removal of the thin film seal 47 for the air passage 43 , the air in the airtight chamber 44 of the toner cartridge 15 is negative in pressure relative to the ambient air. Thus, the toner storage pouch 41 remained expanded (inflated) by the negative air pressure of the airtight chamber 44 .
[0083] Thus, the moment the thin film seal 47 is removed, the ambient air flows (is introduced) into the airtight chamber 44 , cancelling the negative air pressure of the airtight chamber 44 . As a result, the force which kept the toner storage pouch 41 expanded (inflated), in coordination with the negative air pressure in the airtight chamber 44 , is lost. Thus, the toner storage pouch 41 , which is an elastic component, is allowed to be contracted (deflated) by its own resiliency (allowed to deform by contracting).
[0084] That is, the phenomenon that as the air passage 43 is unblocked by the removal of the thin film seal 47 , the airtight chamber 44 stops remaining negative in its internal air pressure, and therefore, the toner storage pouch 41 , which is an elastic component, is allowed to contract, can be utilized to discharge the toner 140 in the toner storage pouch 41 , along with the air in the toner storage pouch 41 , through the toner discharge nozzle 42 . As the toner 140 is discharged through the toner discharge nozzle 42 , it passes through the toner discharge nozzle receptacle 80 , and enters the toner storage chamber 18 a through the toner entrance 22 .
[0085] The above-described structure of the combination of the image forming apparatus 100 and toner cartridge 15 in this embodiment, and its operation and effects, can be summarized as follows. That is, the developer supply container (toner cartridge 15 ) is equipped with a negative pressure maintaining-cancelling means (thin film seal 47 , negative pressure maintenance portion), which is capable of utilizing the resiliency of the developer storage pouch 41 (toner storage pouch 41 ) made of an elastic substance, to keep the airtight chamber 44 (interior of external shell 40 ) negative in internal air pressure relative to the air pressure of the outside of the external shell 40 , or cancelling the negative pressure of the internal air of the airtight chamber 41 .
[0086] Therefore, until the developer supply container is installed into the apparatus main assembly 101 , or in the like situation, the airtight chamber 44 is kept negative in its internal pressure to prevent the developer storage pouch 41 from contracting, in order to prevent the developer in the developer storage pouch 41 from being discharged from the pouch 41 .
[0087] On the other hand, when it is necessary to release the toner in the toner storage pouch 41 to supply the apparatus main assembly 101 with developer after the installation of the toner cartridge 15 into the apparatus main assembly 101 of the image forming apparatus 100 , the airtight chamber 44 is relieved of the negative pressure, being thereby made equal in air pressure to the ambience. Thus, the developer in the developer storage pouch 41 is discharged into the toner storage chamber 18 a of the apparatus main assembly 101 through the developer discharge passage (toner discharge nozzle 42 ) by the resiliency of the developer storage pouch 41 .
[0088] As described above, the developer is discharged by the negative pressure maintaining-cancelling means, the operation for discharging the developer can be controlled while the developer discharge passage (developer discharge nozzle 42 ) is kept open. Therefore, it is possible to prevent the problem which a combination of an image forming apparatus and a developer supply cartridge (toner cartridge 15 ), which is in accordance with the prior art, suffers, more specifically, the problem that, because the operation to discharge the toner in the toner storage pouch is controlled by the opening and closing of the developer discharge passage (developer discharge nozzle 42 ), a part of the developer discharge passage is increased in developer (toner) flow resistance, and therefore, the developer discharge passage is sometimes clogged up by the developer.
Embodiment 2
[0089] Next, the image forming apparatus in another embodiment of the present invention is described.
[0090] The portions of the image forming apparatus in this embodiment, which are the same as, or similar to, the counterparts in the first embodiment are given the same referential codes as those given to the counterparts, and are not described, in order not to repeat the same description. This embodiment is different from the first embodiment only in that the toner cartridge 15 a is different in structure from the toner cartridge 15 in the first embodiment.
(Structure of Toner Cartridge)
[0091] FIG. 7 is a schematic sectional view of the toner cartridge 15 a in this embodiment. It shows the structure of the toner cartridge 15 a.
[0092] Referring to FIG. 7 , the external shell 40 of the toner cartridge 15 a is similar in structure as the toner cartridge 15 in the first embodiment, except that the external shell 40 of the toner cartridge 15 a in this embodiment is provided with a one-way valve 45 for allowing the air in the airtight chamber 44 to be discharged out of the external shell 40 . More specifically, the one-way valve 45 is between the airtight chamber 44 and the outside of the toner cartridge 15 a . It allows the air in the airtight chamber 45 to flow out of the airtight chamber 44 into the ambience, but does not allow the ambient air to enter the airtight chamber 44 . In other words, it is only in one direction, that is, from within the external shell 40 to the outside of the external shell 41 , that the one-way valve 45 allows air to move through it.
[0093] More specifically, this embodiment is different from the first embodiment in the order in which the thin film seal 45 for preventing the ambient air from flowing into the airtight chamber 44 through the air passage 43 , is attached to the external shell 40 . Next, how the toner cartridge 15 a is assembled is described.
[0000] (Filling of Toner Cartridge with Toner)
[0094] First, the process for filling the toner cartridge 15 a with toner 140 is described. In the case of the toner cartridge 15 a in this embodiment, it is after the attachment of the thin film seal 47 to the external shell 40 that the toner storage pouch 41 is filled with the toner 140 .
[0095] When the toner storage pouch 41 for storing toner 140 is filled with toner 140 , not only is it filled with a preset amount of toner 140 through the toner discharge nozzle 42 , but also, the ambient air is forced into the toner storage pouch 40 through the toner discharge nozzle 42 . Thus, as the toner 140 and air are filled into the storage pouch 41 , the toner storage pouch 41 expands in the external shell 40 , because the toner storage pouch 41 is elastic. Thus, the air in the airtight chamber 44 is compressed by the expansion of the toner storage pouch 41 . However, the external shell 40 is provided with the one-way valve 45 . Thus, a certain amount of the air in the airtight chamber 44 is discharged out of the external shell 40 (airtight chamber 44 ) through the one-way valve 45 .
[0096] As described above, the toner cartridge 15 a in this embodiment is provided with the one-way valve 45 . Therefore, the toner storage pouch 41 in the external shell 40 of the toner cartridge 15 a is allowed to expand even after the attachment of the thin film seal 47 to the external shell 40 to block the air passage 43 .
[0097] By the way, the one-way valve 45 allows the air in the airtight chamber 44 to be discharged out of the external shell 40 , but does not allow the ambient air of the external shell 40 to flow into the airtight chamber 44 . That is, the air in the airtight chamber 44 is forced out of the external shell 40 by the expansion of the toner storage pouch 41 . But, as long as the external shell 40 is kept airtight, the ambient air is not allowed to flow into the airtight chamber 44 .
[0098] As the injection of air into the toner storage pouch 41 is stopped, the toner storage pouch 41 is made to contract by its resiliency attributable to its elasticity, like the toner storage pouch 41 in the first embodiment. However, the toner cartridge 15 a in this embodiment is structured as described above. Therefore, it does not occur that as the toner storage pouch 41 contracts, the ambient air flows into the airtight chamber 44 . Therefore, the air in the airtight chamber 44 is reduced in pressure. Thus, the airtight chamber 44 becomes, and remains, negative in air pressure relative to the atmospheric pressure (external pressure). Consequently, the force attributable to the contraction of the toner storage pouch 41 expanded by the air injected into the toner storage pouch 41 along with toner 140 , becomes equal to the force generated by the negative pressure of the air in the airtight chamber 44 . Thus, the toner storage pouch 41 remains expanded in the external shell 40 .
[0099] Therefore, even after the toner storage pouch 41 becomes open to the atmospheric air through the toner discharge nozzle 42 , it is possible to prevent the toner 140 in the toner storage pouch 41 from being discharged, along with the air in the toner storage pouch 41 , from the toner storage pouch 41 .
[0100] Prior to the shipment of the toner cartridge 15 a , a toner discharge passage seal 46 is attached to the external shell 40 to block the toner discharge nozzle 42 , in order to prevent the toner 140 and air in the toner storage pouch 41 from being discharged during the shipment of the toner cartridge 15 a.
[0101] In the first embodiment, it is after the filling of the toner storage pouch 41 with a preset amount of a combination of toner 140 and air that the thin film seal 47 (negative pressure maintaining seal) is attached to the external shell 40 to block the air passage 43 to prevent the ambient air from flowing into the airtight chamber 44 through the air passage 43 , or the air in the airtight chamber 44 from flowing out of the airtight chamber 44 through the air passage 43 , in order to make, and keep, the air in the airtight chamber 44 negative in pressure.
[0102] In comparison, in this embodiment, the external shell 40 is provided with the one-way valve 45 , which does not allow the ambient air to flow into the airtight chamber 44 . Thus, as the toner storage pouch 41 is made to contract by its resiliency attributable to its elasticity after the discharging of the air in the airtight chamber 44 through the one-way valve 45 , the airtight chamber 44 becomes negative in air pressure.
[0103] It takes a certain length of time for the adhesive used to attach the thin film seal 47 to the external shell 40 to block the air passage 43 , to cure enough to prevent air from flowing into, or out of, the airtight chamber 44 through the air passage 43 . Therefore, in the case of a toner cartridge structured like the one in the first embodiment, it was necessary for the toner cartridge to be left alone while the toner storage pouch 41 is kept high in internal pressure.
[0104] In the case of the toner cartridge 15 a in this embodiment, the external shell 40 is provided with the one-way valve 45 . Therefore, this embodiment is shorter than the first embodiment in the length of time it take to make the airtight chamber 44 negative in internal air pressure. In other words, providing a toner cartridge with the one-way valve 45 can improve the manufacturing of the toner cartridge in productivity.
[0105] The installation of the toner cartridge 15 a in this embodiment into the image forming apparatus 100 , and the discharging of toner 140 from the toner cartridge 15 a into the toner storage chamber 18 a to replenish with the toner storage chamber 18 a , are the same as the installation of the toner cartridge 15 in the first embodiment into the image forming apparatus 100 , and the discharging of toner 140 into the toner storage chamber 18 a in the first embodiment.
Embodiment 3
[0106] Next, the image forming apparatus in another embodiment of the present invention is described.
[0107] The portions of the image forming apparatus in this embodiment, which are the same as, or similar to, the counterparts in the first embodiment are given the same referential codes as those given to the counterparts, and are not described in order not to repeat the same description. This embodiment is different from the first embodiment in that the toner cartridge 15 b is different in structure from the toner cartridge 15 in the first embodiment.
(Structure of Toner Cartridge)
[0108] FIG. 8 is a schematic sectional view of the toner cartridge 15 b in this embodiment. It shows the structure of the toner cartridge 15 b . FIG. 9 is a schematic sectional view of the toner cartridge 15 b in this embodiment. It shows the structure of the toner cartridge 15 b.
[0109] Referring to FIGS. 8 and 9 , the toner cartridge 15 b in this embodiment is provided with an air suction nozzle 43 a , which is on the same side as the toner discharge nozzle 42 . The air suction nozzle 43 a is the same in shape as the toner discharge nozzle 42 . That is, it is in the shape of a cylindrical tube, and protrudes from the external shell 40 , in the same direction as the direction in which the toner cartridge 15 b is inserted into the apparatus main assembly 101 .
(Installation of Toner Cartridge)
[0110] FIG. 10 is a schematic sectional view of the toner cartridge 15 b , and the portion of the image forming apparatus 100 a , with which the toner cartridge 15 b is in connection. More specifically, FIG. 10( a ) is a schematic sectional view of the toner cartridge 15 b , and the portion of the image forming apparatus 10 , with which the toner cartridge 15 is in connection, right after the insertion of the installation of the toner cartridge 15 b halfway into the apparatus main assembly 101 . FIG. 10( b ) is practically the same as FIG. 10( a ), except that in FIG. 10( b ), the toner cartridge 15 b is all the way in the image forming apparatus 100 a.
[0111] The image forming apparatus 100 a into which the toner cartridge 15 b is slid is provided with an air suction nozzle receptacle 90 , with which the air suction nozzle 43 a is coupled.
[0112] As the toner cartridge 15 b is slid into the image forming apparatus 100 a , the toner discharge nozzle 42 begins to enter the toner discharge nozzle receptacle 80 of the image forming apparatus 100 a , at a first point, shown in FIG. 10 a ), during the sliding of the toner cartridge 15 b into the image forming apparatus 100 a.
[0113] The toner discharge nozzle receptacle 80 is in connection to the toner entrance 22 with which the toner storage chamber 18 a is provided as is the toner discharge nozzle receptacle 80 in the first embodiment. Thus, the toner 140 in the toner cartridge 15 b can be supplied to the toner storage chamber 18 a . Further, the toner discharge nozzle receptacle 80 is provided with a receptacle seal 81 which airtightly fits around the toner discharge nozzle 42 to prevent toner 140 from being scattered while the toner 140 is supplied into the toner storage chamber 18 a . It is at the first position that the toner discharge nozzle 42 begins to fit into the receptacle seal 81 .
[0114] Then, the toner cartridge 15 b is inserted further into the apparatus main assembly 100 a until it reaches the position (second position) shown in FIG. 10( b ). During this movement of the toner cartridge 15 b , the air suction nozzle 43 enters the air suction nozzle receptacle 90 with which the image forming apparatus 100 a is provided.
[0115] The air suction nozzle 43 a is in the form of a cylindrical tube. It axial line is parallel to the direction in which the toner cartridge 15 b is inserted into the apparatus main assembly 101 . Therefore, as the toner cartridge 15 b is slid into the apparatus main assembly 101 , the air suction nozzle 43 a becomes connected to the air suction nozzle receptacle 90 of the apparatus main assembly 101 .
[0116] The air suction nozzle receptacle 90 is provided with a seal breaking cylindrical member 91 for breaking the thin film seal 47 a (negative pressure maintaining portion) with which the air suction nozzle 43 a remains sealed. The central hollow of the seal breaking cylindrical member 91 is in connection to the internal space of the image forming apparatus 100 a , the air pressure of which is the same as the atmospheric pressure.
[0117] As described before, the air suction nozzle 43 a has been kept sealed by the thin film seal 47 a in order to prevent the ambient air from entering into the airtight chamber 44 , or the air in the airtight chamber 44 from being discharged from the airtight chamber 44 . However, while the toner cartridge 15 b is inserted to the second position from the first position, the thin film seal 47 a for the air suction nozzle 43 a comes into contact with the seal breaking member 91 , and is broken by the seal breaking member 91 .
[0118] Until the thin film seal 47 a for the air suction nozzle 43 a is broken, the airtight chamber 44 of the toner cartridge 15 b remains negative in air pressure relative to the atmospheric pressure. That is, the toner storage pouch 41 is kept expanded by the negative air pressure of the airtight chamber 44 .
[0119] However, the moment the thin film seal 47 a is broken by the seal breaking member 91 , the atmospheric air flows into the airtight chamber 44 through the cylindrical hollow of the seal breaking member 91 and the air suction nozzle 43 a , making the internal air pressure of the airtight chamber 44 the same as the atmospheric pressure. Thus, the force generated by the negative internal air pressure of the airtight chamber 44 in the direction to keep the toner storage pouch 41 expanded is lost. Therefore, the toner storage pouch 41 is made to contract by its resiliency attributable to its elasticity.
[0120] Thus, the moment the airtight chamber 44 is made to lose its negative internal air pressure, it becomes possible to utilize the contraction of the toner storage pouch 41 , which is an elastic member, to discharge the toner 140 in the toner storage pouch 41 , along with the air in the toner storage pouch 41 , through the toner discharge nozzle 42 . As the toner 140 is discharged through the toner discharge nozzle 42 , it travels through the toner discharge nozzle receptacle 80 , and then, is supplied to the toner storage chamber 18 a through the toner entrance 22 .
[0121] In this embodiment, the toner cartridge 15 a is structured so that the toner discharge nozzle 42 and air suction nozzle 43 a protrude from the same side of the external shell 40 . Thus, as the toner cartridge 15 b is slid into the image forming apparatus 101 a , the toner cartridge 15 b is readied at the first position for discharging the toner 140 in the toner storage pouch 41 , and then, the airtight chamber 44 is made to lose its negative internal air pressure at the second position to enable the toner cartridge 15 a to discharge the toner 140 .
[0122] That is, as the toner cartridge 15 b is inserted into the image forming apparatus 100 a , first, the toner passage is fully open, and then, the toner 140 begins to be discharged. Therefore, it does not occur that the toner 140 begins to be discharged before the toner passage is fully opened as in the case of a conventional toner cartridge. In other words, the toner cartridge 15 b in this embodiment is substantially smaller in the amount of developer (toner) flow resistance which toner encounter as it flows through the toner passage of the toner cartridge when the toner is discharged from the toner cartridge, than any toner cartridge in accordance with the prior art.
[0123] Further, in the case of the toner cartridge 15 b in this embodiment, its airtight chamber 44 is made to lose its negative internal air pressure with a preset timing while it is slid into the image forming apparatus 100 a . Thus, it is unlikely for the toner cartridge 15 b to be erroneously installed. That is, in the case of the toner cartridge 15 in the first embodiment, it is structured so that a user has to peel away the thin film seal 47 to make the airtight chamber 44 to lose its negative pressure in order to allow the toner storage pouch 41 to contract. Thus, it has to be after the insertion of the toner cartridge 15 into the image forming apparatus 100 that the thin film seal 47 is to be peed away.
[0124] In comparison, the toner cartridge 15 a and image forming apparatus 100 a in this embodiment are structured so that the thin film seal 47 a (negative pressure maintaining means (portion)) is automatically broken with a preset timing during the insertion of the toner cartridge 15 a into the image forming apparatus 100 a . Thus, this embodiment can prevent the erroneous toner cartridge installation attributable to a user.
[0125] Concretely, in this embodiment, the toner discharge nozzle 42 and air suction nozzle 43 a are 6 mm and 4 mm in internal diameter. In consideration of the developer (toner) flow resistance which the toner encounter as it is discharged from the toner cartridge 15 b , the toner discharge nozzle 42 is desired to be no less than 4 mm in internal diameter. In comparison, the air suction nozzle 43 a is for air to flow into, or out of, the airtight chamber 44 . Therefore, the developer (toner) flow resistance of the air suction nozzle 43 a has little effect upon the performance of the toner cartridge 15 b . Therefore, the air suction nozzle 43 a may be made smaller in internal diameter than the toner discharge nozzle 42 . However, it is desired to be no less than 2 mm in internal diameter.
[0126] Further, making the air suction nozzle 43 a smaller in diameter than the toner discharge nozzle 42 can makes it possible to reduce the toner cartridge 15 b and image forming apparatus 100 a in size, and also, to prevent the installation error.
[0127] Further, in this embodiment, the discharging of the toner 140 from the toner storage pouch 41 is controlled by a portion other than the toner discharge nozzle 42 , through which the toner 140 flows when the toner 140 is discharged from the toner storage pouch 41 . Therefore, the toner cartridge 15 b in this embodiment is smaller in the developer (toner) flow resistance which the toner 140 encounters as it is discharged from the toner storage pouch 41 , than the toner cartridge 15 in the first embodiment. That is, it can prevent the problem that when the toner 140 is discharged, the portion of the toner passage, which has not been fully opened, increases in developer (toner) flow resistance, and therefore, the toner flow is partially dammed up (blocked) by the partially open portion of the toner passage, causing a certain amount of toner 140 to agglomerate into larger particles or the like.
[0128] Further, it is after the toner passage becomes fully opened that the toner 140 is discharged. In addition, the discharging of the toner 140 is triggered by the beginning of the air flow (which is less affected by developer (toner) flow resistance of air passage) into the airtight chamber 44 . Therefore, the pressure can be effectively released from the toner storage pouch 41 even though the image forming apparatus 100 a is structured so that only temporary force, that is, the resiliency of elastic substance, is utilized to discharge the toner 140 . Therefore, the toner cartridge 15 b in this embodiment is less variable in the amount by which the toner 140 fails to be discharged from the toner storage pouch 41 .
Embodiment 4
[0129] Next, the image forming apparatus in another embodiment of the present invention is described.
[0130] The portions of the image forming apparatus in this embodiment, which are the same as, or similar to, the counterparts in the first embodiment are given the same referential codes as those given to the counterparts, and are not described in order not to repeat the same description.
(Structure of Toner Cartridge)
[0131] FIG. 11 is a drawing which shows the structure and operational modes of the image forming apparatus in this embodiment. More specifically, FIG. 11( a ) is a schematic sectional view of the toner cartridge, and the portion of the image forming apparatus, with which the toner cartridge is coupled, and FIG. 11( b ) shows the operational modes of the image forming apparatus.
[0132] The image forming apparatus in this embodiment, shown in FIG. 11( a ), is similar in basic structure to that in the third embodiment. It is different from the image forming apparatus in the third embodiment only in the following features.
[0133] That is, the image forming apparatus 100 b in this embodiment is a toner discharge passage valve 82 (first opening-closing mechanism), which is in the middle of the toner entry passage 120 (developer entry passage), which is between the toner entrance 22 of the toner storage chamber 18 a , and the toner discharge nozzle receptacle 80 . Thus, the movement of airflow into, or out of, the toner storage pouch 41 through the toner discharge nozzle 42 can be controlled by the toner discharge passage vale 82 . Further, an air injection passage 83 is provided between the toner discharge nozzle receptacle 80 and toner discharge passage valve 82 . Further, the image forming apparatus 100 b is provided with an air pump 73 . Therefore, it is possible to inject air into the toner storage pouch 41 through the air injection passage 83 and toner discharge nozzle 42 , with the use of the pump 73 .
[0134] Further, the image forming apparatus 100 b is provided with an air suction nozzle receptacle 90 which couples with the air suction nozzle 43 a of the toner cartridge 15 b when the toner cartridge 15 b is inserted into the image forming apparatus 100 a . The air suction nozzle receptacle 90 is provided with an air seal 92 for keeping airtight the joint between the air suction nozzle receptacle 90 and air suction nozzle 43 a . Further, the air passage 130 which connects the air suction nozzle receptacle 90 and the apparatus main assembly 101 b is provided with an air passage valve 93 (second mechanism for opening or closing air passage), which is for controlling the air movement into, or out of, the airtight chamber 44 (external shell 40 ).
[0135] The air suction nozzle receptacle 90 is provided with a seal breaking cylindrical member 91 , like the seal breaking cylindrical member 91 in the third embodiment, which is for breaking the thin film seal 47 a for the air suction nozzle 43 a . In the third embodiment, the hollow of the seal breaking member 91 is directly in connection to the atmospheric air in the apparatus main assembly 101 a . This embodiment is different from the third embodiment in that the air passage valve 91 in this embodiment is in connection to the atmospheric air through the air passage valve 93 .
(Operation for Re-Expanding (Inflating) Toner Storage Pouch)
[0136] The toner storage pouch 41 is elastic. Thus, as air is injected into the toner storage pouch 41 , it expands (elastically deform). When the toner cartridge 15 b is shipped out of its manufacturing facility, the toner storage pouch 41 contains a preset amount of toner 140 and air, and therefore, remains expanded (inflated) in the external shell 40 . It is possible, however, that as a substantially length of time elapses between when the toner cartridge 15 a was shipped out and when it is used for the first time, the air in the toner storage pouch 41 will escape from the toner storage pouch 41 . The following is the description of the operation to be carried out to re-expand (re-inflate) the toner storage pouch 41 in a case where the air in the toner storage pouch 41 will have escaped.
[0137] The toner discharge passage valve 82 and air passage valve 93 can be opened or closed, and are controlled in the modes shown in FIG. 11( b ).
[0138] The first mode is the initial mode in which both the toner discharge passage valve 82 and air passage valve 93 are kept closed. In the next mode, or the second mode, the toner discharge passage valve 82 is kept closed, whereas air passage valve 93 is kept opened. Further, the pump 73 is activated to being to inject (send) air into the toner entry passage 120 . As air is injected into the toner entry passage 120 by the pump 73 , it is sent into the toner storage pouch 41 through the toner discharge nozzle 42 , because the toner discharge passage valve 82 is closed.
[0139] As air is injected into the toner storage pouch 41 , the toner storage pouch 41 begins to expand (inflate) in the external shell 40 . The air passage valve 93 is open. Therefore, the air in the airtight chamber 44 is discharged out of the external shell 40 through the air suction nozzle 43 a , by the expansion of the toner storage pouch 41 .
[0140] Also in the second mode, as air is sent into the toner storage pouch 41 , the toner 140 in the toner storage pouch 41 is loosened by the air flow, being made to higher in fluidity.
[0141] After the injection of a preset amount of air into the toner storage pouch 41 in the second mode, the operation is switched to the third mode, in which the toner discharge passage valve 82 is kept closed, and the air passage valve 93 , which was kept open in the second mode, is opened. That is, the airflow into, or out of, the toner storage pouch 41 through the air suction nozzle 43 a is blocked in order not to allow ambient air to flow into, or out of, the airtight chamber 44 (internal space of external shell 40 ) from outside the external shell 40 . After the operation is switched to the third mode, the driving of the pump 73 is stopped to stop injecting air into the toner storage pouch 41 .
[0142] Next, in the fourth mode, the air passage valve 93 is kept closed, and the toner discharge passage valve 82 , which was kept closed in the second mode, is opened. Thus, the toner storage pouch 41 begins to be made to contract by its resiliency attributable to its elasticity. However, the air passage valve 93 is closed, and therefore, the atmospheric air is not allowed to flow into the airtight chamber 44 . Thus, as the toner storage pouch 41 begins to contract, the airtight chamber 44 is reduced in its internal air pressure. Consequently, the internal air pressure of the airtight chamber 44 becomes lower than the atmospheric pressure; it becomes negative relative to the atmospheric pressure.
[0143] Thus, the toner storage pouch 41 can remain expanded in the external shell 40 , in such a state that the force generated by the resiliency of the expanded toner storage pouch 41 in the direction to contract the toner storage pouch 41 , is equal to the negative internal air pressure of the airtight chamber 41 .
[0144] Therefore, even when the internal space of the toner storage pouch 41 is in connection to the atmospheric air through the toner discharge nozzle 42 which is in connection to the toner storage pouch 41 , it is possible to prevent the toner 140 and air in the toner storage pouch 41 from being discharged from the toner storage pouch 41 . As described above, in the fourth embodiment, the toner discharge passage valve 82 is fully opened to prepare for the discharging of the toner 140 from the toner storage pouch 41 .
[0145] Lastly, in the fifth mode, the toner discharge passage valve 82 is kept open, and the air passage valve 93 , which was kept closed in the third mode, is opened. Thus, the atmospheric air flows into the airtight chamber 44 through the air suction nozzle 43 a , making the airtight chamber 41 not negative in internal pressure. Consequently, the force generated by the negative air pressure in the internal space of the airtight chamber 44 in the direction to keep the toner storage pouch 41 expanded is lost. Thus, the toner storage pouch 41 is made to contract by its resiliency attributable to its elasticity (deforms in a manner to reduce in size).
[0146] That is, the toner 140 in the toner storage pouch 41 can be discharged along with the air in the toner storage pouch 41 , through the toner discharge nozzle 42 by the unitization of the phenomenon that the moment the airtight chamber 44 is made to begin losing its negative internal air pressure, the toner storage pouch 41 begins to contract.
[0147] After the discharging of the toner 140 in the toner storage pouch 41 , the operation is switched to the initial mode, or the first mode, to prepare the toner cartridge 15 b for the next toner discharging operation.
[0148] As described above, in this embodiment, the apparatus main assembly 101 is provided with a mechanism for re-injecting air into the toner storage pouch 41 . Thus, even the air injected into the toner storage pouch 41 happens to escape from the toner storage pouch 41 , it is possible to discharge the toner 140 from the toner cartridge 15 b.
[0149] Incidentally, in this embodiment of the present invention, the toner passage through which the toner 140 is discharged from the toner storage pouch 41 is provided with the toner discharge passage valve 82 . However, the process of discharging toner 140 is started in the fifth mode after the toner discharge passage valve 82 is fully opened in the fourth mode. Thus, it does not occur that the toner 140 begins to be discharged before the toner passage becomes fully open, as in the case of the toner cartridge in accordance with the prior art. Therefore, the toner cartridge 15 b in this embodiment is substantially smaller in the amount of the developer (toner) flow resistance of its toner passage. Thus, it can prevent the problem that the portion of the toner passage, which is not fully open, increases the toner passage in developer (toner) flow resistance, partially dams up (blocks) the toner flow, and causes the toner particles to agglomerate into large particles or the like.
Embodiment 5
[0150] Next, the image forming apparatus in another embodiment of the present invention is described.
[0151] The portions of the image forming apparatus in this embodiment, which are the same as, or similar to, the counterparts in the first embodiment are given the same referential codes as those given to the counterparts, and are not described in order not to repeat the same description.
(Structure of Toner Cartridge)
[0152] FIG. 12 is a drawing which shows the structure and operational modes of the image forming apparatus in this embodiment. More specifically, FIG. 12( a ) is a schematic sectional view of the toner cartridge, and the portion of the image forming apparatus, with which the toner cartridge is coupled, and FIG. 12( b ) shows the operational modes of the image forming apparatus.
[0153] The image forming apparatus in this embodiment, shown in FIG. 12( a ), is similar in basic structure to that in the fourth embodiment. It is different from the image forming apparatus in the fourth embodiment only in the following features.
[0154] The toner cartridge 15 c in this embodiment has a one-way valve 45 for discharging the air in the airtight chamber 44 out of the external shell 40 .
[0155] The toner cartridge 15 c in this embodiment has the one-way valve 45 . Therefore, it is different from the toner cartridge 15 b in the fourth embodiment in the second and third modes in which air is re-injected into the toner storage pouch 41 .
(Operation for Re-Expanding (Re-Inflating) Toner Storage Pouch)
[0156] Next, the operation to re-expanding (re-inflating) the toner storage pouch 41 in this embodiment is described.
[0157] Referring to FIG. 12( b ), the apparatus main assembly 101 c in this embodiment can be operated in one of the first to fifth modes in order to control the toner discharge passage valve 82 and air passage valve 93 , and pump 73 .
[0158] In the first mode, or the initial mode, both the toner discharge passage valve 82 and air passage valve 93 are kept closed.
[0159] Next, in the second mode, the pump 73 begins to be driven to inject air, with the toner discharge passage valve 82 and air passage valve 93 being kept closed. In the fourth embodiment, the toner discharge passage valve 82 is kept closed, and the air passage valve 93 , which was kept closed in the first mode, is opened. In comparison, in this embodiment, in the second mode, both the toner discharge passage valve 82 and air passage valve 93 are kept closed.
[0160] Since the toner discharge passage valve 82 is kept closed, the air injected by the pump 73 is sent into the toner storage pouch 41 through the air injection passage 83 and toner discharge passage 41 .
[0161] As air begins to be injected into the toner storage pouch 41 , the toner storage pouch 41 begins to be inflated in the external shell 40 , where by the air in the airtight chamber 44 begins to be compressed by the inflation of the toner storage pouch 41 . However, the external shell 40 is provided with the one-way valve 45 . Thus, as the air in the airtight chamber 44 begins to be compressed, it is allowed to be escape from the airtight chamber 44 , into the outside of the external shell 40 . In other words, in this embodiment, in the second mode, the air passage valve 93 is kept closed, the air in the airtight chamber 44 is discharged from the airtight chamber 44 , out into the outside of the external shell 40 , through the one-way valve 45 .
[0162] In the second mode, as air is sent into the toner storage pouch 41 , the toner 140 in the toner storage pouch 41 is loosened by the airflow, becoming therefore higher in fluidity, as in the case of the fourth embodiment.
[0163] After the injection of a preset amount of air into the toner storage pouch 41 in the second mode, the operation is switched to the third mode, in which both the toner discharge passage valve 82 and air passage valve 93 are kept closed as in the second mode, and then, the air injection into the toner storage pouch 41 is stopped by stopping the driving of the pump 73 .
[0164] The one-way valve 45 allows the air in the airtight chamber 44 to be discharged out of the external shell 40 , but, does not allow the ambient air of the external shell 40 to flow into the airtight chamber 44 . That is, the air in the airtight chamber 44 is pushed out of the external shell 40 by the expansion of the toner storage pouch 41 , but the atmospheric air is not allowed to flow into the airtight chamber 44 as long as it is ensured that the external shell 40 is kept airtight.
[0165] As the air injection into the toner storage pouch 41 is stopped as in the case of the fourth embodiment, the resiliency of the toner storage pouch 41 attributable to the elasticity of the toner storage pouch 41 begins to make the toner storage pouch 41 to contract. The image forming apparatus in this embodiment, however, is structured as described above. Therefore, even after the toner storage pouch 41 began to contract, no air flows into the airtight chamber 44 . Thus, the air in the airtight chamber 44 is reduced in pressure. Therefore, the airtight chamber 44 becomes negative in internal air pressure relative to the atmospheric pressure. Consequently, the resiliency of the toner storage pouch 41 , which works in the direction to make the toner storage pouch 41 to contract, balances with the negative internal air of the airtight chamber 44 , allowing thereby the toner storage pouch 41 to remain inflated in the external shell 40 .
[0166] Thus, even when the internal space of the toner storage pouch 41 is open to the atmospheric air through the toner discharge nozzle 42 which is in contraction to the internal space of the toner storage pouch 41 , it is possible to prevent the toner 140 in the toner storage pouch 41 from being discharged along with the air in the toner storage pouch 41 .
[0167] Next, in the fourth mode, the air passage valve 93 is kept closed and the toner discharge passage valve 82 , which was kept closed in the third mode, is opened. As soon as the toner discharge passage valve 82 is opened, the toner storage pouch 41 begins to contract because of its resiliency attributable to its elasticity. However, the image forming apparatus in this embodiment is structured as described above. Thus, even after the toner storage pouch 41 begins to contract, the atmospheric air does not flow into the airtight chamber 44 , because the air passage valve 93 is kept closed. Therefore, the air in the airtight chamber 44 is reduced in pressure, becoming negative in pressure relative to the atmospheric pressure (ambient air pressure).
[0168] Thus, the toner storage pouch 41 is allowed to remain inflated in the external shell 40 , with the force which works in the direction to make the toner storage pouch 41 remain inflated by the air injected into the toner storage pouch 41 , becoming equal to the negative pressure of the air in the airtight chamber 44 .
[0169] Also in the fifth embodiment, the toner discharge passage valve 82 is kept opened, and the air passage valve 93 , which was kept closed in the fourth mode, is also opened. Thus, the atmospheric air flows into the airtight chamber 44 through the air suction nozzle 43 a , making thereby the airtight chamber 44 not negative in pressure. As a result, the force which was generated by the negative air pressure in the airtight chamber 44 and kept the toner storage pouch 41 inflated is lost, and therefore, the toner storage pouch 41 is made to contracts by its resiliency attributable to the elastic substance of which it is made of.
[0170] That is, the phenomenon that as soon as the airtight chamber 44 is made to lose its negative internal air pressure, the toner storage pouch 41 , which is an elastic member, is made to contact by its resiliency, can be utilized to discharge the toner 140 in the toner storage pouch 41 , along with the air in the air in the toner storage pouch 41 , through the toner discharge nozzle 42 .
[0171] After the discharging of the toner 140 in the toner storage pouch 41 in the fifth mode, the operation is switched to the first mode, in which the image forming apparatus is kept in the initial state, in order to prepare the image forming apparatus for the next toner discharge.
Embodiment 6
[0172] Next, the image forming apparatus in another embodiment of the present invention is described.
[0173] The portions of the image forming apparatus in this embodiment, which are the same as, or similar to, the counterparts in the first embodiment are given the same referential codes as those given to the counterparts, and are not described in order not to repeat the same description.
(Structure of Toner Cartridge)
[0174] FIG. 13 is a drawing which shows the structure and operational modes of the image forming apparatus in this embodiment. More specifically, FIG. 13( a ) is a schematic sectional view of the toner cartridge, and the portion of the image forming apparatus, with which the toner cartridge is coupled, and FIG. 13( b ) shows the operational modes of the image forming apparatus.
[0175] Basically, the image forming apparatus in this embodiment, shown in FIG. 13( a ), is similar in basic structure to that in the fourth embodiment. It is different from the image forming apparatus in the fourth embodiment only in the following features.
[0176] In this embodiment, an air suction passage 83 a which is in connection to the pump 73 a is between the air suction nozzle receptacle 90 and air passage valve 93 . Thus, the atmospheric air can be suctioned into the airtight chamber 44 by the pump 73 a through the air suction passage 83 a and air suction nozzle 43 a . The toner cartridge in this embodiment is the same as the toner cartridge 15 b in the fourth embodiment.
(Operation to Re-Expand (Re-Inflate) Toner Storage Pouch)
[0177] Next, the operation to re-expand (re-inflate) the toner storage pouch 41 in this embodiment is described.
[0178] Referring to FIG. 13( b ), the image forming apparatus 100 d in this embodiment is provided with the first to fourth operational modes in which the toner discharge passage valve 82 and air passage valve 93 , and pump 73 a are controlled.
[0179] In the first mode, the image forming apparatus 100 d are kept in the initial state, in which both the toner discharge passage valve 82 and air passage valve 93 are kept closed.
[0180] In the second mode, the air passage valve 93 is kept closed, whereas the toner discharge passage valve 82 is kept opened.
[0181] Also in the second mode, the pump 73 a begins to be driven suction the air in the airtight chamber 44 out of the external shell 40 , into the ambience through the air suction passage 83 a and air suction nozzle 43 a . Thus, the airtight chamber 44 is made to be negative in internal air pressure by the suctioning of the air in the airtight chamber 44 by the pump 73 a.
[0182] As the airtight chamber 44 becomes negative in internal air pressure, the toner storage pouch 41 begins to inflate so that the force generated by the negative pressure of the internal air of the airtight chamber 44 becomes equal to the force generated by the elasticity of the toner storage pouch 41 . In this mode, the toner discharge passage valve 82 is kept open. Therefore, the atmospheric air flows into the toner storage pouch 41 through the toner discharge nozzle 42 , allowing thereby the toner storage pouch 41 to expand (inflate).
[0183] After a preset amount of air is suctioned out of the airtight chamber 44 in the second mode, the operation is switched to the third mode, in which the driving of the pump 73 a is stopped to stop suctioning air out of the airtight chamber 44 , while the air passage valve 93 is kept closed, and the toner discharge passage valve 82 is kept open.
[0184] Thus, the resiliency of the toner storage chamber 44 attributable to the elasticity of the toner storage pouch 41 begins to make the toner storage pouch 44 to contract. However, the air passage valve 93 of the image forming apparatus 100 d in this embodiment structured as described above is kept closed. Thus, even the toner storage pouch 41 begins to contract, no air flows into the airtight chamber 44 . Thus, the air in the airtight chamber 44 is reduced in pressure. Thus, the air in the airtight chamber 44 remains negative in pressure relative to the atmospheric pressure (ambient air pressure). As a result, the toner storage pouch 41 remains expanded (inflated) in the external shell 40 , with the force which is generated by the resiliency of the inflated toner storage pouch 41 , and works in the direction to make the inflated toner storage pouch 40 contracts, becoming equal to the negative air pressure in the toner storage pouch 41 .
[0185] Therefore, even when the toner discharge passage valve 82 is kept open, and therefore, the internal space of the toner storage pouch 41 is open to the atmospheric air through the toner discharge nozzle 42 which is in connection to the internal space of the toner storage pouch 41 , it is possible to prevent the toner 140 in the toner storage pouch 41 from being discharged, along with the air in the toner storage pouch 41 . As described above, in the third mode, the toner discharge passage valve 82 is fully opened to prepare the image forming apparatus 100 d and toner cartridge 15 c , to discharge the toner 140 out of the toner storage pouch 41 .
[0186] Lastly, in the fourth mode, the toner discharge passage valve 82 is kept open, and the air passage valve 93 , which was kept closed in the third mode, is opened. Thus, the atmospheric air flows into the airtight chamber 44 through the air suction nozzle 43 a , making thereby the air in the airtight chamber 44 loses its negative pressure. Therefore, the force which is attributable to the negative air pressure in the airtight chamber 44 and kept expanded (inflated) the toner storage pouch 41 is lost. Consequently, the resiliency of the toner storage pouch 41 which is an elastic member causes the toner storage pouch 41 to contract. In other words, it is possible to discharge the toner 140 in the toner storage pouch 41 , along with the air in the toner storage pouch 41 , by utilizing the phenomenon that the moment the air in the airtight chamber 44 loses its negative pressure, the toner storage pouch 41 contracts because of its resiliency.
[0187] After the discharging of the toner 140 in the toner storage pouch 41 by a present amount in the fourth mode, the operation is switched back to the first mode to prepare the image forming apparatus 100 d for the next toner discharge.
Superiority of Present Invention to Prior Art
[0188] Next, the superiority of the present invention to the prior art is described. In the prior art, in order to control the operation to discharge the developer in a developer supply container with the utilization of the resiliency of the elastic member of the developer supply container, the developer passage through which the developer is discharged is provided with a valve.
[0189] That is, the developer in the developer supply container is prevented by the valve from being discharged from the container. However, the developer pouch is always under the pressure which is attributable to the resiliency of the elastic substance of which the developer pouch is made. This pressure continuously works in the direction to discharge the developer in the developer supply container out of the container. Therefore, as soon as the valve, which has been preventing the developer in the developer supply container from being discharged, begins to be opened, the pressure is released, and therefore, the developer in the developer supply container begins to be discharged.
[0190] This creates the following problem. That is, the developer begins to be discharged from the developer supply container before the valve is fully opened. Thus, the partially open portion of the valve increases the outward developer passage of the developer supply container in developer (toner) flow resistance. As the outward developer flow is impeded by the partially open portion of the valve, it is sometimes partially dammed up (blocked). Thus, some toner particles in the developer flow agglomerate into large particles of toner, which sometimes reduces an image forming apparatus in image quality.
[0191] Further, in the case of a toner cartridge in accordance with the prior art, which is structured to utilize temporary force, such as the force generated by the resiliency of the elastic substance of which the developer storage pouch of the toner cartridge is made, to discharge the developer from the developer storage pouch, it is possible the pressure for discharging the developer will be lost before the valve is fully opened. If the pressure for discharging the developer is lost before the valve is fully opened, the pressure difference for discharging the developer is sometimes lost before the developer is discharged from the developer container by a preset amount. Thus, the amount by which the developer in the developer supply container fails to be discharged is affected by the speed with which the valve is opened. That is, in some cases, the amount by which the developer in the developer supply container fails to be discharged became substantial.
[0192] In comparison, in the case of a toner cartridge in accordance with the present invention, in order to prevent the expanded (inflated) elastic toner storage pouch 41 from contracting (deflating), the air in the internal space (airtight chamber 44 ) of the external shell 40 is kept negative in air pressure. Further, when it is necessary to discharge the toner 140 in the toner storage pouch 41 , the atmospheric air is allowed to flow into the airtight chamber 44 through the air suction nozzle 43 a to make the air in the airtight chamber 44 lose its negative pressure.
[0193] That is, it is in the portion of the image forming apparatus and/or toner cartridge other than the toner discharge nozzle 42 , which is the passage through which the toner 140 flows when it is discharged from the toner storage pouch 41 , that the mechanism for controlling the discharging of the toner 140 in the toner storage pouch 41 is positioned. Therefore, the toner cartridge in accordance with the present invention is significantly smaller than any toner cartridge in accordance with the prior art, in the amount of the developer (toner) flow resistance which the toner 140 encounters in the toner passage while it is discharged from the toner storage pouch 41 .
[0194] Further, in the preceding embodiments of the present invention, it does not occur that the toner 140 begins to be discharged before the toner passage is fully opened as in the case of a toner cartridge in accordance with the prior art. This alone can make the toner cartridges in the preceding embodiments significantly smaller in developer (toner) resistance than any toner cartridge in accordance with the prior art.
[0195] In addition, the preceding embodiments of the present invention can prevent the problem which the prior art suffers, more specifically, the problem that the portion of the toner passage, which is yet to be fully opened, temporarily increases the toner passage in developer (toner) flow resistance, which is likely to results in the formation of large particles of toner. Further, not only can the present invention ensure that it is only after the toner passage becomes fully open that the toner 140 can be discharged, but also, that the discharging of the toner 140 is triggered by the beginning of the airflow (which is less affected by the resistance of its passage than the developer (toner)) into the airtight chamber 44 . Therefore, even thought the image forming apparatus and toner cartridge in accordance with the present invention are structured to utilize the temporary force, such as the force generated by the resiliency of the elastic substance of which the toner storage pouch 41 is made, to discharge the toner 140 in the toner storage pouch 41 , they can effectively release the force attributable to the elastic substance. Thus, a toner cartridge in accordance with the present invention is unlikely to vary in the amount by which the toner 140 therein fails to be discharged.
[0196] Further, in the case of the prior art, the pressure for discharging the toner 140 and air in the toner storage pouch 41 is always present. Therefore, toner is likely to be scattered when the toner storage pouch 41 is refilled with air.
[0197] In comparison, in the case of the present invention, in order to keep expanded (inflated) the expanded (inflated) elastic toner storage pouch 41 , the air in the airtight chamber 44 in the external shell 41 is made negative in air pressure. Therefore, the toner 140 is not discharged until the air in the airtight chamber 44 is made to lose its negative pressure. Therefore, even when the toner storage pouch 41 is refilled with air, the force for discharging the toner 140 can be kept under control. Therefore, the toner 140 can be prevented from scattering even when the toner storage pouch 41 is refilled with air.
[0198] While the present invention has been described with reference to exemplary embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.
[0199] This application claims priority from Japanese Patent Application No. 122650/2013 filed Jun. 11, 2013, which is hereby incorporated by reference. | A developer supply container for an image forming apparatus includes a container shell; a developer accommodation bag contained in the container shell; a developer discharging path for discharging the developer from the bag an outside of the developer supply container; an air fluid communication path for fluid communication between inside and outside of the container shell; and a maintaining portion sealing the air fluid communication path to maintain a pressure inside the container shell in a negative pressure state, wherein the developer accommodation bag deforms to discharge the developer, by the maintaining portion opening the air fluid communication path to permit air to enter the container shell through the air fluid communication path. | 6 |
[0001] Priority is claimed on Japanese Patent Applications 2007-152246 filed Jun. 8, 2007 and 2007-319718 filed Dec. 11, 2007.
BACKGROUND OF THE INVENTION
[0002] This invention relates to a straight-type finish for synthetic fibers, a processing method for false twisted textured yarns using the same and such false twisted textured yarns. In the production and fabrication of synthetic yarns, it has been known that the synthetic fibers tend to become electrically charged due to the mutual friction of the synthetic fibers and the friction with the guides, etc. during the false twisting of the synthetic fibers, for example, and that such static electricity causes imperfect cohesion, tension variations and yarn breaking, resulting in uneven dyeing at the time of the dyeing process. In order to prevent such occurrences, agents for providing smoothness and antistatic characteristics to synthetic fibers are employed in the production and fabrication of synthetic fibers. The present invention relates to a straight-type finish as an example of such agents for synthetic fibers, and a processing method for false twisted textured yarns using such a finish, as well as such false twisted textured yarns.
[0003] Examples of conventionally known processing agent for providing smoothness and antistatic characteristics to synthetic fibers include (1) those containing alicyclic polycarboxylic acid esters of alicyclic polycarboxylic acid and straight chain alcohol with 1-18 carbon atoms, branched alcohol with 3-18 carbon atoms or alicyclic alcohol with 3-10 carbon atoms with terminal normal chain ratio of 50% or more (as disclosed, for example, in Japanese Patent Publication Tokkai 10-265789); (2) those containing copolymers with molecular weight of 20,000-1,000,000 obtained by copolymerizing aliphatic hydrocarbon monomers (as disclosed, for example, in Japanese Patent Publication Tokkai 2-68367); (3) those containing a lubricating oil, oil-soluble polymers with Staudinger's viscosity-average molecular weight of 1,000,000-7,000,000 and a surfactant (as disclosed, for example, in Japanese Patent Publication Tokkai 2001-89975); (4) those containing polyether compounds with molecules including 1,2-epoxyalkane with 6-24 carbon atoms or polymerization residual group of alkylene oxide with 2-4 carbon atoms therewith (as disclosed, for example, in Japanese Patent Publication Tokkai 5-9873); and (5) those containing ester compounds with 25 or more carbon atoms obtained from higher aliphatic acid and higher alcohol by 30 weight % or more and an emulsifier with a cloudy point at 40° C. or more and 80° C. or less by 20 weight % or more (as disclosed, for example, in Japanese Patent Publication Tokkai 5-321058).
[0004] These agents cannot sufficiently prevent synthetic fibers from becoming electrically charged, however, because their storage stability is poor and hence there are limitations to their practical use. As a result, the problem of uneven dyeing remains at the time of dyeing of the woven articles produced from such synthetic fibers.
SUMMARY OF THE INVENTION
[0005] It is therefore an object of this invention to provide a straight-type finish for synthetic fibers which itself is superior in storage stability and is capable of sufficiently preventing synthetic fibers from becoming electrically charged as it is applied thereto and to thereby prevent the occurrence of uneven dyeing, a processing method for false twisted textured yarns using such a finish and false twisted textured yarns obtained by such a method.
[0006] This invention is based on the discovery made by the inventors hereof as a result of their diligent studies to solve the problems described above that use should properly be made of a straight-type finish for synthetic fibers comprising a lubricant and a functional improvement agent at specified ratios, the functional improvement agent containing a specified metal organic sulfonate at a specified ratio.
DETAILED DESCRIPTION OF THE INVENTION
[0007] The invention relates to a straight-type finish for synthetic fibers comprising a lubricant and a functional improvement agent, containing the lubricant at 70-99.5 mass % of the total and the functional improvement agent at 0.5-30 mass % of the total, and the functional improvement agent including metal organic sulfonate shown by formula 1 at 0.05-15 mass % of the total, formula 1 being:
[0000]
[0000] where R 1 and R 2 are each alkyl group with 1-36 carbon atoms, alkenyl group with 2-24 carbon atoms, phenyl group, alkyl-phenyl group having alkyl group with 1-36 carbon atoms, naphthyl group, alkyl-naphthyl group having alkyl group with 1-36 carbon atoms, or 1,2-bis(alkyloxycarbonyl)-1-ethane group having alkyl group with 4-24 carbon atoms; and M is a divalent metal.
[0008] The invention also relates to a processing method for false twisted textured yarns characterized as attaching the straight-type finish for synthetic fibers of this invention described above at the rate of 0.1-5 mass % with respect to the false twisted textured yarns after the false twisting step.
[0009] The invention further relates to false twisted textured yarns obtained by the processing method of this invention described above.
[0010] The straight-type finish for synthetic fibers according to this invention (hereinafter referred to simply as the finish of this invention) is described first. The finish of this invention is characterized as comprising a lubricant and a functional improvement agent, the functional improvement agent including metal organic sulfonate shown by formula 1.
[0011] In formula 1 describing the metal organic sulfonate, R 1 and R 2 may either represent the same group or be different groups. They may each be (1) alkyl group with 1-36 carbon atoms such as methyl group, ethyl group, propyl group, butyl group, pentyl group, hexyl group, heptyl group, octyl group, nonyl group, decyl group, undecyl group, dodecyl group, tridecyl group, tetradecyl group, pentadecyl group, hexadecyl group, heptadecyl group, octadecyl group, nonadecyl group, icosyl group, henicosyl group, docosyl group, tricosyl group, tetracosyl group, pentacosyl group, hexacosyl group, heptacosyl group, octacosyl group, nonacosyl group, triacontyl group, hentriacontyl group, dotriacontryl group, tritriacontyl group, tetratricontyl group, pentatriacontyl group, hexatriacontyl group, 2-methyl-pentyl group, 2-ethyl-hexyl group, 2-propyl-heptyl group, 2-butyl-octyl group, 2-pentyl-nonyl group, 2-hexyl-decyl group, 2-heptyl-undecyl group, 2-octyl-dodecyl group, 2-nonyl-tridecyl group, 2-decyl-tetradecyl group, 2-undecyl-pentadecyl group and 2-dodecyl-hexadecyl group; (2) alkenyl groups with 2-24 carbon atoms such as ethenyl group, propenyl group, butenyl group, pentenyl group, hexenyl group, heptenyl group, octenyl group, nonenyl group, decenyl group, 10-undecenyl group, dodecenyl group, tridecenyl group, tetradecenyl group, pentadecenyl group, hexadecenyl group, heptadecenyl group, 9c-octadecenyl group, 9t-octadecenyl group, 9c,12c-octadecadienyl group, 9c,12c,15c-octadecatrienyl group, 9c-icosenyl group, 5,8,11,14-icosatetraenyl group, 13c-docosenyl group, 13t-docosenyl group, tricosenyl group, and tetracosenyl group; (3) phenyl group; (4) alkyl-phenyl groups having alkyl group with 1-36 carbon atoms such as methyl phenyl group, ethyl phenyl group, propyl phenyl group, butyl phenyl group, hexyl phenyl group, octyl phenyl group, nonyl phenyl group, decyl phenyl group, undecyl phenyl group, dodecyl phenyl group, tetradecyl phenyl group, pentadecyl phenyl group, hexadecyl phenyl group, heptadecyl phenyl group, octadecyl phenyl group, nonadecyl phenyl group, icosyl phenyl group, henicosyl phenyl group, docosyl phenyl group, tricosyl phenyl group, tetracosyl phenyl group, pentacosyl phenyl group, hexacosyl phenyl group, heptacosyl phenyl group, octacosyl phenyl group, nonacosyl phenyl group, triacontyl phenyl group, hentriacontyl phenyl group, dotriacontyl phenyl group, tritriacontyl phenyl group, tetratriacontryl phenyl group, pentatriacontyl phenyl group, hexatriacontyl phenyl group, 2-methyl-pentyl phenyl group, 2-ethyl-hexyl phenyl group, 2-propyl-heptyl phenyl group, 2-butyl-octyl phenyl group, 2-pentyl-nonyl phenyl group, 2-hexyl-decyl phenyl group, 2-heptyl-undecyl phenyl group, 2-octyl-dodecyl phenyl group, 2-nonyl-tridecyl phenyl group, 2-decyl-tetradecyl phenyl group, 2-undecyl-pentadecyl phenyl group and 2-dodecyl-hexadecyl phenyl group; (5) naphthyl group; (6) alkyl naphthyl groups having alkyl group with 1-36 carbon atoms such as methyl naphthyl group, ethyl naphthyl group, propyl naphthyl group, butyl naphthyl group, hexyl naphthyl group, octyl naphthyl group, nonyl naphthyl group, decyl naphthyl group, undecyl naphthyl group, dodecyl naphthyl group, tetradecyl naphthyl group, pentadecyl naphthyl group, hexadecyl naphthyl group, heptadecyl naphthyl group, octadecyl naphthyl group, nonadecyl naphthyl group, icosyl naphthyl group, henicosyl naphthyl group, docosyl naphthyl group, tricosyl naphthyl group, tetracosyl naphthyl group, pentacosyl naphthyl group, hexacosyl naphthyl group, heptacosyl naphthyl group, octacosyl naphthyl group, nonacosyl naphthyl group, triacontyl naphthyl group, hentriacontyl naphthyl group, dotriacontyl naphthyl group, tritriacontyl naphthyl group, tetratriacontyl naphthyl group, pentatriacontyl naphthyl group, hexatriacontyl naphthyl group, 2-methyl-pentyl naphthyl group, 2-ethyl-hexyl naphthyl group, 2-propyl-heptyl naphthyl group, 2-butyl-octyl naphthyl group, 2-pentyl-nonyl naphthyl group, 2-hexyl-decyl naphthyl group, 2-heptyl-undecyl naphthyl group, 2-octyl-dodecyl naphthyl group, 2-nonyl-tridecyl naphthyl group, 2-decyl-tetradecyl naphthyl group, 2-undecyl-pentadecyl naphthyl group and 2-dodecyl-hexadecyl naphthyl group; and (7) 1,2-bis(alkyloxycarbonyl)-1-ethane groups having alkyl group with 4-24 carbon atoms such as 1,2-bis(butyloxycarbonyl)-1-ethane group, 1,2-bis(octyloxycarbonyl)-1-ethane group and 1,2-bis(dodecyloxycarbonyl)-1-ethane group. Among these, alkyl groups with 6-22 carbon atoms, alkyl phenyl groups having alkyl group with 8-18 carbon atoms and alkyl naphthyl groups having alkyl group with 8-18 carbon atoms are preferred.
[0012] Regarding the metal organic sulfonate shown by formula 1, M represents a metal with valence 2, or a divalent metal. Examples of M include beryllium, magnesium, calcium, strontium, barium, manganese, iron, radium, cobalt, nickel, copper and zinc. Among these, calcium and magnesium are preferred. The metal organic sulfonate shown by formula 1 may be used either singly or as a mixture of two of more.
[0013] The metal organic sulfonates shown by formula 1 themselves may be synthesized by any of the known methods such as disclosed in Japanese Patent Publication Tokkai 2000-204193.
[0014] The functional improvement agent that is contained in the finish of this invention besides the metal organic sulfonate shown by formula 1 is to serve as a cohesive agent for bundling synthetic fiber yarns, an auxiliary agent for removing impurities from the synthetic fiber yarns and compatibilizer for uniformizing the metal organic sulfonate shown by formula 1 and the lubricant. Examples of such functional improvement agent include (1) nonionic surfactants of polyoxyalkylene polyol fatty acid ester such as polyoxyalkylene alkylether, polyoxyalkylene alkylphenylether, polyoxyalkylene alkyl esters, polyoxyalkylene castor oil, polyoxyalkylene alkylaminoether sorbitan monolaurate, sorbitan triolate, glycerol monolaurate, diglycerol dilaurate, alkylene oxide adducts of partial ester of trihydric-hexahydric alcohol and fatty acid, partial and complete esters of adducts of trihydric-hexahydric alcohol with alkylene oxide and fatty acid, and alkylene oxide adducts of ester of trihydric-hexahydric alcohol and hydroxyl fatty acid; (2) anionic surfactants such as salts of organic fatty acid and organic phosphates; (3) cationic surfactants such as lauryltrimethylammonium ethosulfate; and (4) amphoteric surfactants such as octyldimethylammonioacetate. Among these, nonionic surfactants are preferred.
[0015] Commonly known kinds of lubricant may be used for the finish of this invention. Examples of such lubricant include (1) aliphatic ester compounds such as lauryl oleate, stearyl oleate, oleyl oleate, octyl oleate, tridecyl oleate, methyl oleate, butyl oleate, 2-ethylhexyl oleate, octyl stearate, oleyl stearate, butyl palmitate, oleyl palmitate, oleyle laurate, oleyl isostearate, oleyl octanoate, ethylene glycol dilaurate, propylene glycol distearate, hexanediol dilaurate, glycerol tri-12-hydroxystearate, glycerol trioleate, glycerol palmitate distearate, trimethylol propane tripalmitate, sorbitan tetraoleate, pentaerithritol tetralaurate, distearyl succinate, distearyl glutarate, dicetyl adipate,dibehenyl pymerate, dibehenyl pimerate, dibehenyl suberate, distearyl azelate and distearyl sebasate; (2) mineral oils of various kinds having various viscosity; (3) linear polydimethyl siloxanes having various viscosity and linear polyorganosiloxanes having various viscosity obtained by modifying such linear polydimethyl siloxanes with ethyl group, phenyl group, fluoropropyl group, aminopropyl group, carboxyoctyl group, polyoxyethylene oxypropyl group or co-methoxypolyethoxy-polypropoxypropyl group; (4) polyether compounds such as polyether monools, polyether diols and polyether triols having polyoxyalkylene group; (5) aromatic ester compounds such as benzyl stearate, benzyl laurate, diisostearyl isophtharate and trioctyl trimellitate; and (6) (poly)etherester compounds such as (poly)etherester compound obtained from (poly)ether compound with alkylene oxide with 2-4 carbon atoms added to monohydric-trihydric aliphatic alcohol with 4-26 carbon atoms and aliphatic carboxylic acid with 4-26 carbon atoms, (poly)etherester compound obtained from (poly)ether compound with alkylene oxide with 2-4 carbon atoms added to monohydric-trihydric aromatic alcohol and aliphatic carboxylic acid with 4-26 carbon atoms, and (poly)etherester compound obtained from (poly)ether compound with alkylene oxide with 2-4 carbon atoms added to aliphatic alcohol with 4-26 carbon atoms and aromatic carboxylic acid. Among these, aliphatic ester compounds, mineral oils and linear polyorgano siloxanes are preferred as the lubricant, and aliphatic ester compounds with 17-60 carbon atoms obtained from aliphatic monohydric alcohol and aliphatic monocarboxylic acid, aliphatic complete ester compounds with 17-60 carbon atoms obtained from aliphatic polyhydric alcohol and aliphatic monocarboxylic acid, aliphatic ester compounds with 17-60 carbon atoms such as aliphatic partial ester compounds with 17-60 carbon atoms obtained from aliphatic polyhydric alcohol and aliphatic monocarboxylic acid, mineral oils with viscosity of 2×10 −6 −2×10 −4 m 2 /s at 30° C. and linear polydimethyl siloxane with viscosity of 1×10 −6 −2×10 −3 m 2 /s at 30° C. are more preferable. Such lubricants may be used either singly or as a mixture of two or more.
[0016] The finish of this invention comprises a lubricant as described above and a functional improvement agent containing metal organic sulfonate shown by formula 1, the lubricant being contained at a rate of 70-99.5 mass % and preferably 70-90 mass % of the total, the functional improvement agent containing metal organic sulfonate shown by formula 1 being contained at a rate of 0.5-30 mass % and preferably 10-30 mass % of the total, and the metal organic sulfonate shown by formula 1 being contained at a ratio of 0.05-15 mass % and preferably 1-10 mass % of the total.
[0017] When the finish of this invention is applied to synthetic fibers, an appearance control agent, an antioxidant agent, a heat-resisting agent, a defoamer, a biocide, an antirust agent, etc. may also be used in addition but their amount should be as small as possible.
[0018] Next, the method of processing false twisted textured yarns of this invention (hereinafter referred to as the processing method of this invention) is explained. The processing method of this invention comprises a method of applying the finish of this invention described above at a rate of 0.1-5 mass % with respect to the false twisted textured yarns after they have undergone the false twisting step.
[0019] According to the processing method of this invention, the finish of this invention is applied by neat oiling by a conventional method such as the roller oiling method, the guide oiling method using a metering pump, the dip oiling method and the spray oiling method at a rate of 0.1-5 mass % and preferably 0.5-3 mass % with respect to the false twisted textured yarns after they have undergone the false twisting step.
[0020] There is no particular limitation on the condition of the false twisting step. Since the heaters that are used for the false twisting may be of a contact type or a non-contact type and their combination may be of the single-step type or the double-step type, the process may be carried out in various combinations. If a heater of the contact type is used, its surface temperature is usually 70-240° C. and preferably 100-220° C. If a heater of the non-contact type is used, its surface temperature is usually 100-600° C. and preferably 150-500° C. In either case, the processing speed is usually 100-1500 m/minute and preferably 200-1200 m/minute. Although the process may be carried out under any condition in these ranges, it is preferable for the purpose of the invention to carry out the false twisting by using heaters of the contact type with surface temperature 100-220° C. at processing speed of 200-1200 m/minute.
[0021] Lastly, false twisted textured yarns of synthetic fibers according to this invention (hereinafter referred to as the false twisted textured yarns of this invention) will be described. The false twisted textured yarns of this invention are characterized as being produced by the processing method of this invention.
[0022] Examples of synthetic fibers for the false twisted textured yarns of this invention include (1) polyester synthetic fibers such as polyethylene terephtharate, polypropylene terephtharate, polybutylene terephtharate and polytetraethylene terephtharate; (2) polyamide synthetic fibers such as nylon 6 and nylon 6,6; (3) polyacrylic synthetic fibers such as polyacrylic and modacrylic; (4) polyolefin synthetic fibers such as polyethylene and polypropylene; (5) polyurethane synthetic fibers, and (6) polylactic acid synthetic fibers. Effects of the present invention are more prominently visible when applied to polyester, polyamide or polylactic acid synthetic fibers.
[0023] The finish of this invention is superior in its storage characteristics, being capable of sufficiently preventing synthetic fibers from becoming electrically charged as it is applied thereto and hence the occurrence of uneven dyeing when woven articles produced from such synthetic fibers are dyed.
[0024] Test examples are shown in what follows in order to describe the invention more clearly but these examples are not intended to limit the scope of the invention. In the following test and comparison examples, “part” will means “mass part” and “%” will mean “mass %”.
TEST EXAMPLES
Part 1 (Synthesis of Metal Organic Sulfonates Shown by Formula 1)
Synthesis of Metal Organic Sulfonate (S-1)
[0025] Propylsulfonic acid (248 parts, 2.0 mol) and deionized water (1000 parts) were charged into a 4-neck flask with flush bottom outlet valves equipped with a thermometer, a stirrer and a reflux condenser and the mixture was stirred with heating for dissolving. While this solution was stirred thereafter, calcium hydroxide (74 parts, 1.0 mol) was added thereto over a period of ten minutes and after its temperature was raised to 70-90° C., a neutralization reaction was carried out at this temperature by stirring for one hour. After the stirring was stopped, it was left quietly for 30 minutes to separate the lower layer portion containing deposited calcium salt of propylsulfonic acid. Water (500 parts) was added to the portion containing the calcium salt of propylsulfonic acid. After it was heated to 70-90° C. and stirred for one hour, the stirring was stopped and it was left quietly for three hours at the same temperature. After the upper layer of aqueous solution was removed from the top by leaving the lower layer portion, it was washed with water. A similar washing process with water was repeated once more and calcium salt of propylsulfonic acid (257 parts, 0.9 mol) was obtained by dehydration and drying. This was collected as metal organic sulfonate (S-1).
Synthesis of Metal Organic Sulfonates (S-2)-(S-35) and (T-1)-(T-3)
[0026] Metal organic sulfonats (S-2)-(S-35) and (T-1)-(T-3) in Table 1 below were synthesized similarly as described above.
[0000]
TABLE 1
Metal organic sulfonates
R 1
R 2
Kind
Kind
Kind
M
S-1
propyl group
propyl group
magnesium
S-2
hexyl group
hexyl group
magnesium
S-3
nonyl group
decyl group
calcium
S-4
dodecyl group
dodecyl group
calcium
S-5
tetradecyl group
pentadecyl group
calcium
S-6
octadecyl group
docosyl group
calcium
S-7
octacosyl group
octacosyl group
barium
S-8
triacontyl group
triacontyl group
barium
S-9
hexatriacontyl group
hexatriacontyl group
magnesium
S-10
hexenyl group
hexenyl group
manganese
S-11
decenyl group
decenyl group
calcium
S-12
tetradecenyl group
hexadecenyl group
calcium
S-13
octadecenyl group
octadecenyl group
iron
S-14
13c-docosenyl group
13t-docosenyl group
calcium
S-15
phenyl group
phenyl group
cobalt
S-16
propyl phenyl group
propyl phenyl group
copper
S-17
octyl phenyl group
octyl phenyl group
calcium
S-18
decyl phenyl group
decyl phenyl group
calcium
S-19
dodecyl phenyl group
octadecyl phenyl group
calcium
S-20
tetradecyl group
hexadecyl phenyl group
magnesium
S-21
octadecyl phenyl group
dodecyl phenyl group
magnesium
S-22
octacosyl phenyl group
octacosyl phenyl group
magnesium
S-23
triacontyl phenyl group
triacontyl phenyl group
magnesium
S-24
hexatriacontyl phenyl group
hexatriacontyl phenyl group
magnesium
S-25
naphthyl group
naphthyl group
calcium
S-26
propyl naphthyl group
propyl naphthyl group
magnesium
S-27
hexyl naphthyl group
diisopropyl naphthyl group
magnesium
S-28
octyl naphtyl group
nonyl naphtyl group
magnesium
S-29
dodecyl naphtyl group
decyl naphtyl group
calcium
S-30
tetradecyl naphthyl group
pentadecyl naphthyl group
calcium
S-31
octadecyl naphthyl group
octadecyl naphthyl group
calcium
S-32
triacontyl naphthyl group
triacontyl naphthyl group
zinc
S-33
hexatriacontyl naphtyl group
hexatriacontyl naphtyl group
magnesium
S-34
1,2-bis(octyloxycarbonyl)-1-ethane
1,2-bis(octyloxycarbonyl)-1-ethane
calcium
group
group
S-35
1,2-bis(dodecyloxycarbonyl)-1-ethane
1,2-bis(dodecyloxycarbonyl)-1-ethane
magnesium
group
group
T-1
dodecyl group
dodecyl group
Sodium
T-2
dodecyl phenyl group
dodecyl phenyl group
Sodium
T-3
dodecyl naphthyl group
dodecyl naphthyl group
Potassium
In Table 1, R 1 , R 2 and M correspond to R 1 , R 2 and M in formula 1.
Part 2 (Preparation of Finishes)
Test Example 1
Preparation of Finish (P-1)
[0027] Mineral oil (A-1) with viscosity at 30° C. of 3.5×10 −5 m 2 /s (82 parts) and metal organic sulfonate (S-1) synthesized in Part 1 (5 parts) were dissolved as lubricant at 60° C. with heating and stirring. After it was ascertained by visual observation that they were completely dissolved, α-dodecyl-ω-hydroxypoly(oxyethylene) (n=15) (B-1) (13 parts) was mixed and dissolved with stirring as a functional improvement agent other than metal organic sulfonate and the mixture was further stirred for one hour. After the stirring was stopped, it was cooled at a normal temperature to obtain finish (P-1).
Test Examples 2-35 and Comparison Examples 1-10
Preparation of Finishes (P-2)-(P-35) and (R-1)-(R-10)
[0028] Finishes (P-2)-(P-35) and (R-1)-(R-10) were similarly synthesized. Details of each example are shown in Tables 2 and 3.
Part 3 (Evaluation of Storage Stability)
[0029] After each of the finishes prepared in Part 2 was placed in a transparent beaker and left quietly for seven days at a normal temperature, the external appearance was observed visually and judged according to the following standards. The results are shown also in Tables 2 and 3.
[0030] A: External appearance is uniform and transparent
[0031] B: External appearance is not uniform and some white turbidity was observed
[0032] C: White turbidity was prominent or separation of liquid phase was observed
[0000]
TABLE 2
Functional improvement agent
Metal organic
Kind
Lubricant
sulfonate
Others
Test
of
Ratio
Ratio
Ratio
Storage
Example
finish
Kind
(%)
Kind
(%)
Kind
(%)
stability
1
P-1
A-1
82
S-1
5
B-1
13
A
2
P-2
A-2
82
S-2
5
B-2
13
A
3
P-3
A-3
82
S-3
5
B-3
13
A
4
P-4
A-1
82
S-4
5
B-1
13
A
5
P-5
A-2
82
S-5
5
B-2
13
A
6
P-6
A-3
82
S-6
5
B-3
13
A
7
P-7
A-4
84
S-7
0.5
B-1
13
A
B-4
2.5
8
P-8
A-5
84
S-8
0.5
B-1
13
A
B-5
2.5
9
P-9
A-6
94
S-9
0.5
B-2
3
A
B-4
2.5
10
P-10
A-1
94
S-10
0.5
B-2
3
A
B-5
2.5
11
P-11
A-2
72
S-11
13
B-2
14
A
B-6
1
12
P-12
A-3
72
S-12
13
B-3
14
A
B-4
1
13
P-13
A-4
72
S-13
13
B-1
14
A
B-5
1
14
P-14
A-5
76
S-14
8
B-2
14
A
B-4
2
15
P-15
A-6
76
S-15
8
B-3
13
A
B-5
3
16
P-16
A-1
76
S-16
8
B-1
13
A
B-6
3
17
P-17
A-1
79
S-17
8
B-1
13
A
18
P-18
A-2
82
S-18
5
B-1
13
A
19
P-19
A-2
82
S-19
5
B-2
13
A
20
P-20
A-1
82
S-20
5
B-3
13
A
21
P-21
A-2
79
S-21
8
B-1
13
A
22
P-22
A-3
94
S-22
2
B-2
3
A
B-4
1
23
P-23
A-4
94
S-23
2
B-1
3
A
B-5
1
24
P-24
A-5
94
S-24
2
B-1
3
A
B-6
1
25
P-25
A-6
88
S-25
5
B-1
5
A
B-4
2
26
P-26
A-1
88
S-26
5
B-1
5
A
B-5
2
27
P-27
A-2
76
S-27
8
B-1
13
A
B-6
3
28
P-28
A-1
82
S-28
5
B-1
13
A
29
P-29
A-1
82
S-29
5
B-2
13
A
30
P-30
A-2
82
S-30
5
B-2
13
A
31
P-31
A-2
82
S-31
5
B-3
13
A
32
P-32
A-3
82
S-32
5
B-2
13
A
33
P-33
A-3
82
S-33
5
B-3
13
A
34
P-34
A-4
82
S-34
5
B-1
13
A
35
P-35
A-4
82
S-35
5
B-1
13
A
[0000]
TABLE 3
Functional improvement agent
Metal organic
Comparison
Kind of
Lubricant
sulfonate
Others
Storage
Example
finish
Kind
Ratio (%)
Kind
Ratio (%)
Kind
Ratio (%)
stability
1
R-1
A-1
80
T-1
5
B-1
15
C
2
R-2
A-1
80
T-2
5
B-4
15
C
3
R-3
A-1
80
T-3
5
B-5
15
C
4
R-4
A-1
99.7
S-4
0.01
B-4
0.29
B
5
R-5
A-1
100
—
—
—
—
A
6
R-6
—
—
S-4
15
B-1
55
B
B-4
10
B-5
20
7
R-7
A-1
30
S-4
20
B-1
20
C
B-4
10
B-6
20
8
R-8
A-1
70
S-2
29
B-1
1
C
9
R-9
A-1
80
—
—
B-2
20
C
10
R-10
A-1
50
S-2
15
B-3
35
C
In Tables 2 and 3:
[0033] A-1: Mineral oil with viscosity at 30° C. of 3.5×10 −5 m 2 /s
[0034] A-2: Isopropyl palmitate
[0035] A-3: Polydimethyl siloxan with viscosity at 30° C. of 7.0×10 m 2 /s
[0036] A-4: Ester compound of α-butyl-ω-hydroxypoly(oxyethylene) (n=3) and dodecanoic acid
[0037] A-5: Benzyl laurate
[0038] A-6: Polyether monool with number average molecular weight of 1000 having ethylene oxide and propylene oxide in random addition at mass ratio of 65/35 to butyl alcohol
[0039] B-1: α-dodecyl-ω-hydroxypoly(oxyethylene) (n=15) (nonionic surfactant)
[0040] B-2: 20 mols ethylene oxide adduct of castor oil (nonionic surfactant)
[0041] B-3: Glycerol monolaurate (nonionic surfactant)
[0042] B-4: Potassium salt of phosphoric acid ester of α-lauryl-ω-hydroxy dioxyethyene (anionic surfactant)
[0043] B-5: Lauryl trimethylammonium ethosulfate (cationic surfactant)
[0044] B-6: Octyl dimethylammonioacetate (amphoteric surfactant)
Part 4
Production and Treatment of False Twisted Textured Yarns
[0045] (A) Production and treatment of polyethylene terephtharate false twisted textured yarns
[0046] After polyethylene terephtharate chips with intrinsic viscosity 0.64 and containing titanium dioxide by 0.2% were dried by a known method, they were spun at 295° C. by using an extruder. After a 10% aqueous solution of a spinning lubricant for synthetic fibers (product name of DELION F-168 produced by Takemoto Yushi Kabushiki Kaisha) was caused to be attached to the running filaments obtained from its spinneret and cooled to become solid by the guide oiling method using a metering pump such that the attached quantity of spinning lubricant became 0.3%, they were collected by a guide and wound up at a speed of 3000 m/minute without mechanical drawing to obtain 128 dtex, 36-filament partially oriented yarns as a 10-kg wound cake. A false twisting process was carried out by using this cake with a false twister with a contact heater (product name of SDS1200 produced by TEIJIN SEIKI CO., LTD.) at a speed of 700 m/minute. The conditions of this process were as follows: draw ratio=1.525; twisting system=one guide disk on entrance side, one guide disk on exit side and four hard polyurethane disks; length and surface temperature of heater on twist side=2.5m and 212° C.; heater on untwist side=none, and number of twists=3300T/m. At the time of this false twisting process, a neat oiling process was carried out on the false twisted textured yarns prior to being wound around a paper tube by a roller oiling method such that the amount shown in Table 4 of the finish (P-1) prepared in Part 2 would become attached so as to obtain polyethylene terephtharate false twisted textured yarns of Test Example 36. Similarly, polyethylene terephtharate false twisted textured yarns of Test Examples 37-72 and Comparison Examples 11-20 were obtained. Details of each example are shown in Table 4.
[0047] (B) Production and Treatment of Nylon 6,6 False Twisted Textured Yarns
[0048] After nylon 6,6 chips with sulfuric acid relative viscosity (ηr) 2.4 and containing titanium dioxide by 0.1% were dried by a known method, they were spun at 290° C. by using an extruder. After a 10% aqueous solution of a spinning lubricant for synthetic fibers (product name of DELION F-168 produced by Takemoto Yushi Kabushiki Kaisha) was caused to be attached to the running filaments obtained from its spinneret and cooled to become solid by the guide oiling method using a metering pump such that the attached quantity of spinning lubricant became 0.4%, they were collected by a guide and wound up at a speed of 4000 m/minute without mechanical drawing to obtain 70 dtex, 24-filament partially oriented yarns as a 10-kg wound cake. A false twisting process was carried out by using this cake with a false twister with a contact heater (product name of SDS1200 produced by TEIJIN SEIKI CO., LTD.) at a speed of 700 m/minute. The conditions of this process were as follows: draw ratio=1.220; twisting system=one guide disk on entrance side, one guide disk on exit side and four hard polyurethane disks; length and surface temperature of heater on twist side=2.5m and 230° C.; heater on untwist side=none, and number of twists=3000T/m. At the time of this false twisting process, a neat oiling process was carried out on the false twisted textured yarns prior to being wound around a paper tube by a roller oiling method such that the amount shown in Table 5 of the finish (P-1) prepared in Part 2 would become attached so as to obtain nylon 6,6 false twisted textured yarns of Test Example 73. Similarly, polyethylene terephtharate false twisted textured yarns of Test Examples 74-109 and Comparison Examples 21-30 were obtained. Details of each example are shown in Table 5.
[0049] (C) Production and Treatment of Polylactic Acid False Twisted Textured Yarns
[0050] Lactic polymer chips with average molecular weight of 120000, melt flow rate of 25g/10 minutes (210°), glass transition temperature of 60° C. and specific gravity of 1.26 were spun at 210° C. by using an extruder. After a 10% aqueous solution of a spinning lubricant for synthetic fibers (product name of DELION F-168 produced by Takemoto Yushi Kabushiki Kaisha) was caused to be attached to the running filaments obtained from its spinneret and cooled to become solid by the guide oiling method using a metering pump such that the attached quantity of spinning lubricant became 0.5%, they were collected by a guide and wound up at a speed of 3800 m/minute by carrying out mechanical drawing to obtain 100 dtex, 36-filament drawn yarns as a 10-kg wound cake. The tensile strength and elongation of the obtained drawn yarns were respectively 4.6 g/dtx and 30%. A false twisting process was carried out by using this cake with a false twister with a contact heater (product name of SDS1200 produced by TEIJIN SEIKI CO., LTD.) at a speed of 500 m/minute. The conditions of this process were as follows: draw ratio=1.25; twisting system=one guide disk on entrance side, one guide disk on exit side and four hard polyurethane disks; length and surface temperature of heater on twist side=2.5 m and 130° C.; heater on untwist side=none, and number of twists=2500 T/m. At the time of this false twisting process, a neat oiling process was carried out on the false twisted textured yarns prior to being wound around a paper tube by a roller oiling method such that the amount shown in Table 6 of the finish (P-1) prepared in Part 2 would become attached so as to obtain polylactic acid false twisted textured yarns of Test Example 110. Similarly, polylactic acid false twisted textured yarns of Test Examples 111-146 and Comparison Examples 31-40 were obtained. Details of each example are shown in Table 6.
Part 5
Evaluation of False Twisted Textured Yarns
[0051] Each of the false twisted textured yarns produced and treated in Part 4 was used as follows to measure the attached amount of the finish and its antistatic and dyeing characteristics were evaluated. The results are shown in Tables 4-6.
[0000] Measurement of Attached Amount of finish
[0052] Attached amount of finish was measured for each example of false twisted textured yarns according to JIS-L1073 (Testing methods for man-made filament yarns) by using a mixed solvent of normal hexane/ethanol (volume ratio of 50/50) as the extracting solvent.
Evaluation of Antistatic Characteristics
[0053] For this evaluation, 100 false twisted textured yarns of each example were hung on a warping machine, arranged in creels, and wound up as a warp beam of 10000 m at the speed of 100 m/minute. At this moment, the electricity generated by the friction with the metal was measured by means of a KASUGA DENKI current-collecting potential meter and the results were evaluated according to the following standards:
[0054] A: Charge voltage was lower than 0.1 kV
[0055] B: Charge voltage was 0.1 kV or higher and lower than 0.5 kV
[0056] C: Charge voltage was 0.5 kV or higher and lower than 1.0 kV
[0057] D: Charge voltage was 1.0 kV or higher and lower than 2.0 kV
[0058] E: Charge voltage was 2.0 kV or higher
Evaluation of Dyeing Characteristics of Polyethylene Terephtharate False Twisted Textured Yarns
[0059] The polyethylene terephtharate false twisted textured yarns wound on the warping machine as described above for the evaluation of antistatic characteristics were subjected to sizing and drying operations and prepared for warping and passed through a sley of a water-jet loom. A plain woven article was prepared by passing the obtained polyethylene terephtharate false twisted textured yarns through the wefts. After this plain woven article was refined at 80° C. for relaxation, a disperse dye (product name of Kayalon Polyester Blue EBL-E produced by Nippon Kayaku Co., Ltd.) was used for dyeing by the high-pressure dyeing method. The dyed plain woven article was washed with water by a known method and after it was subjected to a reduction cleaning process and dried, it was set on a tube made of iron with diameter 70 mm and length 1 m to repeat for five times an evaluation process of visually counting the number of spots of deep dyeing on the surface of the plain woven article. The number of points on each sheet per sheet of plain woven article was obtained from the evaluation results. The results were evaluated according to the following standards:
[0060] A: The surface of the plain woven article was in a uniform plain woven condition and there was no dyeing lines
[0061] B: The surface of the plain woven article was in a uniform plain woven condition but there was one dyeing line
[0062] C: The surface of the plain woven article was in a uniform plain woven condition and there were 2-3 dyeing lines
[0063] D: The surface of the plain woven article was in a non-uniform plain woven condition and there were 3-10 dyeing lines
[0064] E: The surface of the plain woven article was in a non-uniform plain woven condition and there were ten or more dyeing lines with clear lengths over the surface
Evaluation of Dyeing Characteristics of Nylon 6,6 False Twisted Textured Yarns
[0065] The nylon 6,6 false twisted textured yarns wound on the warping machine as described above for the evaluation of antistatic characteristics were subjected to sizing and drying operations and prepared for warping and passed through a sley of a water-jet loom. A plain woven article was prepared by passing the obtained nylon 6,6 false twisted textured yarns through the wefts. After this plain woven article was refined at 80° C. for relaxation, an acid dye (product name of Sandolan Blue E-HRLN produced by Clariant) was used for dyeing by the normal pressure dyeing method. The dyed plain woven article was washed with water by a known method and after it was dried, it was set on a tube made of iron with diameter 70 mm and length 1 m to repeat for five times an evaluation process of visually counting the number of spots of deep dyeing on the surface of the plain woven article. The number of points on each sheet per sheet of plain woven article was obtained from the evaluation results. The results were evaluated according to similar standards as for the evaluation of the dyeing condition of polyethylene terephtharate false twisted textured yarns.
Evaluation of Dyeing Characteristics of Polylactic Acid False Twisted Textured Yarns
[0066] The polylactic acid false twisted textured yarns wound on the warping machine as described above for the evaluation of antistatic characteristics were subjected to sizing and drying operations and prepared for warping and passed through a sley of a water-jet loom. A plain woven article was prepared by passing the obtained polylactic acid false twisted textured yarns through the wefts. After this plain woven article was refined at 90° C. for relaxation, a disperse dye (product name of Kayalon Polyester Blue EBL-E produced by Nippon Kayaku Co., Ltd.) was used for dyeing by a dyeing method under the processing conditions of 100° C. and 40 minutes. The dyed plain woven article was washed with water by a known method and after it was subjected to a reduction cleaning processed and dried, it was set on a tube made of iron with diameter 70 mm and length 1 m to repeat for five times an evaluation process of visually counting the number of spots of deep dyeing on the surface of the plain woven article. The number of points on each sheet per sheet of plain woven article was obtained from the evaluation results. The results were evaluated according to similar standards as for the evaluation of the dyeing condition of polyethylene terephtharate false twisted textured yarns.
[0000]
TABLE 4
Kind
Heater surface
Fabrication
of
temperature
speed
Attached
Antistatic
Dyeing
finish
(° C.)
(m/minute)
amount (%)
characteristic
characteristic
Test Example
36
P-1
212
700
2.2
B
B
37
P-2
212
700
0.7
A
A
38
P-3
212
700
1.3
A
A
39
P-4
212
700
2.0
A
A
40
P-5
212
700
1.9
A
A
41
P-6
212
700
2.6
A
A
42
P-7
212
700
1.8
C
C
43
P-8
212
500
2.3
C
C
44
P-9
212
500
0.4
C
C
45
P-10
212
700
2.6
C
C
46
P-11
212
800
1.8
B
C
47
P-12
200
500
1.2
B
C
48
P-13
200
500
2.2
B
C
49
P-14
190
500
2.1
B
B
50
P-15
190
500
2.4
B
B
51
P-16
200
500
2.3
B
B
52
P-17
200
800
2.7
A
A
53
P-18
200
800
1.8
A
A
54
P-19
200
800
2.0
A
A
55
P-20
200
900
1.2
A
A
56
P-21
200
1000
0.9
A
A
57
P-22
200
1000
1.2
B
B
58
P-23
225
1000
1.8
B
B
59
P-24
225
1000
2.7
B
B
60
P-25
190
900
3.5
B
B
61
P-26
190
900
3.0
B
B
62
P-27
190
900
2.6
B
B
63
P-28
190
600
0.8
A
A
64
P-29
200
700
2.0
A
A
65
P-30
180
700
2.7
A
A
66
P-31
180
900
1.5
A
A
67
P-32
210
1200
1.3
B
B
68
P-33
210
1200
1.8
B
B
69
P-34
210
1200
4.0
B
B
70
P-35
210
1200
0.8
B
B
71
P-1
210
300
0.5
C
B
72
P-4
210
800
4.6
A
B
Comparison
Example
11
R-1
210
800
1.9
E
E
12
R-2
210
800
2.2
E
E
13
R-3
210
800
2.4
E
E
14
R-4
210
800
2.3
D
E
15
R-5
210
800
2.2
E
E
16
R-6
210
800
2.3
E
E
17
R-7
210
800
2.0
C
D
18
R-8
210
800
1.9
D
E
19
R-9
210
800
2.0
E
E
20
R-10
210
800
2.5
E
E
[0000]
TABLE 5
Kind
Heater surface
Fabrication
of
temperature
speed
Attached
Antistatic
Dyeing
finish
(° C.)
(m/minute)
amount (%)
characteristic
characteristic
Test Example
73
P-1
230
700
1.9
B
B
74
P-2
210
700
2.1
A
A
75
P-3
210
700
1.2
A
A
76
P-4
210
800
2.1
A
A
77
P-5
210
800
0.8
A
A
78
P-6
210
800
2.6
A
A
79
P-7
230
800
0.8
C
C
80
P-8
230
300
0.4
C
C
81
P-9
210
500
2.0
C
C
82
P-10
210
500
0.3
C
C
83
P-11
210
800
3.3
B
C
84
P-12
220
800
2.7
B
C
85
P-13
180
600
1.5
B
C
86
P-14
180
600
0.8
B
B
87
P-15
180
600
1.2
B
B
88
P-16
180
600
1.8
B
B
89
P-17
180
600
2.9
A
A
90
P-18
190
600
2.0
A
A
91
P-19
190
800
2.7
A
A
92
P-20
180
700
1.0
A
A
93
P-21
200
800
1.6
A
A
94
P-22
225
900
2.6
B
B
95
P-23
180
900
0.8
C
C
96
P-24
225
700
0.4
C
C
97
P-25
225
900
3.2
B
C
98
P-26
225
900
1.2
B
B
99
P-27
225
900
2.2
B
B
100
P-28
190
700
1.7
A
A
101
P-29
200
700
1.9
A
A
102
P-30
180
700
2.6
A
A
103
P-31
200
900
0.8
A
A
104
P-32
225
1200
2.3
B
B
105
P-33
225
1200
2.1
B
B
106
P-34
225
1200
2.2
B
B
107
P-35
225
1200
2.1
B
B
108
P-1
190
180
0.6
C
C
109
P-4
210
700
4.5
A
B
Comparison
Example
21
R-1
220
800
2.2
E
E
22
R-2
220
800
2.2
E
E
23
R-3
220
800
2.4
E
E
24
R-4
220
800
1.8
D
E
25
R-5
220
800
2.2
E
E
26
R-6
220
800
2.0
E
E
27
R-7
220
800
2.2
D
D
28
R-8
220
800
2.0
E
E
29
R-9
220
800
2.2
E
E
30
R-10
220
800
1.7
E
E
[0000]
TABLE 6
Kind
Heater surface
Fabrication
of
temperature
speed
Attached
Antistatic
Dyeing
finish
(° C.)
(m/minute)
amount (%)
characteristic
characteristic
Test Example
110
P-1
130
500
2.0
B
B
111
P-2
130
600
0.9
A
A
112
P-3
130
500
1.2
A
A
113
P-4
130
600
2.3
A
A
114
P-5
130
500
2.7
A
A
115
P-6
130
600
0.8
A
A
116
P-7
130
500
0.3
C
C
117
P-8
130
500
1.3
C
C
118
P-9
120
400
2.0
C
C
119
P-10
100
400
0.8
C
C
120
P-11
110
400
2.7
B
C
121
P-12
80
300
1.2
B
C
122
P-13
130
500
1.2
B
C
123
P-14
140
600
2.4
B
B
124
P-15
140
500
3.1
B
B
125
P-16
140
600
2.8
B
B
126
P-17
130
600
2.7
A
A
127
P-18
140
600
1.2
A
A
128
P-19
130
600
2.5
A
A
129
P-20
140
600
1.7
A
A
130
P-21
130
500
0.8
A
A
131
P-22
130
500
2.7
B
B
132
P-23
120
400
3.3
B
B
133
P-24
120
400
1.2
B
B
134
P-25
120
400
1.6
C
D
135
P-26
120
200
0.6
C
B
136
P-27
120
300
2.4
C
B
137
P-28
130
400
2.4
A
A
138
P-29
130
400
1.9
A
A
139
P-30
130
400
1.2
A
A
140
P-31
130
500
1.6
A
A
141
P-32
130
500
2.8
B
B
142
P-33
130
500
2.1
B
B
143
P-34
130
400
3.4
B
B
144
P-35
140
400
1.1
B
B
145
P-1
140
500
0.5
C
C
146
P-4
140
400
4.4
A
B
Comparison
Example
31
R-1
130
300
1.8
E
E
32
R-2
130
200
1.9
E
E
33
R-3
130
500
2.4
E
E
34
R-4
130
500
2.2
E
E
35
R-5
130
500
2.3
E
E
36
R-6
130
500
2.5
E
E
37
R-7
130
600
1.7
C
D
38
R-8
130
600
1.3
D
E
39
R-9
130
600
1.9
E
E
40
R-10
130
600
2.4
E
E | A straight-type finish, which has improved storage characteristics and is capable of preventing synthetic fibers from becoming electrically charged and uneven dyeing from being generated, contains a lubricant and a functional improvement agent at specified ratios. A metal organic sulfonate of a specified type is contained at least as a part of the functional improvement agent at a specified mass % of the total. | 3 |
FIELD OF THE INVENTION
The present invention relates to conveyor systems, including conveyor systems that divert items/products from one conveyor to another conveyor.
BACKGROUND OF THE INVENTION
The use of conveyors is well known in many industries. In manufacturing, conveyors are commonly used, for example, to move partially assembled products or parts between workstations. In product packaging environments, conveyors commonly move finished products and packages through packaging stations.
Whatever the application, it is sometimes necessary to selectively divert items/products from one conveyor to another conveyor. For example, when a downstream packaging station is incapable of handling the volume of products arriving from an upstream conveyor, it may be necessary to employ two or more downstream conveyors and packaging machines to avoid a bottleneck in the process. In such cases, some of the products must be diverted from the upstream conveyor to the additional downstream conveyor(s) in order to apportion product between them. In another example, pre-arranged lightweight products, such as a stack of tissue paper or fabric softener sheets, may become misaligned if they are knocked or subjected to rapid acceleration or deceleration during the packaging process. In these cases, product misalignment may be diminished by reducing the speed at which the product is moved during the packaging process. This may be achieved by diverting some upstream products to one or more downstream conveyors to reduce the load of product that each packaging station must handle.
A problem with known diverters is that they too often knock or subject the diverted products to rapid acceleration or deceleration during the diverting process. This may have a number of undesirable effects. For example, in a manufacturing environment, diversion of sensitive or delicate products by a conventional diverter may dislodge components or otherwise damage the products. In a packaging environment, pre-arranged lightweight products may easily become misaligned during the diverting process by these conventional diverters and thereby compromise the proper operation of packaging machines.
Known diverters utilise apparatus which selectively divert items or products in a generally horizontal plane. Items are taken out of the incoming conveyor stream and moved sideways or at an angle, but in a generally horizontal plane. These types of diverters are not particularly good at providing a low level of acceleration or deceleration during the diversion process.
Accordingly, there is a need for diverters that can diminish the amount of acceleration, deceleration and knocking that products are subjected to during the diverting process.
Another problem with some conveyor systems exists at the end of a conveyor where product has to be transferred from the conveyor into a bucket that will take the product to a further station. If the product is flexible about its transverse axes, then if there is any misalignment or any force applied to the front of the product, such as from movement through air as the product leaves the conveyor for the bucket, then the product can fold about a transverse axis, possibly resulting in mis-feed into the bucket. Accordingly, it is desirable to provide a bucket in-feed station that reduces the risk of mis-feeding.
SUMMARY OF THE INVENTION
It is desirable to provide a conveyor system that has a diverter for selectively diverting products from one conveyor to another conveyor. It is also desirable to provide a conveyor system that can easily transfer flexible products into a bucket. The diverter will be particularly useful in high-speed conveyor systems.
Advantageously, the present invention may diminish product acceleration, deceleration and knocking during the diverting process so as to reduce product misalignment; may reduce the volume of product on the conveyors after selected products are diverted; and may reduce the incidence of product misfeeds.
In accordance with an aspect of the present invention there is provided an apparatus for transferring a selected product of a plurality of products carried on a first conveyor, from a pickup position on said first conveyor to a delivery position on a second conveyor, said second conveyor being vertically displaced relative to said first conveyor, said apparatus comprising: (a) a member having a transfer effector, said member mounted to a frame for movement to move said transfer effector between said pick-up position and said delivery position; (b) a drive mechanism for moving said member; and (c) a control system operable to control the speed and position of said transfer effector; said transfer effector being adapted for retrieving said selected product at said pick-up position and depositing said selected article at said delivery position, wherein said control system controls the speed and position of said transfer effector from retrieval of said selected product at said pickup position to delivery of said selected product at said delivery position.
In accordance with another aspect of the present invention there is provided an apparatus for transferring a selected product from a pick-up position on a first conveyor to a delivery position on a vertically displaced second conveyor, comprising: (a) a plurality of rotary members rotatable in a substantially vertical plane of rotation about a sun axis; (b) a plurality of radial arms extending outward from each of said rotary members, said radial arms spaced equally apart along said plane of rotation; (c) a drive mechanism for rotating each of said rotary members about said sun axis; (d) a lifting effector extending from each of said radial arms; and (e) a control system for controlling the speed and position of each said lifting effector by controlling the rotation of said rotary members; wherein said control system controls the rotation of each of said rotary members so that said lifting effector obtains said selected product at said pickup position and delivers said selected product to said delivery position.
In accordance with another aspect of the present invention there is provided a system for diverting selected product from non-selected product comprising: (a) a first conveyor; (b) a second conveyor vertically displaced from said first conveyor; (c) a rotary diverter for acquiring said selected product from said first conveyor at substantially the same horizontal velocity as said first conveyor, and for delivering said selected product onto said second conveyor at substantially the same horizontal velocity as said second conveyor; and (d) a pair of in-feed conveyor stations, one of said in-feed conveyor stations positioned at the terminal end of said first conveyor for receiving said non-selected product, and the other one of said in-feed conveyor stations positioned at the terminal end of said second conveyor for receiving said selected product.
In accordance with another aspect of the present invention there is provided a conveyor system comprising: (a) a diverter station having a diverter; (b) a first conveyor diverter portion, said first conveyor being configured to deliver items in succession, to and through said diverter station; (c) a second conveyor having a receiving portion vertically displaced in relation to said first conveyor, said second conveyor operable to move selected items transferred from said first conveyor to said receiving portion of said second conveyor by said diverter, away from said diverter station; said diverter, having a pick-up member, said diverter operable to move said pick-up member to pick up selected items positioned at said diverter portion from said first conveyor in succession and move said selected items from said first conveyor to said receiving portion and release said selected items in succession at said receiving portion of said second conveyor; whereby at least some of said items arriving at said diverter station on said first conveyor are diverted by said diverter onto said second conveyor.
In accordance with another aspect of the invention there is provide a conveyor system comprising: (a) a diverter station having a diverter; (b) a first conveyor diverter portion, said first conveyor being configured to deliver items in succession, to and through said diverter station, said first conveyor having a receiving portion; (c) a second conveyor that is vertically displaced in relation to said first conveyor, said second conveyor operable to move selected items to said unloading portion for transfer to said first conveyor by said diverter; said diverter, having a pick-up member, said diverter operable to move said pick-up member to pick up selected items positioned at said unloading portion in succession from said second conveyor and move said selected items from said unloading portion of said second conveyor to said receiving portion of said first conveyor and release said selected items in succession at said receiving portion of said second conveyor; whereby at least some of said items arriving at said diverter station on said first conveyor are diverted by said diverter onto said second conveyor.
In accordance with another aspect of the invention there is provide a conveyor system comprising: (a) a first conveyor having a moving conveyor carrier; (b) a second conveyor having a moving conveyor carrier; (c) a driving system to drive both said carriers at substantially the same speed; said first conveyor carrier being mounted in spaced, opposed relation to said second conveyor carrier to permit a deflectable product to be received between said first conveyor carrier and said second conveyor carrier and be carried between said carriers when said driving system is operated; at least one of said first conveyor carrier and said second conveyor carrier having a contoured inward facing surface configured and adapted to press against a surface of said deflectable product received between said first conveyor carrier and said second conveyor carrier, to deflect a side portion of said product relative to a medial portion of said product; whereby said deflectable product is bent along a longitudinal axis.
BRIEF DESCRIPTION OF THE DRAWINGS
In figures which illustrate embodiments of the invention, by way of example only:
FIG. 1 is a schematic plan view of a conveyor system employing a rotary diverter positioned between a single upstream conveyor and two downstream conveyors terminating with separate bucket in-feed conveyor stations;
FIG. 2 illustrates an enlarged side elevation view of the rotary diverter taken in the direction of arrows 2 — 2 of FIG. 1;
FIG. 3 is an enlarged side view of part of the diverter of FIG. 1, in the direction of arrow 3 of FIG. 1;
FIG. 4 is a perspective view of another part of the diverter of FIG. 1, taken in the direction of arrows 4 — 4 of FIG. 2;
FIG. 5 is a cross-sectional view of part of the diverter of FIG. 1, in the direction of arrows 5 — 5 of FIG. 1;
FIG. 6 is a perspective view of an in-feed conveyor station in the general direction of arrow 6 of FIG. 1;
FIG. 7 is a cross-sectional side view of a bucket in-feed station in the system of FIG. 1, in the direction of arrows 7 — 7 of FIG. 1;
FIG. 7A is a cross-sectional view of a convex transverse member and top conveyor belt of the in-feed station in FIG. 7;
FIG. 7B is a cross-sectional view of a product bent between a convex transverse member of FIG. 7A and a concave transverse member of FIG. 7B;
FIG. 7C is a cross-sectional view of a concave transverse member and bottom conveyor belt of the in-feed station in FIG. 7;
FIG. 8 is a perspective view of part of the diverter of FIG. 1, in the direction of arrow 8 of FIG. 1;
FIG. 9 is a perspective view of a part of the diverter of FIG. 2, in the direction of arrow 9 of FIG. 2;
FIG. 10 is a chart illustrating how rotational speed of part of the diverter is varied during rotation; and
FIG. 11 is a schematic side elevation view, similar to FIG. 2 .
Similar references are used in different figures to denote similar components.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIGS. 1 and 2, a conveyor system generally designated 140 , includes a rotary diverter station 111 having a diverter 10 positioned between a single conveyor 80 moving products from a product feed station 13 to diverter 10 , and downstream conveyors 90 , 92 . Conveyors 80 , 90 and 92 may be operate continuously or intermittently and at constant or variable speed. Conveyors 90 , 92 , move product to conveyors 91 , 93 respectively, which in turn each move product to separate bucket in-feed conveyor stations 100 . As an item or product 101 , such as a pre-arranged stack of fabric softener sheets, as shown in FIGS. 2, 3 , 6 , and 7 C travels down conveyor 80 , rotary diverter 10 selectively diverts product 101 from upstream conveyor 80 to downstream conveyor 92 . Products 101 that are not diverted from upstream conveyor 80 , continue along downstream conveyor 90 . In this embodiment, every other product 101 on upstream conveyor 80 can be diverted to downstream conveyor 92 at diverter station 13 , so that the resulting delivery rate of products 101 on each of downstream conveyors 90 and 92 is half of the delivery rate of products 101 on upstream conveyor 80 . In this specification the term “delivery rate” means the number of products that pass a point on the conveyor path in any given period of time (eg. 5 units every second passing a point on the path). It is possible however, to vary the distribution of products diverted as between conveyor 90 and conveyor 92 , as will be evident hereinafter.
The specific configuration of high-speed rotary diverter 10 is shown in FIGS. 2 to 5 and 8 to 9 . With particular reference to FIG. 2 and FIG. 8, rotary diverter 10 has a left hand section 18 and a right hand section 19 , which are constructed of the same parts and mounted substantially in the same way as each other, but in a way so that the operation of one section does not interfere with the operation of the other section during the transfer of products between conveyors. Sections 18 and 19 can be driven independently of each other, in that one can be driven at a rotational speed different than the other, but co-operate in that they work together to transfer products from one conveyor to another.
Unless otherwise indicated, for ease of reference, complementary left hand and right hand sections of rotary diverter 10 are denoted by similar reference numbers. In overview, each section 18 , 19 has an arm each having a pair of opposed, integrally connected arm portion 62 which rotate about the centre of the arm at a central sun axis 15 . Each arm portion has an end effector such as for example, an end effector 20 , at its outer end. As arm portions 62 are rotated, they each are able to pick up a product 101 arriving on conveyor 80 . In this embodiment, the pick-up of a product 101 by an end effector 20 is possible because of the co-operating configuration of the end effectors and the end portion of conveyor 80 . Once product 101 is picked-up, the arm portions 62 then rotate and end effectors 20 lift the product 101 upwards in a vertical direction, following a curved path about axis of a sun shaft 15 . As each arm portions 62 reaches conveyor 92 , the end effector 20 and conveyor 92 are also co-operatively configured such that the end effector can deposit the product 101 onto conveyor 92 . In the preferred embodiment, the arm portions 62 of section 18 co-operate with the arm sections of section 19 , so that each section in turn will rotate an arm portion so that an end effector will transfer a product 101 from conveyor 80 to conveyor 92 .
Referring to FIGS. 2, 3 , 4 and 5 , illustrating section 19 in detail, illustrate a rotary member 60 mounted for rotation in a vertical plane about the central axis X—X of sun shaft 15 . Shaft 15 is fixedly mounted in stationary shaft block 14 , which is secured to a frame. Thus, shaft 15 is held in a stationary position relative to the frame.
As shown in FIG. 5, shaft 15 has a variable, stepped diameter, upon which various components are mounted. Main pulley 35 is rotatably mounted about sun shaft 15 on main bearings 11 and 12 (FIG. 5 ), which are retained by main bearing housing 16 . Sun pulley 32 is concentrically mounted about shaft 15 using a key-way 23 (so sun pulley 32 is fixed relative to shaft 15 ). Main pulley 35 is mounted by bolts on bearing housing 16 and on rotary hub 70 , so that all these parts ( 35 , 16 , 60 ) rotate together about shaft 15 as one unit. Accordingly, when main pulley 35 is rotated by a drive belt 17 , rotary member 60 and bearing housing 16 wall also rotate together with main pulley 35 , about shaft 15 .
Rotary member 60 has two radial arm portions 62 that extend radially outward in a vertical plane, in opposite directions, from a round central portion 61 . In other embodiments, each section's rotary member 60 could have only one radial arm or more than two radial arms may extend from said round central portion 61 , although it will be appreciated that particularly in high speed applications it is desirable to ensure that during the rotation there is proper balancing of the loads resulting from rotation from the arms. Thus, there should be a relatively balanced placement of the arms around central portion 61 , such as for example, three arm portions 62 spaced at 120 degrees from each other or four arm portions 62 spaced at 90 degrees to each other. Alternatively, counter-weights could be used if the placement of the end effectors 20 alone does not provide for proper balancing.
Planetary shaft bearings 102 are retained by a bushing 63 in the outward end of each radial arm portions 62 . A planetary shaft 34 is rotatably mounted through each bushing 63 on bearings 102 . Planetary shafts 34 extend through either side of radial arm portions 62 along an axis parallel to sun shaft 15 .
On the same side of radial arm portions 62 that main pulley 35 is mounted to rotary member 60 , planetary pulleys 103 are fixedly mounted on planetary shafts 34 and thus will rotate with shafts 34 . Planetary pulleys 103 are retained in place by flat washers 104 bolted to planetary shaft 34 . A planetary pulley spacer 106 prevents frictional contact between planetary pulleys 103 and radial arms 62 .
Terminating each planetary shaft 34 , on the end opposite from which planetary pulley 103 is a flange 23 (FIGS. 3 to 5 ). An end effector 20 extends vertically from each flange 23 . Each end effector 20 comprises a centre lifter segment 22 (FIGS. 4 and 5) bolted with bolts 27 to flange 23 and two side lifter segments 24 bolted through lifter segment separators 25 , on either side of centre lifter segment 22 . Side lifter segments 24 are separated in parallel relation from centre lifter segment 22 by lifter segment separators 25 (FIG. 5 ). Above horizontal plane Y—Y which is aligned with the top surface of lifter segments 25 , it is possible for conveyor belt 80 , 90 , 92 to pass between a side lifter segment 24 and centre lifter segment 22 (FIG. 9 ).
In this embodiment, centre lifter segment 22 and side lifter segments 24 are generally triangularly shaped wherein one side of said triangular lifting segments of each end effector 20 define a flat lifting plane that is in parallel orientation to the centre axis of planetary shaft 34 . The bases of side lifter segments 24 are fitted with product guide rails 26 in opposing parallel relation, which define the outer side edges of said lifting plane (FIG. 5 ).
End effector 20 could be comprised of a variety of shapes, structures or mechanisms capable of transferring a selected product 101 from a pickup point P to a delivery point D. For example, depending on the nature and configuration of product 101 , the rotary path of radial arm 62 , and the configuration of the conveyors from which the product is to be transferred from and to, end effector 20 could be for example any of a platform, hook, pair of rails, magnet, suction cup, pincer or clamp.
Rotary member 60 is driven by a drive mechanism 50 (FIGS. 2, 3 and 5 ), which is clamped to a stationary portion of work frame 127 by clamping plate 38 . Drive mechanism 50 drives a drive pulley 21 , which transfers power to main pulley 35 through drive belt 17 to turn main pulley 35 . Thus, the rotation of drive pulley 21 causes main pulley 35 to rotate. As pulley 35 rotates, so does rotary member 60 , along with its arm portions 62 . As arm portions 62 rotate, the position of planetary shafts 34 and planetary pulleys 103 move relative to sun pulley 32 is altered. As sun pulley 32 is fixed on main shaft 15 , the interconnection of sun pulley 32 to planetary pulley 103 through timing belt 105 will cause pulley 103 , shaft 34 and effector 20 to rotate in the opposite direction to the rotation of arm portions 62 . So long as the turning belt 105 and sun pulley 32 counteract precisely the rotation of arm portions 62 , then the orientation of effector 20 will not be changed during rotation of arm portions 62 (eg. in the preferred embodiment the orientation of the top surface of end effector 20 will remain horizontal). This will be the case if the outer diameter of sun pulley 32 is the same as the outer diameter of planetary pulley 103 , with each typically having the same number, and same spacing of teeth.
By way of further explanation, timing belt 105 causes the rotation of each planetary pulley 103 as it is driven around stationery sun pulley 32 in order to maintain the lifting plane of each end effector 20 in a constant (eg. horizontal) position during the rotation of rotary member 60 . The timing belt 105 , planetary pulleys 103 and sun pulley 32 are arranged so that the ratio of end effector 20 rotation to rotary member 60 rotation is set to 1:−1, wherein each end effector 20 will rotate one revolution in the opposite direction for every revolution of rotary member 60 . It may of course be desirable in some applications to vary the orientation of position of the plane or one or more of the effectors during its change in position from pick-up to drop-off of the product. This could be accomplished in another set-up by providing gearing to effect the rotation of the end effectors and by varying the gear ratios of the sun pulley 32 to the planetary pulley 103 .
A way of simply varying the orientation of the end effector relative to the arm portions 62 is to make an adjustment to shaft 15 by rotating it (while the drive is disengaged), such a rotation will cause sun pulley 32 to rotate, thus then turning belt 105 rotating end effector 20 . Thus, as shown in outline in FIG. 3, both end effectors 20 orientation can be altered by angle alpha, by a corresponding rotation of shaft 15 relative to rotary member 60 .
Two idler pulleys 107 are rotatably mounted by idler bearings 108 on shoulder screws 109 , which are attached to the circular portion of rotary member 60 . Idler pulley spacers 36 prevent frictional contact between idler pulleys 107 and rotary member 60 . Idler pulleys 107 are arranged on opposite sides of sun pulley 32 and are situated inside timing belt 105 . During high speed rotation, idler pulleys 107 assist in maintaining the shape and proper positioning of, and provide an efficient path for, timing belt 105 , which, in turn, better maintains the orientation of end effectors 20 . Two tension rollers 33 are rotatably mounted to the circular portion of rotary member 60 . As best seen in FIG. 3, tension rollers 33 are arranged on opposite sides of sun pulley 32 and outside of timing belt 105 so as to urge timing belt 105 into better contact with sun pulley 32 .
Sensor bracket 40 (FIG. 5) is mounted to shaft block 14 by sensor mounting bracket 39 . A flag 41 associated with each of arm portions 62 is attached to bearing housing 16 so that flag 41 rotates with bearing housing 16 . An optical sensor, or any other conventional, suitable sensor (“sensor 1”), not shown, is mounted to sensor bracket 40 to monitor the position of flag 41 . A conventional programmable logic controller (“PLC1”), not shown, or any other conventional electronic control mechanism, communicates with drive mechanism 50 and sensor 1 . The angular position of each radial arm portions 62 and the corresponding position of the lifting plane of end effectors 20 is ascertained by sensor 1 sensing the position of flag 41 and sending a signal to PLC 1 . Accordingly, once sensor 1 detects the flag 41 , PLC 1 know the position of the lifting plane of end effectors 20 is at the “homing” or “ready” position for the end effector 20 . Once identified to be in the homing position (angular position H in FIG. 11 ), an end effector 20 can be held there until it is ready to be rotated to pick up a product 101 .
A second conventional optical or other suitable sensor 31 (FIG. 2 ), also in communication with PLC 1 is mounted to work frame 127 or a stationary portion of upstream of a pick-up point P, on or adjacent conveyor 90 or conveyor 80 . Sensor 31 is appropriately configured to monitor the position of products 101 on upstream conveyor 80 and sends a signal to PLC 1 when a product 101 approaches designated pickup point P on upstream conveyor 80 . A third conventional optical or other suitable sensor 30 , also in communication with PLC 1 could optionally be utilized to confirm the synchronization of movement of product 101 and end effector 20 pick-up point , as is hereinafter described. Sensor 30 can be mounted to work frame 27 or a stationary portion of upstream conveyor 80 . Sensor 30 sends a signal to PLC 1 when a product 101 is exactly at a designated pick-up point P on upstream conveyor 80 .
The position of the pickup point P is programmed into PLC 1 and from this reference point, the rotary members 60 are appropriately rotated in accordance with the angular displacement from this reference point. Also, PLC 1 is programmed such that only certain selected products of the group of products 101 are diverted by diverter 10 from conveyor 80 onto conveyor 92 , whereas other products are allowed to proceed on to conveyor 92 . Thus, PLC 1 will upon the identification of a product 101 approaching pickup point P, determine if this is a product which should be diverted to conveyor 92 , and then either give or not give an instruction to drive mechanism to rotate an arm portion 62 of one of sections 18 or 19 .
Upon receipt of an appropriate signal from sensor 31 , PLC 1 will if designated for diversion, instruct drive mechanism 50 to rotate drive pulley 21 to move a lifting plane of an end effector 20 from its homing position H, to underneath the pickup point P on upstream conveyor 80 in order to position end effector 20 for pick up of a selected product 101 . Under the control of PLC 1 , the drive mechanism 50 will rotate drive pulley 21 to move a lifting plane of an end effector 20 through the pickup point P on upstream conveyor 80 to obtain the selected product 101 (FIG. 9 ). After a selected product 101 is obtained by an end effector 20 , PLC 1 controls drive mechanism 50 in continuing to rotate drive pulley 21 until the lifting plane of end effector 20 crosses the plane of downstream conveyor 92 and deposits product 101 at the delivery point D (FIG. 9 ).
PLC 1 controls the speed of rotation of drive pulley 21 . The rotational speed of the pulley 21 can be selected such that the horizontal component of velocity of an end effector 20 is substantially equal to the horizontal velocity of the upstream conveyor 80 when the lifting plane of end effector 20 obtains a selected product 101 at the pickup point P. Similarly, PLC 1 can control the rotation of drive pulley 21 so that the horizontal component of velocity of an end effector 20 is substantially equal to the horizontal velocity of the downstream conveyor 92 when the lifting plane of end effector 20 delivers a selected product 101 at the delivery point D. By substantially matching the horizontal velocity of the end effector 20 with the horizontal velocity of the upstream conveyor 80 and downstream conveyor 92 at the pickup and delivery points P and D, sudden acceleration and deceleration of product 101 is reduced during the diverting process and the risk of misalignment is accordingly diminished. The speeds at which the conveyors will operate are input into the PLC 1 , which can then determine an appropriate velocity profile for the end effector 20 (for example see FIG. 10 ).
With reference to FIGS. 10 and 11, the rotational speed of an arm portion 62 is shown as the arm moves from the homing position H (−10 degrees in FIG. 11) to the pickup position P (0 degrees in FIG. 11) through the drop-off position D to approximately 100 degrees as shown in FIG. 11 . The curve marked “TL” is the speed curve if the linear speed of the end effector is to remain constant as it rotates from position P through position D to 100 degrees rotation. In one practical embodiment, the rotational speed is controlled by PLC 1 to follow line PL 1 between 0 degrees (position P) and just past 50 degrees at drop off position D. In a preferred embodiment, the speed can actually be increased once product 101 is deposited on conveyor 92 , so that it quickly moves away from the product. Thus, the rotational speed after release of product, may be programmed to follow line PL 2 between drop-off to 100 degrees. This increase in speed, particularly the linear component, will ensure that any following product 101 moving along conveyor 90 and not being diverted will not have its movement interfered with by end effector 20 as it passes back through conveyor 90 during its further rotation.
The drive mechanism 50 is a servo drive, so that the speed of rotation or radial arms 62 can be varied during the rotation, as discussed above. With respect to the two sections 18 and 19 , each of their rotary members 60 are driven separately, so that their speeds at any particular time, can be different. This provides for much greater flexibility in the operation of the diverter 10 . For example, the effector 20 of one section 18 can be stationary at position H, while an effector 20 of the other section 19 can be moving while dropping a product at position D.
As illustrated in FIG. 2 and FIG. 9, diverter 10 is generally positioned between upstream conveyor 80 and downstream conveyors 90 and 92 . In the present embodiment, upstream conveyor 80 and downstream conveyors 90 and 92 each comprise two parallel carrying belts (not shown) in the area between the pickup point P and delivery point D. The belts are separated to provide enough space for centre lifter segment 22 to pass in between the belts and for side lifter segments 24 to pass outside the belts when an end effector 20 crosses the plane of upstream and downstream conveyors 80 and 92 . It will be understood that the number of belts comprising conveyors 80 and 92 , both inside and outside the above noted area, may be greater or less than two.
Downstream conveyor 92 is vertically displaced and from and vertically aligned with, upstream conveyor 80 and they are aligned in a parallel plane to the plane of rotation of rotary member 60 . The vertical displacement between downstream conveyor 92 and upstream conveyor 80 is sufficient to permit non-diverted product 101 to continue along upstream conveyor 80 to downstream conveyor 90 without contacting the underside of downstream conveyor 92 , but less that the distance between plane Y—Y of each end effector 20 and the lifting plane of end effector 20 , so that lifter segment separators 25 do not contact the underside of upstream conveyor 80 during diversion of product 101 .
As rotary member 60 rotates in a clockwise direction, the top surfaces of side segments 24 and centre segment 22 of end effectors 20 define a circular path. In the upper left quadrant of the lifting plane path, the lifting plane has a lifting (upward) and translating (forward) component of motion. In the upper right quadrant of the circular path the lifting plane has a lowering (downward) and translating (forward) component of motion. In the particular arrangement of the preferred embodiment shown in FIG. 2 . and FIG. 9, downstream conveyor 92 is positioned above upstream conveyor 80 , pickup point P is positioned in the upper left quadrant of the circular path and delivery point D is positioned in the upper right quadrant of the lifting plane path. With this arrangement selected product 101 is raised by the lifting plane of end effector 20 at pickup point P as it crosses upstream conveyor 80 and is lowered onto delivery point D as it crosses downstream conveyor 92 . As explained above, PLC 1 controls the rotation of drive pulley 21 to substantially match the translating component of the lifting plane's motion with the translating component of the upstream conveyor 80 at the pickup point P and of the downstream conveyor 92 at the delivery point D. It will also be noted from FIG. 2, that throughout the rotation from pick-up and particularly at drop-off, the vertical component of velocity will be relatively small compared to the horizontal component, and provides for relatively small accelerations in the vertical direction. Furthermore, with respect to certain flimsy products such as a stack of fabric softeners, any vertical acceleration during pick-up will actually serve to stabilize the product as it is pushed against the under supporting segments of end effectors 20 .
As referenced above, in this embodiment, there are two sections 18 and 19 . It will be observed in FIG. 8 that left hand section 18 and right hand section 19 are arranged in opposing relation to one another so that the lifting plane paths of their respective end effectors 20 are concentric and travel in the same vertical plane. This arrangement may be achieved by orienting the sun shafts 15 (as shown in FIG. 5 for right hand section 19 ) of both left hand section 18 and right hand section 19 along the same axis of rotation and by aligning both sets of centre lifter segments 22 on the same plane of rotation.
Left hand section 18 and right hand section 19 may be controlled by a single programmable logic controller, by separate programmable logic controllers in communication with one another, or some other combination of conventional controller devices. The radial arms 72 of left hand section 18 and of right hand section 19 maintain a minimum angular separation so as to prevent the lifting plane of an end effector 20 of one radial arm 60 from contacting the planetary shaft 34 of the next radial arm 60 .
With reference to FIG. 2, the employment of both a left hand section 18 and a right hand section 19 , described above, increases the capacity of products 101 that may be diverted from upstream conveyor 80 . Moreover, if left hand section 18 and right hand section 19 are controlled and are driven independently of each other, the end effector 20 of the one section may be positioned under pickup point P in preparation to obtain a selected product 101 , while the end effector 20 of the other section is still in the process of diverting a previously selected product 101 .
It will be appreciated many different variations to the preferred embodiment described above are possible. For example, multiple radial arms may be provided in a single section rotary diverter instead of or in addition to positioning a left hand section 18 and a right hand section 19 in opposite arrangement. The path of the end effectors does not necessarily have to be circular.
Other variations of the diverter station are possible. For example, it would be possible to arrange diverter 10 to consolidate two streams of product arriving on two separate conveyors, into a single stream of products leaving on a single conveyor. This would be accomplished by the diverter picking up product from one of the incoming conveyors, and depositing the product on an outgoing conveyor, that also receives product from an second incoming conveyor.
Once product 101 reaches the end of downstream conveyors 90 it can be transferred to a conveyor 91 (FIG. 2) which could be operated at a lower speed, with the result that the products can again have their spacing decreased, now some product has been diverted to conveyor 92 . Likewise product carried on conveyor 92 can be transferred to a slower conveyor 93 (FIG. 2) with the same effect.
At the end of conveyors 91 , 93 are in-feed conveyor stations 100 , load products 101 into buckets 112 , shown in FIG. 6, carried on auto-loader 110 . When bucket 112 is filled with a predetermined amount of product 101 , auto-loader 110 advances said filled bucket 112 and positions an empty bucket 112 in its place. Product 101 in filled buckets 112 is eventually transferred to a packaging conveyor (not shown) for transport to a packaging machine (not shown) for packaging. The use of auto-loaders 110 , packaging conveyors and packaging machines to load and package various products positioned in buckets is well known to those skilled in the art.
With reference to FIGS. 6 and 7, in-feed conveyor station 100 has a top conveyor portion 130 in fixed vertical displacement from a bottom conveyor portion 120 . Bottom portion 120 comprises of a conveyor 122 having a bottom conveyor carrier such as belt 124 that is driven in a conventional manner through in-feed conveyor station 100 . As illustrated in FIG. 6, bottom conveyor carrier such as belt 124 has mounted to it a series of concave up (or generally V-shaped) transverse members 125 (one of which is separately shown in FIG. 7C) mounted along its length. Bottom conveyor 120 is positioned at the terminal end of downstream conveyor 90 or 92 so that any product 101 transported by downstream conveyors 90 or 92 is received by a bottom conveyor 120 and can be transported at substantially the same velocity by bottom conveyor belt 124 .
Top portion 130 includes a conveyor 132 on which a top conveyor carrier such as belt 134 can be driven in a conventional manner. As illustrated in FIG. 6, top conveyor belt 134 has mounted along its length a series of convex down (also generally V-shaped) transverse members 135 (one of which is separately shown in FIG. 7 A). In operation, top conveyor belt 134 revolves in an opposite direction to bottom conveyor belt 124 so that the velocity of the bottom surface of top conveyor belt 134 is substantially equal to the velocity of the top surface of bottom conveyor belt 124 .
Product 101 is a product or item that can be deformed when a load is applied to it by being pinched between members 125 and 135 of the bottom and top conveyors respectively. As illustrated in FIG. 7, the vertical separation between the bottom surface of top conveyor belt 134 and the top surface of bottom conveyor belt 124 diminishes from upstream to downstream. The upstream separation diminishes from a separation greater than the height of product 101 to a separation less than the height of product 101 , to compress the product 101 . As product 101 is moved along by bottom belt 124 under top portion 130 it is gradually pinched between bottom conveyor belt 124 and top conveyor belt 134 . As product 101 is pinched by belts 124 and 134 (shown in FIG. 7 B), convex transverse members 135 and concave transverse members 125 gently bend product 101 along its longitudinal centre line of motion. It will be appreciated that flexible products, like paper or fabric softener sheets, are more resistant to bending in one direction when a bend is introduced in the transverse direction. Accordingly, by bending product 101 along a central longitudinal axis, in-feed conveyor station 100 makes product 101 more resistant to bending in the transverse direction (ie. about a transverse axis) and, therefore, less likely to fold or become misaligned as it is loaded into bucket 112 .
The conveyor system referred above can be operated at relatively high speeds, including the diverter 10 . For example, in the preferred embodiment, the conveyors 80 , 90 and 92 can be operated with a linear speed of in the order of 250 feet per minute.
Numerous other modifications, variations and adaptations may be made to the particular embodiments of the invention described above without departing from the scope of the invention, which is defined in the claims. | A rotary diverter can be operated at high speed to divert selected products from one conveyor to a vertically displaced second conveyor. The rotary diverter can have at least one rotary member with a plurality of radial arms. Each radial arm can have an end effector with a lifting platform. A timing belt may be coupled to each end effector to the rotary member in order to keep the lifting platform substantially horizontal. A control system is provided to control a drive mechanism for rotating the rotary member. As the rotary member rotates, the lifting platform of the end effector rises through the first conveyor to lift a selected product over the second conveyor. As the rotary member continues to rotate the lifting platform can then descend through the second conveyor to deliver the selected product upon the second conveyor. During operation, the control system can ensure that the lifting platform of the end effectors: (i) substantially matches the horizontal velocity of the first conveyor when they lift a selected product from the first conveyor; and (ii) substantially matches the horizontal velocity of the second conveyor when they deliver a selected product upon the second conveyor. This arrangement diminishes the amount of acceleration, deceleration and knocking that the selected products are subjected to during the diverting process, which reduces the risk of product misalignment. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to improvements in refuse bins incorporating compacting means, for domestic use.
2. History of the Prior Art
FR-A-2 135 322 discloses a refuse bin of the type in question, comprising:
an upwardly open bin;
a lid articulated on the bin;
a compacting plate disposed inside the bin and comprising two upwardly oriented tabs which pass through the lid and comprise means for sliding and pivoting association with the manoeuvring rod which rests on the lid. By subjecting this rod to a translation, the latter may, at the end of stroke, be pivoted with respect to said means of the tabs in order to orient it vertically with a view to actuating the compacting plate downwardly and upwardly.
However, the position of the manoeuvring rod on the lid is neither practical nor aesthetic.
Moreover, assembly of the low end of the manoeuvring rod and of the compacting plate necessitates a pusher system controlled by a handle, the whole being complex and uneconomical.
SUMMARY OF THE INVENTION
It is an object of the improvements according to the present invention to overcome these drawbacks and to allow a compacting refuse bin to be produced which responds better than heretofore to the desiderata of the users.
To this end, the tabs of the compacting plate come, in high position of the latter, into housings in thc lid opcning out in a longitudinal groove made in the top of the latter and which slidably contains thc plate controlling member so that the catches come into this groove and penetrate in known manner in two longitudinal slides made in the two opposite longitudinal faces of the control member.
According to another feature of the invention, the slides of the plate control member comprise two notches thanks to which the catches of said plate may be engaged in these slides in a position thereof which is never presented during operation.
According to another feature of the invention, the active end of the plate control member comprises a depression in which a fixed projection on this plate penetrates in order to lock the member perpendicularly to the latter and be automatically released as soon as the member is pulled upwardly.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more readily understood on reading the following description with reference to the accompanying drawings, in which:
FIG. 1 is an exploded view in perspective of a compacting refuse bin incorporating the improvements according to the invention.
FIG. 2 is a transverse section of the upper part of the refuse bin according to the invention.
FIG. 3 is a view similar to that of FIG. 2, but made in the centre of the refuse bin, so as to show the assembly of the control member and of the compacting plate.
FIG. 4 shows the manner in which the compacting plate is positioned in the slides of its control member.
FIG. 5 is a longitudinal section of the upper part of the refuse bin according to the invention showing the manner in which the plate control member is displaced from its rest position to its active position.
FIG. 6 is a detailed view showing thc control mcmber in vertical position before the projection on the lid is fitted in the terminal depression of the control member.
FIG. 7 illustrates the manner in which compacting is effected.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, the refuse bin illustrated in FIG. 1 essentially comprises a bin 1 of rectangular cross section of which the upper part is covered by a frame 2 on which is articulated a lid 3, whilst, inside this bin, a compacting plate 4 may be displaced vertically with a view to compressing the refuse contained in a plastic bag. The latter is disposed inside the bin and its opening is wedged between the frame 2 and the upper part of bin 1, as illustrated in FIG. 2 et seq., the bag being referenced 5 and shown schematically in broken lines. Openings 1a and 2a are made in register in the bin and the frame respectively, so that, by passing his hands through these openings, the user grips these two elements without separating them.
As illustrated in FIG. 1, the compacting plate 4 is adapted to be associated with a control member 6 which is normally, i.e. not during periods of compacting, located in a groove 3a in the lid 3. The latter pivots with respect to frame 2 via pins 2b on the latter which engage in perforations 3b made in lugs 3c on lid 3.
It is observed that groove 3a is traversed by an opening 3d located at the centre thereof and which is intended, on the one hand, for the passage of the control member 6 during compacting and, on the other hand, to allow permanent assembly of this member and of the compacting plate 4.
The 1atter comprises a network of reinforcing ribs issuing from a central vertical extension composed of two vertical tabs 4a, 4b of which the opposite faces each bear a catch 4c, 4d comprising a common horizontal geometrical axis. Between the two tabs 4a and 4b is located a hollow projection 4e whose role will be set forth hereinbelow.
The control member 6 is in the form of a rectangular parallelepiped whose length corresponds to that of lid 3 and whose section is identical to that of groove 3a (FIG. 2), with the result that this member is embedded in the lid. One of the ends of member 6 comprises a downwardly projecting gripping handle 6a which engages in a hollow 3e made at one of the ends of groove 3a. In this way, as will be emphasized hereinafter, the outward slide of member 6 in groove 3a can only be effected in the direction of arrow F of FIG. 5. Member 6 further comprises an opening 6b adjacent handle 6a and facilitating gripping thereof. The two longitudinal faces of member 6 are hollow so as to determine two slides 6c, 6d whose height is slightly greater than the diameter of catches 4c, 4d. The end of member 6 opposite its handle 6a is provided with a depression 6e of section complementary to that of projection 4e of the compacting plate 4.
FIG. 4 illustrates the refuse bin according to the invention in a partial plan view, its lid 3 being open as illustrated in discontinuous lines in FIG. 3, i.e. it has been pivoted about pins 2b of frame 2, so that its rear edge 3f comes into abutment against the corresponding face of the frame so as to constitute stop of maximum opening. In this position, the control member 6 is introduccd horizontally in the opening 3b in the lid, so that it is presented horizontally once its handle 6a abuts against thc top of said lid. As the two slides 6c, 6d of member 6 each comprise a notch 6f, 6g, if the compacting plate 4 is presented in vertical position with its tabs 4a, 4b turned towards notches 6f, 6g, catches 4c, 4d may be made to penetrate in slides 6c, 6d further to the position of notches 6f, 6g. Arrangements are such that, in no position of the control member 6 during operation do the catches 4c, 4d ever come to the level of notches 6f, 6g. In fact, once said catches are engaged in slides 6c, 6d of member 6, any axial displacement of the latter is made in the zone included between these notches and its end opposite handle 6a. It is noted in particular on this subject that member 6 cannot be displaced in the direction opposite that of arrow F of FIG. 5 beyond the position of abutment of the handle 6a against the hollow 3e. The catches are then made to slide in slides until they come into abutment against end stops 6h, 6i of the slides opposite handle 6a (FIG. 6), then the plate is pivoted so that it is oriented perpendicularly to its manoeuvring member 6 (FIG. 6). The manoeuvring member is then withdrawn outwardly by sliding it in opening 3d in lid 3 until plate 4 comes against the underneath of lid 3. The opening 3d of the lid comprises two lateral cut-outs 3g, 3h by which open out into groove 3a two housings 3i, 3j into which come tabs 4a, 4h in high position of the plate 4, the catches 4c, 4d then being crosswise in said groove whilst being engaged in the slide of member 6, as illustrated in FIG. 3. In this way, an articulation is constituted between this member and plate 4. Finally, the lid is closed and the control member 6 is folded down to the horizontal with respect to plate 4, so that it rests in groove 3 a in the lid. The latter is displaced axially until it no longer projects from said lid, the handle 6a cooperating with the hollow 3e. The refuse bin is then in rest position, i.e. not in use.
If a user desires to place refuse in the bin, it suffices to open the lid, pour the refuse into bag 5, and to close the lid again. If he then desires to compress the products deposited in the bag, he extracts the manoeuvring member by subjecting it to a longitudinal translation in the direction of arrow F of FIG. 5, such translation bringing the two catches 4c, 4d to near the end of the member 6 opposite its handle 6a. Under these conditions, it is possible to pivot member 6 to bring it to the vertical in the direction of arrows Fl and F2 of FIG. 5. The following operation consists in vertically lowering the manoeuvring member downwardly in the direction of arrow F3. When plate 4 comes into contact with refuse, it is immobilized whilst member 6 may be descended a little more in order to engage the projection 4e of this plate in the depression 6e of the manoeuvring member 6 (FIG. 7). In this way, the angular positions of these two elements are locked and compacting may be practised without pivoting the plate 4.
Return into position is effected in reverse. When the member 6 is withdrawn by a vertical displacement, tabs 4a, 4b of the plate come into housings 3i, 3j of the lid against the bottom of which they abut in order to allow disengagement of the projection 4e with respect to the end depression 6e of the member 6. The latter returns into the position illustrated in FIG. 2, so that it may again pivot with respect to catches 4c and 4d in order to be placcd in horizontal position in the groove 3a of the lid. This member is then returned into its rest position by sliding in the direction opposite that of arrow F of FIG. 5.
A compacting refuse bin has thus been produced of which the compacting plate is actuated by a control member which, in rest position, is perfectly included within the general volume of the bin.
It goes without saying that the article forming the subject matter of the present invention may be made of any appropriate materials, but that its different elements are advantageously made by moulding a plastics material under pressure.
It will be noted that the handle 6a abuts against the bottom of groove 3a if the manoeuvring member 6, placed vertically, is released by the user when the bin is empty.
It must, moreover, be understood that the foregoing description has been given only by way of example and that it in no way limits the domain of the invention which would not be exceeded by replacing the details of execution described by any other equivalents. | This invention relates to improvements in refuse bins incorporating compacting means for domestic use, wherein the compacting plate comprises two upwardly oriented tabs which are placed in housings in the lid to be slidably associated with a control member. Catches facing opposite each other and borne by said tabs come into slides in the control member embedded in a groove in the lid. In this way, by subjecting the control member to a translation, it may, at the end of a stroke, be pivoted with respect to the catches in order to orient it vertically with a view to vertically actuating the compacting plate. | 8 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to devices for use with trust falls and other team-building activities.
[0003] 2. General Background
[0004] “Trust falls” are a common team-building exercise used by corporations and other groups to foster trust among groups of people. In a trust fall, an individual lets himself or herself fall backwards from a standing position. A number of other individuals stand behind the “faller,” ready to catch the person before he or she hits the ground. The point of the exercise is for the faller to learn that he or she can count on the others for back-up and support.
[0005] However, trust falls can be dangerous, both because the catchers might lose their grip and drop the faller, and because the faller might swing his or her arms out when falling and hit the catchers. Also, because it involves hand-to-body contact between a number of people, conventional trust falls can be embarrassing or uncomfortable for some.
[0006] Therefore, there is a need to improve the safety of trust falls, and to provide a means so that participants do not have to catch the faller with their bare hands.
SUMMARY OF THE INVENTION
[0007] The present invention is a “trust fall mat,” which can be held by participants to catch the faller in trust fall exercise. The mat is large enough to catch most any person, and has handles at the periphery for the catchers to hold. The mat can be made of cloth, webbing, canvas, plastic, re-inforced fabric, etc. It can also have lateral supports for increased strength.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] [0008]FIG. 1 is a frontal perspective view of a trust fall mat according to the present invention, with participants using the mat.
[0009] [0009]FIG. 2 is a side cut-away perspective view, taken along line 2 - 2 of FIG. 1, of a trust fall mat according to the present invention.
[0010] [0010]FIG. 3 is a top view of a trust fall mat according to the present invention.
[0011] [0011]FIG. 4 is a bottom view of a trust fall mat according to the present invention.
[0012] [0012]FIG. 5 is a side view of a trust fall mat according to the present invention.
[0013] [0013]FIG. 6 is a close-up of a portion of a trust fall mat according to the present invention, as identified in FIG. 4.
[0014] [0014]FIG. 7 is a side cross-sectional view of the portion of a trust fall depicted in FIG. 6, taken along line 7 - 7 .
DETAILED DESCRIPTION
[0015] The present invention is a trust fall mat 10 comprised of handles 20 , a catching mat 30 , and optional lateral supports 40 .
[0016] As shown in FIGS. 1 - 7 , the handles 20 are placed around the periphery of the mat, and are used by participants to hold the mat while another participant falls into the mat. The handles may have cylindrical grips 22 for ease of holding, as depicted in FIGS. 6&7. The trust fall mat may also have a top handle 24 , placed at the portion of the mat near where the faller's head will land. The handles can be made of many materials, including cloth, canvas, plastic, fabric, rubber, wood, etc.
[0017] The handles can be attached to the catching mat through conventional means, including adhesives, stitches, mechanical fasteners, etc. See FIG. 4. In one embodiment of the present invention, some of the handles 20 extend into lateral supports 40 . These supports 50 provide extra strength.
[0018] The catching mat 30 can be large enough to accommodate even large persons, and can be made of strong material, such as cloth, canvas, plastic, fabric, etc. In one embodiment, the area of the mat may be large enough to catch a human being, but not so large as to make it cumbersome for as few as two individuals to use the mat as catchers. In this embodiment, the area of the mat could be from 15 to 70 square feet. In one particular version of this invention, the mat is approximately six feet wide by seven feet long, thus providing an area of 42 square feet.
[0019] The mat 30 can take any number of shapes, including the six-sided shape shown in FIGS. 3&4, as well more circular shapes, or a simple rectangular or square shape. Other shapes include but are not limited to: substantially triangular, five-sided, oval, key-shaped, etc.
[0020] In operation, a plurality of participants hold the mat 10 using the handles 20 . See FIG. 1. The “faller” would stand in front of the mat, typically facing away from the other participants, and would let himself or herself fall backwards into the mat. The trust fall would thus be completed, with improved safety due to the superior catching ability of the mat.
[0021] One skilled in the art will appreciate that the present invention can be practiced by other than the preferred embodiments, which are presented for purposes of illustration and not of limitation. | A “trust fall” mat having peripheral handles, a catching mat, and optional lateral supports is disclosed. The mat can be used to catch individuals falling during trust fall or other team-building exercises. | 6 |
BACKGROUND
This application claims priority from Korea Patent Application 10-2009-0065898, filed Jul. 20, 2009.
The present invention relates to a system for preventing flames and toxic gas from passing through a hole or opening in a partition or wall, such as an interior structure of a building, ship, or the like, upon occurrence of fire, and to a method of making such a system.
When fire occurs, serious damage to life and property may result. Regarding such damage, in addition to damage resulting directly from fire, loss of life caused by suffocation due to toxic gas generated from burning of flammable material and its rapid diffusion is a serious problem. Flames and toxic gas tend to pass through passages, such as doors, open holes, and cracks, of partition walls and interior structures of a building. Open holes in partition walls may be formed in partition walls of a building to pass wires, cables, or pipes through the partition walls. In particular, the interior of a ship has numerous pipes, wires, and cables, which are connected with one another. These pipes, wires, and cables are connected with one another by passing them through the open holes formed in the partition walls.
Conventionally, a volume space left in an open hole through which a cable or pipe already pass has remained empty or been filled with general filling foam or silicon sealants. As a result, there has been a problem because when fire occurs, the general material used to fill the empty space in the open hole easily burns or melts, and flames and toxic gas can easily pass through the open hole.
In addition, some conventional ships have used silica (glass fiber) as a material for filling a space in an open hole. Thus, there have been difficulties in constructing such ships due to skin irritation from glass dust, respiratory disorders, and dust generated during construction of the ships. And such ships are not environmentally friendly.
For an open hole through which a wire and a cable, etc., pass, the sheath of the wire and the cable, etc., may burn or fuse due to heat, thereby forming additional space in the open hole. In the circumstances, there has been a problem because if flames and gas are spreading, there is no system or device to stop the spread.
SUMMARY
The present invention provides a system that can effectively fix, support, and connect a cable, wire, pipe, or the like in an open hole formed in a partition wall, and a construction method thereof. In particular, by using the convenient and rapid construction method, the present invention can completely seal an empty space in an open hole.
In one aspect, the present invention provides a flame-blocking system and a construction method thereof, which are better for the environment and human body, by using the materials described herein, instead of silica (glass fiber), which is conventionally used as a filling material.
Unlike conventional systems for sealing an open hole, the present invention uses a combination system of flame retardant foam and a flame retardant tube. Thus, in another aspect, the present invention provides a flame-blocking system that can more closely seal an open hole formed in a partition wall by using the flame retardant foam and the flame retardant tube that swell due to an increase of temperature when fire occurs so as to completely block flame and toxic gas, and a construction method thereof.
In a particular embodiment, the present invention provides a flame-blocking system comprising flame retardant foam having at least one through hole, and at least one flame retardant tube passing through the through hole of the flame retardant foam.
In one aspect, the flame retardant foam comprises graphite, aluminum hydroxide, and ammonium phosphate, in addition to polyurethane base foam.
In another aspect, the flame retardant tube comprises graphite, aluminum hydroxide, and ammonium phosphate, in addition to a base resin made of EVA (ethylene vinyl acetate) or PVCA (poly vinyl chloride acetate).
In one aspect, if a temperature of more than 200° C. is maintained for three or more minutes, the flame retardant foam swells 150% to 300%, and the flame retardant tube swells 300% to 1500%.
In another aspect, the present invention provides a method of constructing the flame-blocking system. The method comprises preparing a flame retardant foam, cutting the flame retardant foam to a size suitable for an open hole formed in a wall to be installed, making a hole in the flame retardant filling foam to insert the flame retardant tube, and inserting at least one flame retardant tube into the hole.
As described above, the present invention can effectively fix, support, and connect a cable, a wire, and a pipe, which pass through an open hole of a partition wall in various buildings and ships.
In addition, because the present invention simultaneously uses the flame retardant foam and the flame retardant tube that swell at a high temperature upon occurrence of fire, it can effectively block flames and gases, thereby reducing damage to human life caused by suffocation or smoke inhalation.
Additionally, because the construction method is simple and does not require high facility and material costs, construction time and labor costs are reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
The flame-blocking system and the construction method thereof according to the present invention will be described with reference to the accompanying drawings. The descriptions are merely exemplary in nature for understanding of the present invention and are not meant to limit the scope of the present invention to the exemplary embodiments.
FIG. 1 is a perspective view showing the installment of the flame-blocking system according to an embodiment of the present invention.
FIG. 2 shows a cross-sectional view of the flame-blocking system according to an embodiment of the present invention.
FIG. 3 is a top view of the flame-blocking system installed according to an embodiment of the present invention.
DETAILED DESCRIPTION
With reference to FIGS. 1 to 3 , various cables, wires, and pipes, etc., pass through an open hole ( 20 ) formed in a partition wall of, for example, a building or ship. The flame-blocking system is installed in the open hole ( 20 ) and generally includes flame retardant foam ( 30 ) and a flame retardant tube ( 40 ).
In the state that the flame retardant foam ( 30 ) is cut to have a size suitable for the open hole ( 20 ) and fills the open hole ( 20 ), at least one flame retardant tube ( 40 ) is inserted into the flame retardant foam ( 30 ). Various cables, wires, and pipes, etc., ( 50 ) which are connected with one another through a partition wall ( 10 ) in a building, are positioned in the flame retardant tube ( 40 ). In other words, the flame retardant tube ( 40 ) encircles, surrounds or covers a portion of the cable, etc., and is inserted into the flame retardant foam ( 30 ).
The partition wall ( 10 ) may be, for example, a cement or brick partition wall for a general building, or a steel plate partition wall for an interior structure of a ship. Thus, the partition wall ( 10 ) of the present invention is not limited to particular materials. In addition, the open hole ( 20 ) defines a hole in the partition wall ( 10 ), through which various cables and wires, etc., pass. The hole may have diverse sizes and shapes according to features of a building.
The flame retardant foam ( 30 ) according to the present invention uses polyurethane foam having high elasticity and excellent physical properties as basic foam, and uses graphite, aluminum hydroxide, and ammonium phosphate as functional additives to enhance the fire stopping capability of the foam ( 30 ).
As to each of the functional additives, the graphite has a plate-shape structure. When the graphite encounters a temperature of more than 200° C., vapor is generated among lattices of the plate-shape structure. As a result, the plate-shape structure is pressed and swells. In addition, a carbon layer swelling upon occurrence of fire does not burn and remains so as to prevent the spread of heat. The aluminum hydroxide undergoes an endothermic reaction that absorbs heat when it is converted into an aluminum oxide. The ammonium phosphate used in the present invention rapidly absorbs oxygen so as to contribute to the carbonization of the graphite, etc.
With the properties of the functional additives, i.e., swelling, flame retardant property, and endothermic reaction, the flame retardant foam ( 30 ) expands or swells up to ten-fold when fire occurs (i.e. temperature increases). As a result of swelling, pressure is generated so that the open hole ( 20 ) can be more tightly sealed.
In one embodiment, the flame retardant foam ( 30 ) has the following composition and expansion properties:
Amount (part by weight)
Composition of the flame retardant foam
Min
Max
Basic mixing ratio for synthesis of
100
polyurethane
Graphite
20
75
Aluminum hydroxide
14
50
Ammonium phosphate
3
25
Swelling rate (%)
150
300
The flame retardant foam ( 30 ) may comprise 20 to 75 parts by weight of graphite, 14 to 50 parts by weight of aluminum hydroxide, and 3 to 25 parts by weight of ammonium phosphate, based on 100 parts by weight as a basic mixing ratio for synthesis of polyurethane (foam density: 100 to 150 kg/m3). The flame retardant foam ( 30 ) may expand from about 150% to about 300% when exposed to temperatures such as those encountered during a fire. The basic mixing ratio for synthesis of polyurethane is the mixing ratio that is essentially required to prepare polyurethane foam, i.e., 50 to 75 parts by weight of toluene diisocyanate, 2 to 5 parts by weight of water, 0.5 to 2.5 parts by weight of silicone surfactant, 0.1 to 1 parts by weight of an amine catalyst, 0.5 parts by weight of a tin catalyst, and 10 to 30 parts by weight of an additive, based on 100 parts by weight of polyol (halogenated polyether polyol). However, the present invention is not limited to this mixing ratio. The mixing ratio and the additives, etc., may be changed according to properties of the base urethane foam as is known in the art.
Although the embodiment described uses polyurethane foam as a base foam resin, it is merely one example. Other general foam resins, which can be prepared to expand to form foam by incorporating graphite, aluminum hydroxide, and ammonium phosphate in sufficient amounts used as functional additives or have elasticity in a foam form, may also be used.
The flame retardant tube ( 40 ) uses a base resin made of EVA (ethylene vinyl acetate) or PVCA (poly vinyl chloride acetate), and also uses graphite, aluminum hydroxide, and ammonium phosphate for swelling, flame retardant activity, and heat absorption.
In one embodiment, the flame retardant tube ( 40 ) has the following composition and expansion properties:
Amount (part by weight)
Composition of the flame retardant tube
Min
Max
EVA (ethylene vinyl acetate) or PVCA
100
(poly vinyl chloride acetate)
Graphite
20
100
Aluminum hydroxide
15
60
Ammonium phosphate
3
29
Swelling rate (%)
300
1500
The flame retardant tube ( 40 ) comprises about 20 to about 100 parts by weight of graphite, about 15 to 60 parts by weight of aluminum hydroxide, and about 3 to 29 parts by weight of ammonium phosphate, based on 100 parts by weight of a base resin made of EVA (ethylene vinyl acetate) or PVCA (poly vinyl chloride acetate). The swelling rate measured for the part by weight of each of the functional additives was 300% to 1500%.
For the base resin used in the flame retardant tube ( 40 ), each or a mixture of EVA and PVCA can be used. According to one embodiment, the flame retardant tube ( 40 ) was prepared by mixing the base resin and the functional additives and forming the tube shape through an extrusion process (extrusion temperature: approximately 150° C.). However, the preparation method is not limited to extrusion. The diameter and thickness of the flame retardant tube ( 40 ) may be diversely prepared according to shape and size of a wire, a cable, and a pipe, etc., to be inserted into the tube.
In order to measure a free swelling rate of the flame retardant foam and the flame retardant tube, a coin-shaped specimen (diameter: 18 mm; thickness: 3.5 mm) was prepared and put into a furnace. After the specimen in the furnace maintained at 200° C. for three minutes, the swelling rate was measured. As a result, it was confirmed that the flame retardant foam and the flame retardant tube swelled 150% to 300% and 300% to 1500%, respectively.
The flame blocking mechanism according to the physical properties of the elements used in the present invention will be described. First, when fire occurs and, thereby, generates flames and rapidly increasing the ambient temperature, the flame retardant foam ( 30 ) and the flame retardant tube ( 40 ) swell. Consequently, the space in the open hole ( 20 ) is filled with pressure as much as the swelled volume. As a result, flames and gas generated from fire are blocked so as to not move through a partition wall.
Even if the sheath, etc., of a cable, a wire, and a pipe, etc., fuses due to high heat generated from fire, the flame retardant foam ( 30 ) and, even more so, the flame retardant tube ( 40 ) passing through the through hole ( 45 ), swell due to the rapidly increasing temperature, thereby filling the volume space, i.e., the fused sheath of the wire, etc., in the flame retardant tube ( 40 ). As a result, flame and toxic gas are effectively blocked so as to not move through the open hole ( 20 ).
The construction method of the flame-blocking system according to the present invention will now be described. First, the flame retardant foam ( 30 ) is prepared. As described previously, the flame retardant foam ( 30 ) comprises a polyurethane foam resin as a base foam material, and further comprises graphite, aluminum hydroxide, and ammonium phosphate as functional additives contributing directly to swelling, endothermic reaction, and other firestopping properties.
The process for cutting the flame retardant foam ( 30 ) to a size suitable for the open hole ( 20 ) in a wall to be installed means a process for preparing and cutting the flame retardant foam ( 30 ) to a suitable size based on the shape and size of the open hole ( 20 ). Because the flame retardant foam ( 30 ) is compressible or resilient, it is desirable to cut the flame retardant foam ( 30 ) with a size a little larger than the space size of the open hole ( 20 ).
The process for making a hole in the flame retardant foam ( 30 ) to insert the flame retardant tube ( 40 ) means a process for forming a hole, i.e., the through hole ( 45 ), through which the flame retardant tube ( 40 ) passes, prior to inserting a cable ( 50 ), a wire, and a pipe, etc., into the flame retardant tube ( 40 ). The number of through hole(s) ( 45 ) in the flame retardant foam ( 30 ) may vary depending on the circumstances and for example, the number of cables ( 50 ) etc., present, and is not limited to any particular number.
The process for inserting the flame retardant tube ( 40 ) refers to a process for inserting the flame retardant tube into the through hole ( 45 ) in the flame retardant foam ( 30 ) after making a hole in the flame retardant foam ( 30 ). Installation may take place, for example, at the initial stage for constructing a building or ship. Alternatively, the construction and installation may be performed thereafter. For easy insertion and packing of an already installed wire, cable ( 50 ), and pipe, etc., the flame retardant foam ( 30 ) or the flame retardant tube ( 40 ) with one side cut off may be provided.
In addition, the construction method according to the present invention further comprises a process for inserting one of a cable ( 50 ), a wire, and a pipe into the flame retardant tube ( 40 ) and treating the surface with a silicone sealant.
Numerous substitutions, modifications, and variations to the present invention that has been described are possible by one of ordinary skill in the art of the present invention within the technical gist of the present invention. Thus, the scope of the present invention is not limited to the examples described herein and the appended drawings. | A flame-blocking system includes flame retardant foam having at least one through hole and at least one flame retardant tube passing through the through hole. Both the flame retardant foam and the flame retardant tube comprise graphite, aluminum hydroxide and ammonium phosphate in addition to a base resin. The flame-blocking system prevents flames and toxic gases generated during a fire or a similar accident from being spread through holes through which a wire, a cable or a pipe is installed across a wall of buildings or ships, which can reduce damage to life and property. | 5 |
REFERENCE TO PRIOR PROVISIONAL APPLICATION
This non-provisional application is based on and claims the benefit of the filing date (priority) of co-pending provisional application Ser. No. 60/393,220; filed Jul. 2, 2002, under 35 USC Sec. 119.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to conjugates of hydrophilic biopolymers such as hyaluronans (including hylans) with drugs or other pharmacologically active substances including anti-neoplastic drugs such as alpha-interferon formed by covalently bonding them with divinyl sulfone (“DVS”); sometimes referred to herein as vinylsulfone, methods of preparing them and using them.
2. Description of Related Art
Conjugation of polyethylene glycol (“PEG”) and certain biological polymers and enzymes including insulin and catalase are disclosed in U.S. Pat. No. 4,179,337. U.S. Pat. Nos. 5,539,063 and 6,042,822 disclose respectively, (a) methods of conjugation of PEG using so-called “unique linkers” to improve the attachment and activity of the conjugates; and (b) active conjugates of alpha-interferon to PEG. U.S. Pat. No. 5,366,958 discloses the attachment of biologically active agents to fibronectin using N-hydroxysuccinimide; and International Patent No. WO 0,078,365 teaches oxidizing hyaluronans to form aldehyde groups reactive with diamines or amino polyalkylene glycols which are then reacted with oxidized sulfated polysaceharides. In U.S. Pat. Nos. 4,582,865 and 4,605,681, the preparation of cross-linked hyaluronan though vinyl sulfone linkages, as well as the attachment of these materials to the matrix of an insoluble gel-via ether linkages are described.
Prestwich, Glenn D., in “Biomaterials from Chemic ally-Modified Hyaluronan, Glycoforum (Mar. 29, 2001) suggests that drags way be conjugated with hyaluronan. Finally, Cirino, et al., Carbohydrate Research (1971), 17(1), 67–68) teaches that, in addition to simple cross-links (a) and simple substitutions (b), divinyl sulfone can also react with carbohydrates (e.g., cellulose, D-glucose) leading to complex modification of the carbohydrate: RO—CH 2 —CH 2 —SO 2 —CH 2 —CH 2 —OR; and (b) RO—CH 2 —CH 2 —SO 2 —CH═CH 2 , wherein R is a carbohydrate.
BRIEF SUMMARY OF THE INVENTION
The invention provides methods for producing conjugates formed of a hydrophilic biopolymer such as a hyaluronan (including hylan) and a biologically active substance selected from among a large group of materials which have at least one functional group suitable for reaction with divinyl sulfone. The biologically active substance may be any substance which has biological or pharmacological activity and which is normally considered to be a drug and can thus be used as a drug component in the products according to the invention. Additionally, any such substance capable of reacting with a cross-linking agent may be the biologically active substance. The biologically active substance may, for example, be an antineoploastic agent such as vinblastin or paclitaxel, an antibiotic such as gentamicin, a protein such as α-interferon (which is also an antineoplastic agent) or Cytochrome C, an enzyme such as thrombin or a peptide such as avidin. The group of biologically active substances listed above is merely illustrative of a larger group of such substances, and is not intended to limit the scope of the invention. In fact, the biologically active substance may be any such substance having at least one chemical group reactive toward DVS. These chemical groups are typically hydroxyl, amino or sulfhydryl groups. The conjugate not only retains the biological activity of the substance, but in many instances, especially with α-interferon, exhibits enhanced, improved and/or longer lasting activity than does the un-conjugated substance, or a simple mixture of the hyaluronan and the substance.
The invention also provides the conjugates prepared by the methods of the invention.
The conjugate is the reaction product of the above-described intermediate which has the general formula P—(O—CH 2 —CH 2 —SO 2 —CH═CH 2 ) n , wherein n is an integer and is at least 1, P represents a hydrophilic biopolymer, and in a preferred embodiment, the biopolymer (P) is a hyaluronan or a hylan and a biologically active material capable of being covalently and nucleophilically bonded to said intermediate. The intermediate may also contain, in addition to the free, or reactive vinyl groups, some extent of DVS cross-linking.
In still a further embodiment the invention provides, in addition to the simple cross-links and substitutions described by Cirino, et al., the preparation of DVS+carbohydrate (e.g., cellulose, D-glucose, etc.) complexes of the formula: RO—CH 2 —CH 2 —SO 2 —CH 2 —CH 2 —O—(—CH 2 —CH 2 —SO 2 —CH 2 —CH 2 —O—)n-CH 2 —CH 2 —SO 2 —CH═CH 2 , wherein R is a carbohydrate and n is 0, 1, 2, 3, . . . , which complex is then reacted with R′OH, wherein R′ is a drug molecule, water, a protein or an additional carbohydrate to form: RO—CH 2 —CH 2 —SO 2 —CH 2 —CH 2 —O—(—CH 2 —CH 2 —SO 2 —CH 2 —CH 2 —O—)n-CH 2 —CH 2 —SO 2 —CH 2 —CH 2 —OR′, wherein n is 0, 1, 2, 3, . . . . The foregoing reaction path shows how the complex and the drug carbohydrate complex are formed. The advantage of this kind of modification is that the drug is conjugated to the carbohydrate carrier with a longer linking arm, as a result of which, the intermediate may be mare reactive to conjugating a drug.
The invention further provides pharmaceutical compositions comprising a therapeutically effective amount of the conjugate in a pharmacologically acceptable carrier or vehicle therefor.
The invention additionally provides methods of using the pharmaceutical compositions comprising the conjugates in treating neoplastic conditions comprising administering a therapeutically effective amount of the pharmaceutical composition to an animal afflicted with a neoplastic condition.
The invention still further provides methods for preparing a stable intermediate which is suitable for conjugation with drugs. The stable intermediate is prepared by reacting a hyaluronan with divinyl sulfone under controlled pH, time and temperature conditions so selected as to permit the reaction between the hyaluronan and DVS to proceed and thereafter be stopped before completion so as to leave free, or unreacted vinyl groups thereon, which are available to react with the biologically active substance to produce the conjugate.
Finally, the invention also provides the intermediate per se.
The intermediate has the general formula P—(O—CH 2 —CH 2 —SO 2 —CH═CH 2 ) n , wherein n is an integer and is at least 1, P represents a hydrophilic biopolymer having a functional groups capable of reacting with divinyl sulfone.
As used herein, the term hydrophilic biopolymer is intended to cover hyaluronans, hylans, or a mixture of a hylan and a hyaluronan or derivatives thereof having a molecular weight of 1×10 3 to 1×10 7 Da with at least one other hydrophilic polymer having a functional group capable of reacting with divinyl sulfone; said other hydrophilic polymer being a natural or synthetic polyanionic polysaccharide selected from among hydroxyethyl cellulose, carboxymethyl cellulose, xanthan gum, chondroitin sulfate and heparin, a protein selected from collagen, elastin, albumin, a globulin, keratin sulfate, a sulfated aminoglycosaminoglycan or a synthetic water soluble polymer.
DETAILED DESCRIPTION OF THE INVENTION
Recently, the conjugation of various biologically active materials to certain polymers has become of significant medical interest. Such conjugated materials have been found to exhibit an increase in circulatory residence time, enhanced or increased drug stability and also the ability to target specific locations for the drugs to work most effectively.
In achieving the present invention we have prepared, inter alia, conjugates of the anti-viral, anti-cancer drug α-interferon covalently attached to hyaluronan using divinyl sulfone (DVS) as a linker. Subsequent investigation of the resulting conjugates shows that the α-interferon maintains its biological activity after being coupled, or conjugated to a hyaluronan or hylan (“hereinafter sometimes referred to as “HA”). We have also demonstrated the ability of hyaluronan to bind CD44 receptors, thereby providing a targeting mechanism.
In achieving the present invention, the following experimental methods were used:
The preparation of cross-linked hyaluronan through vinyl sulfone linkages is known; see patents cited above. The reaction requires an elevated pH, typically, 9 or higher to convert the hydroxyl groups of the hydrophilic biopolymer to alkoxide ions and allow rapid reaction with the vinyl groups. The rate of the reaction is known to be dependent on pH and temperature. A rate-controlled process for effecting this was developed and is described below.
The Preparation of the Stable Intermediate
Rooster comb hyaluronan (MW 100,000 Da) was reacted with DVS while controlling the reaction rate via pH adjustment, starting at a pH of about 9.6. The reaction was stopped after 30 minutes by adjusting the pH to 6.5 with HCl. This leaves any unreacted vinyl groups covalently attached to the HA backbone, creating an “activated HA,” which is the intermediate of the present invention. The unreacted DVS and hydrolysis products were removed by exhaustive dialysis. The presence of free, or reactive vinyl groups on the HA was determined by thiosulfate consumption, (J. Org. Chem., 11 (46) 719) which liberates an equivalent amount of OH into solution. By measuring pH changes in the thiosulfate with activated HA, the presence and amount of vinyl groups on the HA can be measured. The product of the reaction at this stage is a stable, reactive intermediate which can be isolated as such and then used to conjugate to a biologically active substance.
The Preparation of an Alpha-interferon+HA Conjugate
Alpha-interferon in 0.1 M carbonate buffer, pH 9.8, was added to the activated HA sample and reacted overnight in the cold. Exhaustive dialysis in 50,000 M.W. cutoff was used to eliminate excess interferon not coupled to the HA.
Samples were analyzed to determine the biological activity using an in vitro assay on a bovine kidney epithelial cell line sensitive to alpha-interferon.
Cell Adhesion
Falcon cell tissue culture plates with removable wells were coated with 1 mg per ml of hyaluronan in saline and allowed to dry overnight. Mouse melanoma cells (B16-F10) were cultured in EMEM, a commercially available tissue culture medium, with 5% fetal bovine serum. Confluent cells were dislodged with 5% EDTA, suspended in serum free medium, and labeled with Chromium-51. The 51 Cr-labeled cells were plated at 40,000 cells per well for 30 minutes at 37° C. One group of cells was also incubated in the presence of anti-mouse CD44 monoclonal antibody prior to being plated. The wells were washed with PBS (phosphate buffered saline) to remove unattached cells. The entire well was then placed in a gamma counter where the radioactivity was measured to determine cell number.
Results
To determine the biological integrity of the coupled interferon, the samples were tested. The activity of the hylaluronan+alpha-interferon conjugate, sometimes hereinafter (“HA-INF conjugate”) was conserved, maintaining the drug's activity after chemical modification. There was only a modest change in activity after treatment. See Table 1. To verify that HA did not interfere with the biological assay, HA was tested in the presence of interferon, and HA alone. There was no significant change in interferon activity noted in the presence of HA. HA alone had no detectable activity. It can therefore be concluded that the presence of HA does not interfere with the biological assay.
TABLE 1
Measured Interferon Activities
Sample
Antiviral Activity
HA Interferon conjugate
1.68 × 10 u/ml
Interferon
2.38 × 10 u/ml
Interferon + HA
2.76 × 10 u/ml
HA
Below Detectable Limit
In order for the conjugate to target cells, a specific binding must be established. To investigate this aspect of the invention, we studied the binding of B16-F10 mouse melanoma cells with HA. Mouse melanoma cells over-express CD44 providing a good model for HA targeting of CD44 receptors. In the melanoma cell assay, significant binding of cells to the HA coated plates was detected, with an appreciable decrease in binding of cells that were incubated with anti-CD44 antibody prior to being plated. See Table 2. The results imply that CD44 receptors are involved in the interactions between HA and the cell. These data suggest that CD44 receptors facilitate the targeting of HA conjugated anti-cancer agents to specific cells.
TABLE 2 Cell binding to HA coated Plates Sample % Binding Coated 1.0 mg/ml HA 35.0% Coated + Anti CD44 Antibody 11.8%
The present invention is described in more detail in the following examples, which are given merely by way of illustration and are not intended to limit the invention as set forth in the claims. Unless otherwise indicated, all concentrations given are by weight. The hyaluronan used in the following examples was rooster comb hyaluronan (MW 100,000 Da) which is described in the prior art
EXAMPLE 1
0.05 gram of hyaluronan was dissolved in 10 ml of sterile water. The final concentration was 5 mg per ml. After 2 days of mixing, the sample was autoclaved for 30 minutes at 121° C. to reduce the molecular weight of the sample. The sample was subsequently diluted with 10.0 ml of 0.5M carbonate buffer at pH 9.6, after which 5.0 μg of vinyl sulfone were added to the solution followed by vigorous mixing. The sample was placed on a shaker at 4° C. for 30 minutes. The pH was adjusted to 6.5 by the addition of HCl. The sample was then placed in dialysis against 2 liters of 0.1M phosphate buffer pH 6.5 followed by dialysis against 800 volumes of water.
EXAMPLE 2
0.05 gram of hyaluronan was dissolved in 10 ml of sterile water. The final concentration was 5 mg per ml. After 2 days of mixing, the sample was autoclaved for 30 minutes at 121° C. to reduce the molecular weight of the sample. The sample was subsequently diluted with 10.0 ml of 0.5M carbonate buffer at pH 9.6, after which 5.0 μg of vinyl sulfone were added to the solution followed by vigorous mixing. The sample was placed on a shaker at room temperature, i.e., about 20° C. for 30 minutes. The pH was adjusted to 6.5 by the addition of HCl. The sample was then placed in dialysis against 2 liters of 0.1M phosphate buffer pH 6.5 followed by dialysis against 800 volumes of water.
EXAMPLE 3
Alpha-interferon (500,000 units) in 1 ml of 0.1M carbonate buffer, pH 9.9, were mixed with 2 ml of the sample from Example 1. The mixture was placed on a shaker for 24 hours in the cold and dialyzed against 10,000 volumes of saline solution. Samples were tested for biological activity in an assay using interferon sensitive bovine kidney epithelial cells. The biological activity of the composition was 230,064 units per ml.
EXAMPLE 4
Alpha-interferon (500,000 units) in 1 ml of 0.1M carbonate buffer, pH 9.9, were mixed with 2 ml of the sample from Example 2. The mixture was placed on a shaker for 24 hours in the cold and dialyzed against 10,000 volumes of saline solution. Samples were tested for biological activity in an assay using interferon sensitive bovine kidney epithelial cells. The biological activity of the composition was 167,000 units per ml.
EXAMPLE 5
0.5 gram of hyaluronan was dissolved in 100 ml of sterile water. The final concentration was 5 mg per ml. After 2 days of mixing, the sample was autoclaved for 20 minutes at 121° C. to reduce the molecular weight of the sample. 15 ml of the solution were subsequently diluted with 15.0 ml of 0.5M carbonate buffer at pH 9.6.5 after which 5.0 μg of divinyl sulfone were added to the solution followed by vigorous mixing. The sample was placed on a shaker at room temperature for 30 minutes. The sample was then neutralized by adding 4.9 ml of 0.5M sodium phosphate monobasic to the solution. The sample was adjusted with HCl to pH 6 and placed into sterile dialysis tubing and dialyzed against 500 volumes of water.
EXAMPLE 6
Alpha-interferon (four million units) were reconstituted in 1 ml of 0.5 M carbonate buffer, pH 9.9. One ml of the interferon solution was added to 3 ml of the composition prepared in Example 5, then placed in the cold for 24 hours. The sample was then dialyzed against 500 volumes of saline in the cold for 18 hours. Samples were tested for biological activity in an assay using human pancreatic carcinoma cells. The biological activity of the composition was 1,620,247 units per ml.
EXAMPLE 7
0.25 gram of hyaluronan was dissolved in 50 ml of sterile water. The final concentration was 5 mg per ml. After 2 days of mixing, the sample was autoclaved for 45 minutes at 121° C. to reduce the molecular weight of the sample. The sample was subsequently diluted with 50 ml of 0.5M carbonate buffer at pH 9.6, after which 10.0 μl of vinyl sulfone were added to the solution followed by vigorous mixing. The samples were placed on a shaker at 4° C. for 30 minutes. The pH was adjusted to 6.5 by the addition of HCl. The sample was then placed in dialysis against 2 liters of 0.1M phosphate buffer pH 6.5 followed by 8 changes of 2 liters of water.
EXAMPLE 8
200 μl of epidermal growth factor were brought to a final volume of 1.0 ml in 0.1M carbonate buffer, pH 9.6, and mixed with 1 ml of the activated hyaluronan from Example 7. The mixture was placed on a shaker for 24 hours in the cold and dialyzed against 1,000 volumes of saline. An increase in the molecular weight profile of the HA was observed using HPLC. An absorbance at 280 nm indicated the presence of protein that was not separated by HPLC.
EXAMPLE 9
0.2 mg of Rhodamine labeled Avidin in 1.0 ml of 0.1M carbonate buffer, pH 9.6, was mixed with 1 ml of the activated hyaluronan from Example 7. The mixture was placed on a shaker for 24 hours in the cold and dialyzed against 1,000 volumes of saline. After exhaustive dialysis, a strong fluorescent signal was observed indicating the presence of Avidin that could not be separated by HPLC.
EXAMPLE 10
20 μg of Paclitaxel in 0.20 ml were brought to a final volume of 1.0 ml in 0.1M carbonate buffer, pH 9.6 and mixed with 1 ml of activated hyaluronan from Example 7. The mixture was placed on a shaker for 24 hours in the cold and dialyzed against 1,000 volumes of saline. 100 μl of the resulting conjugate in 1 ml of media were incubated with human hepatoma cells for 24 hours causing a 53% reduction in cell growth.
EXAMPLE 11
0.2 ml of Anti-BSA Antibody was brought to a final volume of 1.0 ml in 0.1M carbonate buffer, pH 9.6, and mixed with 1 ml of the activated hyaluronan from Example 7. The mixture was placed on a shaker for 24 hours in the cold and dialyzed against 1,000 volumes of saline. An increase in the molecular weight profile of the HA was observed using HPLC. An absorbance at 280 nm indicated the presence of protein that was not separated by HPLC.
EXAMPLE 12
200 μg of Cytochrome C were dissolved in 1.0 ml of 0.1M carbonate buffer, pH 9.6, and mixed with 1 ml of the activated hyaluronan from Example 7. The mixture was placed on a shaker for 24 hours in the cold and dialyzed against 1,000 volumes of saline. An increase in the molecular weight profile of the HA was observed using HPLC. An absorbance at 280 nm indicated the presence of protein that was not separated by HPLC.
EXAMPLE 13
25 μg of Vinblastin were dissolved in 1.0 ml of 0.1M carbonate buffer, pH 9.6, and mixed with 1 ml of the activated hyaluronan from Example 7. The mixture was placed on a shaker for 24 hours in the cold and dialyzed against 1,000 volumes of saline. 100 μl of the conjugate in 1 ml of media were incubated with human hepatoma cells for 4 hours causing a 34% hepatoma cell death. | Disclosed are methods of conjugating biologically active substances, particularly, alpha-interferon, with a hyaluronan or a mixture of a hyaluronan with at least one other hydrophilic polymer having a functional group capable of reacting with divinyl sulfone. Also disclosed are stable intermediates formed by partially reacting a hyaluronan with divinyl sulfone and stopping the reaction before completion to leave free, or reactive vinyl groups on the hyaluronan molecule available for conjugation with the biologically active substance. | 0 |
FIELD OF THE INVENTION
[0001] This invention relates to a method and apparatus for measuring cardiac output (CO) in spontaneously breathing humans whose tracheas are not intubated.
BACKGROUND OF THE INVENTION
[0002] Measurement of cardiac output (CO) is frequently performed to guide hemodynamic management of critically ill patients. Since the introduction of the pulmonary artery catheter (PAC) by Swan and Ganz in 1970, the thermodilution technique using PAC has gained widespread acceptance, and is considered the clinical gold standard for the measurement of CO. However, PACs are invasive and have been associated with serious errors and complications. The ideal method for measurement of CO should be noninvasive, accurate, reliable, and continuous.
[0003] The noninvasive cardiac output monitor (NICO) manufactured by Respironics, Inc., Wallingford, Conn. uses the differential carbon dioxide (CO 2 ) Fick partial rebreathing technique to determine CO non-invasively. This technique compares measurements of exhaled CO 2 obtained during a non-rebreathing period with those obtained during a subsequent re-breathing period. The ratio of the change in end-tidal carbon dioxide partial pressure (PETCO 2 ) and carbon dioxide elimination (VCO 2 ) after a brief period of partial rebreathing provides the noninvasive estimate of CO.
[0004] One problem with this technique, however, is that using NICO to determine CO requires tracheal intubation and mechanical ventilation in order to insure a constant minute ventilation. If minute ventilation varies, the CO measurement with the NICO monitor is inaccurate, due to inconsistent CO 2 removal. As a result, many patients whose tracheas are not intubated are excluded from using the current NICO technique to obtain CO.
[0005] It would therefore, be desirable, to provide a method and device to use a NICO monitor to measure CO in humans whose tracheas are not intubated.
[0006] The foregoing features of this invention, as well as the invention itself, may be more fully understood from the following description of the drawings in which:
SUMMARY OF THE INVENTION
[0007] A method for determining cardiac output of a patient comprising directing airflow or gas flow to a fluid containment structure coupled to a ventilator circuit instead of to the patient by a one-way valve and enabling the patient to directly inhale air or gas from the fluid containment structure by a operating a second one-way valve in concert with the first one-way valve. The method further includes preventing inhalation by the patient from an expiratory limb of the ventilator circuit by a third one-way valve and preventing exhalation into the fluid containment structure by a one-way valve.
[0008] A method for providing visual feedback to a patient to help the patient control their ventilation pattern includes providing a fluid containment structure which the patient looks at and when the patient sees the fluid containment structure filled with a volume of fluid, the patient inhales. When the patient sees the fluid containment structure empty of fluid, the patient exhales. The fluid containment structure thus provides visual feedback to a patient to help the patient control their ventilation pattern The fluid containment structure (which may be provided as a balloon, bellows or syringe, for example) acts as a metronome which aids patients in becoming consistent in their breathing patterns. In one exemplary embodiment, the fluid containment structure is provided as a balloon and the patient looks at the balloon; when the patient sees the balloon filled with a volume of fluid (e.g. by observing the size and shape of the balloon), the patient inhales. When the patient sees the balloon empty of fluid (e.g. by observing the size and shape of the balloon), the patient exhales. Thus, the balloon provides visual feedback to a patient to help the patient control their ventilation pattern. This affects both the rate and volume which the patient breathes). This technique provides a visual aid which the patient can utilize to see how fast they are breathing. In other embodiments, audio and/or mechanical aids can be used either in conjunction with or in place of a visual aid. For example, an audio aid can be provided such that a sound is made when the fluid containment structure is either filled or empty. Or an mechanical aid can be provided such that a vibration occurs when the fluid containment structure is either filled or empty. Other visual, audio or mechanical aids (or combinations of such aids) not specifically described or mentioned herein will be readily apparent to those of ordinary skill in the art. An airflow direction system may be provided by three one-way valves operated in concert to appropriately direct airflow to/from the patient.
[0009] A device includes an oral-nasal face mask, a ventilator having a first port, a ventilator circuit in fluid communication with said oral-nasal face mask, said ventilator circuit having an inspiratory limb having a port coupled to said ventilator and an expiratory limb having a port, a fluid containment structure having a first port in fluid communication with the inspiratory limb of said ventilator circuit and having a second port, an airflow direction system in fluid communication with the inspiratory and expiratory limbs of said ventilator circuit, said airflow direction system coupled to allow gas to only fill the fluid containment structure at a first point in time and to allow a patient to breathe gas only from the a fluid containment structure and a non-invasive cardiac output (NICO) monitor coupled to the ventilator circuit. With this arrangement, a device for determining cardiac output of a patient is provided. The device is non-invasive. In one embodiment, the ventilator circuit comprises a y-piece having a first path corresponding to the inspiratory limb of the ventilator circuit, a second path corresponding to the expiratory limb of the ventilator circuit and a third path adapted to couple to a rebreathing valve. The airflow direction system can be provided from three valves. The first valve disposed in the inspiratory limb of the ventilator circuit and having a first port in fluid communication with the ventilator and a second port in fluid communication with a first port of the fluid containment structure. The second valve disposed in the inspiratory limb of the ventilator circuit and having a first port in fluid communication with a second port of the fluid containment structure and a second port in fluid communication with the third path. The third valve disposed in the expiratory limb of the ventilator circuit. The first and second valves open in alternated order, but not at the same time. The first valve is operable to allow a patient to inhale gas only from the fluid containment structure, the second valve is operable to deliver a targeted volume of gas to the fluid containment structure only, but not to the patient. The third valve is operable to prevent the patient from inhaling gas from the expiratory limb of the ventilator circuit.
[0010] A method includes applying a ventilator circuit to a patient's natural airway using an oral-nasal face mask, delivering mechanical ventilation with a specific predetermined tidal volume and ventilatory rate and measuring cardiac output (CO) with a non-invasive cardiac output (NICO) monitor using a NICO technique. In one embodiment, delivering mechanical ventilation with a specific predetermined tidal volume and ventilatory rate comprises operating a first valve in fluid communication with and positioned between the ventilator and the fluid containment structure to fill the fluid containment structure with gas and to allow a patient to inhale gas only from the fluid containment structure, operating a second valve in fluid communication with and positioned in the inspiratory limb of the ventilator circuit between the fluid containment structure and the Y-piece to deliver a targeted volume of gas to the fluid containment structure only, but not to the patient wherein the first and second valves open in alternating order, but not at the same time and operating a third valve in fluid communication with the expiratory limb to prevent the patient from inhaling gas from the expiratory limb of the ventilator circuit. In one embodiment, the patient breathes normally through the oral-nasal face mask and the non-invasive cardiac output (NICO) monitor without attachment to a ventilator until their ventilatory pattern is stable. The patient's tidal volume, respiratory rate and minute ventilation are then measured and the average tidal volume and respiratory rate are computed. The method further includes attaching the ventilator to the NICO monitor and operating the ventilator to provide volume targeted mechanical ventilation to a fluid containment structure and holding the patient's minute volume and carbon dioxide (CO 2 ) elimination constant. In one embodiment, the ventilator is operated to provide volume targeted mechanical ventilation to a fluid containment structure with the ventilator set at or slightly above the patient's average tidal volume and respiratory rate. In one embodiment, a plurality of valves are operated in concert to fill the fluid containment structure with gas and to allow a patient to inhale gas only from the fluid containment structure and to prevent the patient from inhaling gas from any other portion of the ventilator circuit.
[0011] A method comprises ventilating a fluid containment structure in fluid communication with an inspiratory limb of a ventilator circuit and having a patient passively inspire a fixed volume of gas only from the fluid containment structure wherein the fluid containment structure prevents ventilator pressure from being applied directly to the patient's airway such that a ventilatory pattern is maintained consistent and a cardiac output of the patient is prevented from being altered by the application of positive pressure.
[0012] A method for determining cardiac output of a patient includes operating an airflow direction system to allow a fluid containment structure to be filled with a substantially predetermined volume of gas, providing an indication that the fluid containment structure is filled with the substantially predetermined volume of gas and in response to the indication that the fluid containment structure is filled with the substantially predetermined volume of gas, allowing the patient to inhale the volume of gas from the fluid containment structure. The method further includes, in response to an indication that the substantially predetermined volume of gas has been emptied from the fluid containment structure, allowing the patient to exhale. The fluid containment structure provides an indicator of when it is filled with and empty of gas and also provides the patient with feedback such that patients can easily keep up with the indicator of when to inhale and exhale and thus maintain a substantially constant tidal volume constant. The indicator may be provided as one or all of a visual, audio and/or mechanical aid. The indicator(s) can be used either in conjunction with each other or individually. For example, an audio aid can be provided such that a sound is made when the fluid containment structure is either filled or empty. Or an mechanical aid can be provided such that a vibration occurs when the fluid containment structure is either filled or empty. Other visual, audio or mechanical aids (or combinations of such aids) not specifically described or mentioned herein will be readily apparent to those of ordinary skill in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a schematic diagram of a device used to measure cardiac output (CO) with a noninvasive cardiac output (NICO) monitor and which includes three one way valves and a fluid containment structure; and
[0014] FIG. 2 is an exemplary embodiment of a NICO system having a Y-piece from a ventilator circuit and facemask coupled thereto.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0015] Referring now to FIG. 1 , a device 10 to measure cardiac output (CO) in humans whose tracheas are not intubated includes a fluid containment structure or reservoir 12 . It should be appreciated that reservoir 12 may be provided as any container with high compliance and low resistance. In one exemplary embodiment, a balloon having a capacity of 1 to 3 liters and which could be extended to 10 liters with pressure no higher that 40 cm of water was used. The fluid containment structure 12 may, for example, be provided as a balloon, a bellows, or a syringe. In one embodiment, a balloon comprised of a compliant material may be used. Such balloons are commercially available. In another exemplary embodiment, a balloon capable of holding three litters of gas at ambient pressure and which can be extended up to ten liters with maximal pressure less than forty centimeters of water (cm H 2 O) may be used. In another embodiment, a highly compliant balloon may be used. As used herein, the term “highly compliant balloon” refers to a balloon having compliance of greater than or equal to about 300 ml/cm H 2 O. Such balloons are commercially available.
[0016] In alternate embodiments, a syringe can be used instead of a balloon. It should be appreciated, of course, that the fluid containment structure may be provided as any type of fluid reservoir including but not limited to the above-mentioned high compliance balloon or the syringe.
[0017] The fluid containment structure 12 is in fluid communication with a ventilator 14 through an inspiratory limb 16 of a ventilator circuit. The ventilator circuit can be provided as a double-limb ventilator circuit or as a single limb ventilator circuit with an exhalation valve. The ventilator circuit ( 16 , 18 , 20 ) includes an inspiratory limb 16 , an expiratory limb 18 and also a Y piece 20 which is coupled to a conventional NICO sensor (not shown in FIG. 1 ). The NICO sensor is then applied to a patient's natural airway (not sown in FIG. 1 ) using an oral or nasal or oral-nasal face mask (not shown in FIG. 1 ). In some alternate embodiments, a mouth piece and nose clip (not shown in FIG. 1 ) may be used in place of the oral-nasal face mask. Such oral-nasal facemasks (or mouth piece and nose clip) are well known to those of ordinary skill in the art and are commercially available.
[0018] Mechanical ventilation is delivered with a specific predetermined tidal volume and ventilatory rate. A NICO monitor is attached to the ventilator circuit in its usual manner and CO is measured by the well-known NICO technique.
[0019] It should be appreciated that the ventilation structure and technique described in conjunction with FIG. 1 allows one to obtain constant minute ventilation without tracheal intubation.
[0020] In operation, the patient first breathes normally through the mask and NICO monitor without attachment to the ventilator (i.e. the ventilator and the ventilator circuit are not initially attached to the NICO monitor). This mode of operation continues until the patient's ventilatory pattern is stable (less than about a 10% variation in tidal volume and minute volume). When the patient breathes comfortably and the minute ventilation is fairly constant (less than about a 10% variation), their tidal volume, respiratory rate and minute ventilation are measured. The average tidal volume is then calculated using the minute ventilation volume divided by the measured respiratory rate (breaths/minute). The average respiratory rate is calculated by averaging the patient's ventilation rate during the initial breathing period (breaths/minute).
[0021] The ventilator and the ventilator circuit are then attached to the NICO monitor and assisted volume targeted mechanical ventilation is provided. It should be emphasized that the ventilator is set at or slightly above the patient's average tidal volume and respiratory rate during this process (less than or equal to about 15% greater) to insure the patient's end-tidal CO 2 is decreased in the range of about 2% to about 12% with a decrease in the range of about 5% to about 10% being preferred. By appropriately setting the ventilator, the patient's minute volume is held substantially constant and their carbon dioxide (CO 2 ) elimination is constant. The constant CO 2 elimination is accomplished by constant minute ventilation, which is accomplished by appropriate ventilator settings and coaching by a health care provider. The fluid containment structure (e.g. a balloon of highly compliant material) coupled to the inspiratory limb of the ventilator circuit prevents ventilator pressure from being applied directly to the patient's airway and thus, the patient airway is not exposed to the positive pressure generated by the ventilator. That is, the ventilator ventilates the fluid containment structure (e.g. the balloon, bellows, or syringe) and the patient passively inspires the fixed volume from the fluid containment structure. Accordingly, any structure which provides this function (i.e. allows a patient to passively inspire a fixed volume) can serve as the fluid containment structure.
[0022] There is a one-way valve 22 (first valve) in fluid communication with and positioned between the ventilator 14 and the fluid containment structure 12 (e.g. up-stream from the fluid containment structure and between the fluid containment structure and the ventilator), which allows the patient to inhale the gas from the fluid containment structure only (i.e. not from the ventilator).
[0023] A second one-way valve 24 in fluid communication with and positioned in the inspiratory limb between the fluid containment structure and the Y-piece 20 (e.g. down stream from the fluid containment structure and between the fluid containment structure and the Y-piece) allows the ventilator 14 to deliver a targeted volume of gas to the fluid containment structure only, but not to the patient. These two valves (i.e. valves 22 , 24 ) open in alternated order, but not at the same time. This prevents the patients' cardiac output from being altered by the application of positive pressure. Therefore, the tidal volume per breath, the respiratory rate (frequency of breathing) and the minute CO 2 removal are kept constant just as if the person's trachea was intubated and their lungs mechanically ventilated. CO measurement with the NICO is also conducted just as in the patient who is mechanically ventilated.
[0024] As stated above, valve 22 is placed between the ventilator and the fluid containment structure. This valve is a passive valve, with opening pressure in the range of about 15 to about 30 cm H 2 O. The purpose of this valve is to prevent the patient from inhaling additional gas volume directly from the ventilator. It works as follows: when the ventilator delivers gas, the airway pressure increases; when pressure generated by the ventilator reaches the opening pressure in the range of greater than about 15 to about 30 cm H 2 O, the valve opens, and gas will go to the fluid containment structure but not to the patient due to the second one way valve 24 . The fluid containment structure has less resistance to air flow than the patient's lungs which is insured by the one way valve 24 . Thus, air will be delivered only to the fluid containment structure but not to the patient.
[0025] When the ventilator stops delivering gas, the ventilator pressure drops below the opening pressure of the one-way valve 22 , then valve 22 will be closed. Then the patient is instructed to inspire gas passively from the fluid containment structure (e.g. the balloon). Since the opening pressure of the valve is much higher then the inspiratory pressures generated by quiet breathing, the valve prevents the patient from inhaling any additional gas except that in the fluid containment structure. This prevents the patients' cardiac output from being altered by the application of positive pressure. Therefore, the CO measurement with the NICO is conducted just as if the person's trachea was intubated and their lungs mechanically ventilated.
[0026] The second valve 24 is placed between the balloon and the Y piece, it is a passive valve with opening pressure of about 0.5 to about 2.0 cm H 2 O with about 1.0 cm H 2 O being preferred. When the patient inhales, the negative pressure generated in the airway will open the second valve 24 . This valve prevents backflow of gas into the inspiratory limb (e.g. into the limb having the balloon coupled thereto) of the circuit when the patient exhales. The second valve 24 also prevents the gas delivered by the ventilator from going to the patient directly, since the pressure required to open the valve is higher than the pressure in the fluid containment structure.
[0027] A third valve 26 is placed in fluid communication with the expiratory limb 18 . This valve prevents the patient from inhaling gas from the expiratory limb of the ventilator circuit. This valve should have an opening pressure in the range of about 0.5 to about 2.0 cm H 2 O with about 1.0 cm H 2 O being preferred.
[0028] This technique has been tested on 20 healthy volunteers. The preliminary study has demonstrated the feasibility of using this technique and the ability to maintain a constant respiratory rate and inspired gas volume. The cardiac output determined by this technique in these volunteers was highly reproducible. It has also been found that this technique is very comfortable for the volunteers and easy to coach.
[0029] In particular, the balloon (or some other fluid containment structure) acts as a metronome which aids patients in becoming consistent in their breathing patterns. This is accomplished as follows: the patient looks at the balloon (or other fluid containment structure) and when the patient sees the fluid containment structure filled with a volume of fluid, the patient inhales. When the patient sees the fluid containment structure empty of fluid, the patient exhales. Thus, the balloon (or other fluid containment structure) provides visual feedback to the patient to help the patient control their ventilation pattern. This affects both the breathing rate and breathing volume of the patient). The system and techniques described herein thus provide a visual aid which a patient can utilize to see how fast they are breathing.
[0030] Referring now to FIG. 2 , the portion of the system for measuring cardiac output (CO) in humans whose tracheas are not intubated includes a facemask 30 , or an oral piece or a nasal mask coupled to a CO 2 sensor 32 which in turn is coupled to a flow sensor 34 . The flow sensor 34 is coupled to a disposable automatic rebreathing valve 36 . The two tubes 34 a, 34 b emanating from the flow sensor 34 and the tube 36 a emanating from the rebreathing valve are coupled to the NICO monitor (not shown in FIG. 2 ). In one embodiment, the CO 2 sensor maybe provided as the type manufactured by Respironics and marketed under the tradename CAPNOSTAT®.
[0031] A NICO loop 40 has a first end coupled to a first port 37 a of the disposable automatic rebreathing valve 36 . A second end of the NICO loop is adapted to be coupled to a second port 37 b of the disposable automatic rebreathing valve 36 through a loop drainage coupler 42 . A Y-piece 20 has a first port adapted to be coupled to a third port 37 c of the disposable automatic rebreathing valve 36 , a second port (i.e. a first one of the limbs of the Y) adapted to be coupled to the inspiratory limb 16 of a ventilator circuit and a third port (i.e. a second one of the limbs of the Y) adapted to be coupled to the expiratory limb 18 of a ventilator circuit. The CO 2 sensor, flow sensor, disposable automatic rebreathing valve and the NICO loop form a portion of a NICO monitor. Thus, the NICO circuit is coupled to the ventilator circuit through the Y piece, which is also a part of the ventilator circuit while the flow sensor is a part of the NICO rebreathing circuit.
[0032] The purpose of the flow sensor 34 is to monitor respiratory parameters such as tidal volume and respiratory rate. This information will allow an operator of the system (e.g. a health care practitioner) to set up the same or slightly higher tidal volume and respiratory rate for the ventilator to deliver to the fluid containment structure patient. This part of the NICO system also measures pressure and exhaled CO 2 .
[0033] 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. Accordingly, it is submitted that the inventions described herein should not be limited to the described embodiments but rather should be limited only by the spirit and scope of the appended claims. | A method and apparatus ( 10 ) for determining cardiac output by directing airflow or gas flow (fluid) to a fluid containment structure ( 12 ) coupled to an inspiratory limb ( 16 ) of a ventilator circuit instead of the patient and enabling the patient to directly inhale fluid from the fluid containment structure and preventing the patient from inhaling through an expiratory limb ( 18 ) of the ventilator-circuit. The method and apparatus also prevents exhalation by the patient into the fluid containment structure. The method and apparatus also comprises an aid helps the patient become consistent in their breathing patterns. When the fluid containment structure fills with a volume of fluid, the aid provides an indication that the patient should inhale; when the fluid containment structure empties of fluid, the aid provides a signal that the patient should exhale. Thus, the aid provides feedback to the patient to help the patient control their ventilation pattern. | 0 |
TECHNICAL FIELD
The present invention relates to the synthesis of mixed-metal catalysts, more particularly, high activity, long life, alcohol reforming catalysts, especially methanol, based upon nanosize Pt/Ru particles supported on an electroactive support, especially carbon.
BACKGROUND ART
Battery packs are currently the worldwide portable/emergency power source of choice for electrical devices. Researchers have long sought to develop small footprint fuel cells to replace rechargeable battery packs. Fuel cells offer efficient and direct conversion of the chemical energy stored in fuels to electricity in a very environmentally friendly (low polluting) fashion. In principle, fuel cells offer the potential to achieve higher power densities per unit volume, longer use times, and longer total equipment lifetimes than standard battery packs. Long term, this translates to lower cost, higher utility, and increased mobility.
For example, depending on device performance specifics, a battery pack for a laptop computer can provide ≈40-50 W-h of energy. If the laptop requires an average of 20 watts of power to run, then the battery pack can provide only 2-3 h of running time before requiring recharging. Although larger batteries can be used, one pays a price in weight and convenience (size). Furthermore, recharging requires access to a power grid. In contrast, a similar sized fuel cell based on methanol is anticipated to produce 50 W of power and last for 10-20 h before total methanol consumption. In this instance, replacing a used canister of methanol with another does not require access to a power grid (not rechargeable), provides instant continuity and saves weight if it replaces a second, backup battery. Finally, if lost or destroyed, a methanol canister will be easier to replace and much lower in cost than a high-tech, high-density battery pack.
The most efficient fuel cells use H 2 as the reductant, and oxygen or air as the oxidant. The more advanced H 2 based fuel cells can produce 0.8-1.0 A/cm 2 at ≈0.7 V (0.5 W/cm 2 ) with performance lifetimes measured in hundreds of hours. Unfortunately, the cost and weight required to store large quantities of gaseous H 2 , even as metal hydrides, are major drawbacks. Hence, fuel cells that use liquid hydrocarbon fuels, especially methanol (MeOH), are the focus of commercialization efforts.
Two of the more promising direct methanol fuel cell systems are the polyphosphoric acid fuel cell and the proton exchange membrane fuel cell (PEMFC). PEM based fuel cells are more convenient to work than polyphosphoric acids because they employ a solid acid electrolyte, e.g. Nafion® membrane.
The drawback to using MeOH as a fuel is that energy output can be much lower than hydrogen, typically in the 300-500 mA range at 0.5 to 0.3 V. For short runs, 0.8 A/cm 2 at ≈0.5 V (0.25 W/cm 2 ) have been achieved. In part, the lower performance is due to CO and/or methanol poisoning of the cathode due to crossover through the membrane (CO and MeOH compete with O 2 for active catalyst sites). In part, this difference is due to the need to catalytically reform MeOH at the anode coincident with reacting the product hydrogen with oxygen, some efficiency is lost in the process. The methanol reforming reaction (1) is shown below:
CH 3 OH+H 2 O→CO 2 +3H 2 (1)
For example, platinum metal by itself is an excellent catalyst for hydrogen fuel cells based on:
However, CO (a typical impurity in many H 2 sources) competes with H 2 for active catalytic sites on Pt metal particles and readily poisons the catalyst. Thus, CO coverage of active catalyst sites limits the rate at which reaction (2) proceeds.
MeOH reforming, as shown in reaction (1), can actually proceed via two stepwise processes that can involve the formation of CO and/or CO 2 :
The CO produced via reaction (4), is very effective in poisoning simple Pt catalysts. The actual problem lies in the fact that Pt metal alone is not an effective catalyst for the water-gas shift reaction, reaction (7), making CO difficult to remove from the surface.
For the direct methanol fuel cell to be successful, an effective catalyst that promotes reaction (7) as part of the overall methanol reforming reaction is needed. Ruthenium is one of several metals that aid in promoting reaction (7).
Thus, improving the efficiency and activity of the MeOH reforming catalyst is desirable. A higher efficiency catalyst means less of the precious metal catalyst is required, and higher activity will minimize CO crossover poisoning of the cathode. It will be appreciated that there is a need in the art for highly active and efficient methanol reforming catalysts.
DISCLOSURE OF THE INVENTION
The present invention is directed to high activity, supported, nanosized mixed-metal catalysts, especially Ru/Pt catalysts for methanol reformation, and to methods of fabricating such catalysts. These methanol reformation catalysts are useful in methanol fuel cells, particularly portable, small footprint fuel cells such as polymer electrolyte membrane fuel cells (PEMFCs) that use methanol as a primary fuel source.
In a currently preferred embodiment within the scope of the present invention, the soluble metals are dissolved in a polyhydroxylic alcohol (polyol). The ratio of M 1 :M 2 :M 3 :M 4 will typically vary from (0.001 to 1):(0.001 to 1):(0.001 to 1):(0.001 to 1). Presently preferred catalysts typically contain Ru and Pt, with or without additional metals. The ratio of Ru:Pt will typically vary from 0.001:1 to 1:0.001, and preferably from 0.1:1 to 1:0.1, and more preferably from 0.5:1 to 1:0.5. The polyols are preferably viscous alcohols to minimize diffusion and thereby prevent particle growth. Typical polyols used in accordance with the present invention include organic diols, triols, and tetraols. Ethylene glycol, glycerol, triethanolamine, and trihydroxymethylaminomethane are examples of currently preferred polyols. In the polyol process one has two choices, (1) make the colloid in the absence of support and then deposit it on the support or (2) make it in the presence of the support such that the support aids in minimizing particle growth. A typical example of each option is described below, realizing that variations of these examples can be made by persons having ordinary skill in the art.
Typical Colloid Preparation Procedure
An amount of metallic precursor (or precursors) is added to 100 mL of refluxing ethylene glycol. The reaction mixture is refluxed for 15 min. A first aliquot is taken out and quenched in water at ice-water bath temperatures. The quenched solution is centrifuged several times by decanting supernatant and washing with ethanol. A second aliquot is taken after 1 h and same workup process is applied. Samples are then vacuum dried overnight. These materials can then be redispersed in alcohol and deposited on a known amount of pretreated support material, such as carbon black.
Typical Supported Powder Preparation Procedure
An amount of metallic complex (M 1 such as Ru complex) and an equivalent amount (by weight or mole) of a second metallic complex (M 2 , such as Pt complex) are dissolved in 10 mL of ethylene glycol, respectively. The two solutions are mixed and then added to a dispersion consisting of a weighed amount of support material, such as activated carbon, in 80 mL of ethylene glycol. The resulting mixture is refluxed and samples are taken after 15 minutes and 1 hour. Samples are quenched as above. The quenched solutions are centrifuged several times by decanting supernatant and washed with ethanol. Finally samples are vacuum dried overnight. The resulting catalyst is ready to use as is. Sometimes, it is flammable if kept from air during the preparation procedure.
The resulting catalysts include nanometallic powders on a support, bimetallic powders on a support, polymetallic nanopowders on a support, high surface area powders on a high surface area support, and low porosity metal nanopowders on a support.
The polyol solution is heated to a temperature in the range from 20° C. to 300° C. to reduce the metallic precursors to a zero valent state. If mixed with a support material, the mixed metallic catalyst particles form on the support material. The mixture is preferably heated to a temperature in the range from 60° C. to 220° C., and more preferably the mixture is heated to a temperature in the range from 70° C. to 190° C. The time required to heat the mixed-metal catalyst can vary, but the typical heating period generally ranges from 1 minute to 24 hours. Preferably, the heating period ranges from 1 minute to 5 hours, and more preferably, the heating period ranges from 1 minute to 1 hour.
The concentration of metallic precursors, such as Ru and Pt, affects the resulting mixed-metal catalyst particle size. Higher concentrations result in more particle growth and larger average particle size. The resulting mixed-metal catalyst particles typically have a particle size less than 1 μm, preferably less than 0.1 μm, and more preferably less than 0.05 μm. Systems where the catalyst loading approaches that of the mass of the support are more prone to produce micron size metal particles on the support than nanometer size particles in support pores. Preferable loadings are less than 50 wt. % of catalyst to support weight. In addition, the amount of polyol used per gram of support/catalyst also affects the size of the metal particles simply on a dilution effect basis. Larger polyol volumes give smaller catalyst particles, even on the support.
For Pt/Ru catalysts, typical soluble metal species include, but are not limited to, PtCl 2 , H 2 PtCl 6 , Pt 2 (dba) 3 (dba=dibenzylideneacetone), Pt(dvs) (dvs=divinyltetramethyl-disiloxane), Pt(Oac) 2 (Oac=acetate), Pt(acac) 2 (acac=acetylacetonate), Na 2 PtCl 6 , K 2 PtCl 6 , platinum carbonate, platinum nitrate, platinum perchlorate, platinum amine complexes, RuCl 3 .xH 2 O, Ru(acac) 3 , Ru 3 (CO) 12 , Ru(Oac) 3 , ruthenium nitrate, ruthenium perchlorate, ruthenium amine complexes, and mixtures thereof. Soluble platinum and ruthenium compounds are commercially available from a variety of vendors such as Strem Chemicals (Danbury, Mass.), Alfa Asear (Ward Hill, Mass.), and Aldrich (Milwaukee, Wis.). Other soluble metal species can be included in such as CuCl x , Cu(Oac) x , CoCl x , Co(Oac) x , and soluble Group 6, 7 and 8 metals. These metals can be used to aid in the water-gas shift reaction, reaction (7), or in forming stable metal hydrides for eliminating hydrogen, or to electronically modify the properties of the other metals in the mixed-metal catalysts.
Low metal loading on the support material is preferred. The soluble metallic precursors preferably have concentrations in the polyol sufficient to yield a metal loading on the support less than 100 wt. % metal to 100 wt. % support. More preferably, the metal loading on the support is less than 50 wt. % metal to 100 wt. % support, and most preferably less than 20 wt. % metal to 100 wt. % support. The catalyst loading is preferably in the range from 0.1 to 0.5 mg/cm 2 of the support.
The support material preferably has a high surface area in the range from 10 to 2000 m 2 /g. More preferably, the support material has a surface area in the range from 200 to 1500 m 2 /g, and most preferably from 300 to 1500 m 2 /g. The high surface area is a result of an open porous structure. The support material preferably has pores sufficiently small to capture nanoparticles, but not too small to interfere with gas/liquid flow. Typical pore sizes will be in the range from 1 nm to 100 nm. Preferably, the pore size is in the range from 1 nm to 30 nm, and more preferably from 1 to 10 nm. Carbon is a currently preferred support material because of its high surface area and porosity, as well as its electrical conductivity properties. Other support materials can be used, including conductive metals and metal oxides such as indium tin oxide, silver, gold, Pt/Ag alloys, copper, and indium zinc oxides.
It will be appreciated that the present invention provides methods of preparing supported, mixed-metal MeOH reforming catalysts that are highly active and efficient.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a field emission scanning electron micrograph (FE-SEM) of a single carbon particle for a PtCl 2 /RuCl 3 40 wt. % loading on 1500 m 2 /g pretreated carbon.
FIG. 2 is a FE-SEM of a single carbon particle for a PtCl 2 /RuCl 3 40 wt. % loading on 1500 m 2 /g pretreated carbon at maximum SEM magnification.
FIG. 3 is a FE-SEM of PtCl 2 RuCl 3 60 wt. % loading on 1500 m 2 /g pretreated carbon.
FIG. 4 is a FE-SEM of PtCl 2 /RuCl 3 60 wt. % loading on 1500 m 2 /g pretreated carbon at maximum SEM magnification.
FIG. 5 is a graph of a typical gas chromatogram of methanol reforming reaction products from an active catalyst and support.
FIG. 6 is a graph of CO 2 production vs. time for four catalysts based upon an equal mass of catalyst and support.
FIG. 7 is a graph of H 2 production vs. time for four catalysts based upon an equal mass of catalyst and support.
FIG. 8 is a graph of CO 2 production vs. time for four catalysts based upon equimolar amounts of metal.
FIG. 9 is a graph of CO 2 production vs. time comparing a commercially available catalyst with a catalyst within the scope of the present invention based upon an equal mass of catalyst and support.
FIG. 10 is a graph of H 2 production vs. time comparing a commercially available catalyst with a catalyst within the scope of the present invention based upon an equal mass of catalyst and support.
FIG. 11 is a graph of CO 2 production vs. time for several catalysts based upon an equal mass of catalyst and support.
FIG. 12 is a graph of CO 2 production vs. time for the catalysts of FIG. 11 showing an expanded time scale.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is directed to high activity, supported, nanosized mixed-metal catalysts, and more particularly to methanol reformation catalysts and to methods of fabricating such catalysts. In a currently preferred embodiment within the scope of the present invention, the catalysts are prepared using a polyhydroxylic alcohol (polyol) to reduce the metal species. In this polyol approach, soluble metals are dissolved in a polyhydroxylic alcohol. The polyols used are preferably viscous alcohols to minimize diffusion and inhibit particle growth. The alcohol viscosity will typically range from 1 to 1000 cp, more preferably from 50 to 500 cp, and most preferably from 100 to 250 cp. The metal/polyol solution is heated to coincidentally reduce the metals and produce polyol stabilized metal colloid particles. The metal colloid can be prepared in the absence of a support material and then deposited on the support to form the catalyst, or the metal colloid can be prepared in the presence of the support, in situ.
It has been observed that the presence of a support material helps to prevent aggregation and particle growth of the product colloids. It also helps achieve well-dispersed nano-sized metal particles. Thus, it is presently preferred to prepare the supported catalysts in situ.
EXAMPLES
The following examples are given to illustrate various embodiments within the scope of the present invention. These are given by way of example only, and it is to be understood that the following examples are not comprehensive or exhaustive of the many embodiments within the scope of the present invention.
Examples 1 and 2, below illustrate the preparation of carbon supported bimetallic catalysts.
Example 1
Formation of Metallic Colloids by Polyol Process
An amount of metallic precursor (or precursors) was added to 100 mL of refluxing ethylene glycol. The reaction mixture was refluxed for 15 min. A first aliquot was taken out and quenched in water at ice-water bath temperatures. The quenched solution was centrifuged several times by decanting supernatant and washing with ethanol. A second aliquot was taken after 1 h and same workup process was applied. Samples were then vacuum dried overnight. As a modified process, treated activate carbon was added to a solution of the precursor or precursor after refluxing 15 min. Then the resulting suspension was refluxed for 5 min. and then the sample was taken.
High surface area activated carbon (Aldrich) was used. The carbon black was pretreated to remove oxidation products, moisture, and organic volatiles on its outer surface. This was accomplished by heating the carbon black in an air-free environment. One-gram samples of carbon were heated in a Micromeritics ASAP 2000. This removed typical impurities by first drying under vacuum at 200° C. for several hours and then degassing them at 400° C. overnight (12 h). The resulting materials showed surface areas of 1500 m 2 /g per the specification sheets.
A summary of the types of variables studied in the simple formation of colloids is given in Table 1.
TABLE 1
Reaction variables for the preparation of bimetallic colloids
subsequently impregnated on activated carbon support
description of sample
Sample no.
wt. RuCl 3
wt. PtCl 2
wt. AC*
rxn. Time
1
0.06 g
15 min.
2
0.02 g
0.02 g
11 min.
3
0.02 g
0.02 g
20 min.
4
0.02 g
0.02 g
3 hours
5
0.02 g
0.2 g
1 hour
6*
0.01 g
0.01 g
0.05 g
15 min.
7
0.01 g
0.01 g
0.05 g
15 min.
8
0.02 g
0.02 g
0.2 g
1 hour
*Activated carbon was added 15 min. after the solution was refluxed.
Mechanism of Particle Formation
The reduction of the metal precursors (or mixtures of precursors) by the polyol process produces nano-sized metal (or bimetallic or polymetallic) particles. The size of particles formed without carbon were in the range of 50-100 nm and in the presence of carbon cannot really be seen by scanning electron microscopy.
The nanosized particles obtained in this Example were bigger than those obtained by Miyazaki et al., “Formation of Ruthenium Colloid in Ethylene Glycol,” Chemistry Letters , pp. 361-62, 1998. This difference in size is probably due to different concentrations of starting materials and the reaction scale. When more concentrated solutions are used, the size of particles increases because the number of nucleation sites is likely concentration dependent and growth then competes effectively with further nucleation. Also, the use of smaller scale (less solvent) increases the efficiency of heat transfer, which also accelerates the growth of particles.
As noted above, the use of activated carbon helps to prevent aggregation of colloids. Thus, the addition of activated carbon as a dispersing matrix appears to be important in obtaining well-dispersed, nano-sized bimetallic particles.
Example 2
In Situ Impregnation of Bimetallic Nanoparticles Formed by Polyol Process
An amount of Ru complex and an equivalent amount (by weight or mole) of Pt complex were dissolved in 10 mL of ethylene glycol, respectively. The two solutions were mixed and then added to a dispersion consisting of a weighed amount of activated carbon in 80 mL of ethylene glycol. The resulting mixture was refluxed and two samples taken after 15 min. and 1 h. Samples were quenched as above. The quenched solutions were centrifuged several times by decanting supernatant and washed with ethanol. Finally samples were vacuum dried overnight.
Variations of this example are disclosed in Table 2, below.
TABLE 2
Pt/Ru bimetallic catalysts impregnated coincidentally on activated carbon
Sample
Rxn. time
No.
Description
PtCl 2
H 2 PtCl 6
RuCl 3
C*
EG
15 min
1 hr
1
20 wt % loading
0.021 g
0.02 g
0.1 g
50 ml
(Pt + Ru)
(10 ml)
(10 ml)
(30 ml)
2
20 wt % loading
0.014 g
0.02 g
0.1 g
50 ml
(Pt + Ru)
(10 ml)
(10 ml)
(30 ml)
3
40 wt % loading
0.042 g
0.04 g
0.1 g
50 ml
(Pt + Ru)
(10 ml)
(10 ml)
(30 ml)
4
40 wt % loading
0.027 g
0.04 g
0.1 g
50 ml
(Pt + Ru)
(10 ml)
(10 ml)
(30 ml)
5
PtCl 2 /EG
0.054 g
Black ppt. with gentle heating
(20 ml)
6
40 wt % loading
0.042 g
0.04 g
0.1 g
150 ml
(Pt + Ru)
(10 ml)
(10 ml)
(130 ml)
7
40 wt % loading
0.027 g
0.04 g
0.1 g
150 ml
(Pt + Ru)
(20 ml)
(10 ml)
(120 ml)
8
40 wt % loading
0.08 g
g
50 ml
Ru
(20 ml)
(30 ml)
9
40 wt % loading
0.054 g
0.1 g
50 ml
Pt
(30 ml)
(20 ml)
10
60 wt % loading
0.084 g
0.04 g
0.1 g
50 ml
(2 Pt + Ru)
(20 ml)
(20 ml)
add
11
60 wt % loading
0.054 g
0.04 g
0.1 g
50 ml
(2 Pt + Ru)
(20 ml)
(20 ml)
add
12
60 wt % loading
0.042 g
0.08 g
0.1 g
50 ml
(Pt + 2 Ru)
(20 ml)
(20 ml)
add
13
60 wt % loading
0.027 g
0.08 g
0.1 g
50 ml
(Pt + 2 Ru)
(20 ml)
(20 ml)
add
14
100 wt % loading
0.105 g
0.1 g
0.1 g
50 ml
(Pt + Ru)
(20 ml)
(20 ml)
add
15
100 wt % loading
0.068 g
0.1 g
0.1 g
50 ml
(Pt + Ru)
(20 ml)
(20 ml)
add
16
100 wt % loading
0.21 g
0.1 g
0.2 g
100 ml
(Pt + Ru)
(20 ml)
(20 ml)
add
17
100 wt % loading
0.136 g
0.2 g
0.1 g
100 ml
(Pt + Ru)
(20 ml)
(20 ml)
add
18
20 wt % loading
0.042 g
0.04 g
0.2 g
100 ml
(Pt + Ru)
(20 ml)
(20 ml)
add
19
20 wt % loading
0.027 g
0.04 g
0.2 g
100 ml
(Pt + Ru)
(20 ml)
(20 ml)
add
20
20 wt % loading
0.042 g
0.04 g
0.2 g
150 ml
(Pt + Ru)
(20 ml)
(20 ml)
add
21
20 wt % loading
0.027 g
0.04 g
0.2 g
150 ml
(Pt + Ru)
(20 ml)
(20 ml)
add
22
10 wt % loading
0.042 g
0.04 g
0.4 g
100 ml
(Pt + Ru)
(20 ml)
(20 ml)
add
23
10 wt % loading
0.027 g
0.04 g
0.4 g
100 ml
(Pt + Ru)
(20 ml)
(20 ml)
add
24
10 wt % loading
0.042 g
0.04 g
0.4 g
150 ml
(Pt + Ru)
(20 ml)
(20 ml)
add
25
10 wt % loading
0.027 g
0.04 g
0.4 g
150 ml
(Pt + Ru)
(20 ml)
(20 ml)
add
26
40 wt % loading
0.054 g
0.04 g
0.2 g
100 ml
(Pt + Ru)
(20 ml)
(20 ml)
add
27
40 wt % loading
0.084 g
0.04 g
0.2 g
100 ml
(Pt + Ru)
(20 ml)
(20 ml)
add
Several samples were characterized by field emission SEM (FE-SEM). X-ray diffraction (XRD) and surface area analysis were also performed.
As noted above, the surface area of treated Aldrich activated carbon was 1500 m 2 /g. Following a typical catalyst preparation procedure, see above, the surface area dropped to about 1000 m 2 /g. The reduced surface area of the impregnated carbon likely indicates that the catalyst particles fill the necks and pores of the carbon. This is also an indirect indication that the particle sizes are small enough to fit in these pores (typically<100 nm) and therefore are very well dispersed. If large particles had formed very little change in surface area would be expected. XRD analysis of an impregnated carbon exhibited broad peaks indicative of nanosized Ru/Pt alloy particles.
The general results suggest that if the polyol process was carried out with too high a metal concentration and without support material (approximately 0.01 to 0.1 M), then larger (1-10 μm diameter particles) were seen, and the resulting materials precipitated out of solution easily. If lower concentrations (0.001 M) were used, the solutions typically remained brown as the colloidal particles remained suspended. SEMs of the precipitated materials provided clean images of particles but SEM images of the nanosized particles were poor as expected, since the resolution of FE SEMs is poor below ≈0.5 μm. Likewise, in the presence of the pretreated carbon black, essentially no metal particles were visible.
A preliminary EDS element mapping study shows that the Ru and Pt were uniformly distributed throughout the carbon materials supporting the formation of evenly distributed bimetallic nanoparticles.
The FIG. 1 FE-SEM micrograph shows a single carbon particle for a PtCl 2 /RuCl 3 40 wt % loading on 1500 m 2 /g pretreated carbon. The scale bar is 5 μm. Metal particles, because of their much higher electron density, should be readily visible in this micrograph if they were at the 0.5 μm size. Given that there is no indication of such particles, one can conclude that the catalyst particles are likely to be much smaller. This was confirmed in the FIG. 2 micrograph, which is at the highest SEM magnification possible. The white particles on the image are metal particles.
Arrow A appears to point to a particle<25 nm in diameter. The particles identified by Arrows B are 50 to 100 nm in size. Furthermore, no pores are visible, indicating that the porosity is extremely fine. The material shown in FIG. 2 is a catalyst that has a 40 wt. % loading. Because much of the metal cannot be seen as distinct particles, it is likely well dispersed and probably in the pores of the carbon. This may be a problem as noted above because fine porosity may create mass transport limitations, which in turn may limit the catalyst activity, not the degree of metal dispersion.
FIG. 3 is a micrograph for a PtCl 2 /RuCl 3 60 wt % loading on 1500 m 2 /g pretreated carbon. It suggests that there may be some agglomeration of metal particles. At the 5 μm scale there are clearly some very large particles of metal on the surface. Some of them appear to have a size of about 5 μm, but these may be agglomerates. In addition, the amount of metal loaded onto the support is of nearly the same mass as the carbon black. Although there is a significant difference in the density of the carbon (<1.8 g/cc) compared to the metals (>5 g/cc), if the metal were not well dispersed it would be quite obvious. Also, based on the higher magnification micrograph of the same material, shown in FIG. 4, it is likely that the above large metal particles are rare. In summary, it appears that the polyol process works well and provides reasonable, if not excellent, dispersions.
Qualitative Testing Using a Parr Pressure Reactor
To assess qualitatively the catalytic activity of prepared samples, 5 ml of MeOH and 5 ml of H 2 O were added to a 45 ml vol. Parr reactor with a small amount of catalyst (25 mg for samples 1, 14, and 15, and 50 mg for samples 17 and 19, see Table 2) in air. Then the reactor was then sealed, degassed 3× with nitrogen and heated to 100°, 150°, and 180° C. using an oil bath. A blank run without catalyst was also run. The pressure build-up was 150 psi at 150° C. and 200 psi at 180° C.
For selected runs with a catalyst with 100% loading [1:1 metal (Ru:Pt of 1:1): carbon], pressures of 150 psi at 150° C. and 300 psi at 180° C. over a period of 12 h. However, similar studies with a 20% loading gave the same results suggesting that equilibrium was reached early on. The pressure increase was assumed to result from production of CO 2 and H 2 .
Example 3
In Situ Impregnation of Trimetallic Nanopowder Catalyst on Support Formed by the Polyol Process
In this synthesis, 1.000 g activated carbon, but not pretreated, was suspended in 800 mL EG. The solution was refluxed under N 2 flow for a period ≦2 h to degas it.
A 1:1:1 molar concentration of Pt:Ru:Cu solution was made using 0.265 g of PtCl 2 dissolved in 67 mL EG (stirred overnight to ensure complete dissolution), 0.207 g RuCl 3 dissolved in 67 mL EG (also stirred overnight), and 0.201 g Cu(Oac) 2 .2H 2 O dissolved in 66 mL EG and stirred overnight. To each of the three solutions was added 2 mL H 2 O to facilitate dissolution.
The three solutions were combined and stirred together for a 2-3 h period. Simultaneously, the activated carbon/EG solution was refluxed for 25 min, cooled, and the 200 mL Pt/Ru/Cu solution was syringed into this carbon/EG solution. This new solution was refluxed for 15 minutes and then cooled in a water bath overnight. The catalyst settled to the bottom of the flask and was recovered by centrifugation. The catalyst was then dried overnight in a heating oven at 120° C.
Example 4
In Situ Impregnation of Trimetallic Nanopowder Catalyst on Support Formed by the Polyol Process
In this synthesis, 1.000 g activated carbon, but not pretreated, was suspended in 800 mL EG. The solution was refluxed under N 2 flow for ≦2 h to degas it.
A 1:1:1 molar concentration of Pt:Ru:Co solution was made using 0.265 g of PtCl 2 dissolved in 67 mL EG (stirred overnight to ensure complete dissolution), 0.207 g RuCl 3 dissolved in 67 mL EG (also stirred overnight), and 0.130 g Co(Cl) 2 .2H 2 O was dissolved in 70 mL EG and stirred overnight. To each of the three solutions was added 2 mL H 2 O to facilitate dissolution.
The three solutions were combined and stirred together for 2-3 h. Simultaneously, the activated carbon/EG solution was refluxed for 25 min, cooled, and the 200 mL Pt/Ru/Co solution was syringed into this carbon/EG solution. This new solution was refluxed for 15 minutes and then cooled in a water bath overnight. The catalyst settled to the bottom of the flask and was recovered by centrifugation. The catalyst was then dried overnight in a heating oven at 120° C.
Example 5
Quantitative Testing of Catalyst Activity
A computer controlled, gas/liquid phase catalyst test system was used to quantitatively measure catalyst activity in the methanol reforming reaction. MeOH/H 2 O mixtures were metered via a HPLC pump directly (as gases or liquids) onto preheated catalyst samples (10-50 mg). The reacted gases and/or liquids were transported via a heated transfer line to a computer controlled gas chromatograph, and the amounts of products and reactants were measured from known standards, and the rates of reactions and catalyst activities were computed. The activity of commercially available methanol reforming catalysts from EBTech and ElectroChem was also examined.
A standardized test system was established for both dynamic and static test conditions. These conditions are as follows:
Catalytic reactor test conditions
Molarity of solution:
2M MeOH, 3M H 2 O
Solution feed rate:
0.02 mL/min
Sample loop length:
26 cm (dia. 0.22 cm): volume 100 ≈ μl
Reaction temperature:
140° C.
Catalyst loading size:
500 mg for ElectroChem [40 wt. % metal (30 wt.
% Pt, 10 wt. % Ru],
50 mg for synthesized catalysts
Static conditions:
After 5 h under dynamic conditions
Gas Chromatography Studies
FIG. 5 shows a typical gas chromatogram from an active catalyst running in dynamic mode. There are several points to be made: First, a blank reaction without catalyst shows only the MeOH and H 2 O peaks and nothing else. No dissolved air is present in the system. Second, the hydrogen elutes first, and because of its lower heat capacity then the helium carrier gas, it appears as a negative peak. Third, the unknowns have not been identified but are likely the compounds shown below:
Order of Importance
Size Order-Likely elution seguence from GC
CO
CO
H 2 C = O
CH 4
CH 2 (OCH 3 ) 2
H 2 C = O
CH 4
CH 2 (OCH 3 ) 2
Unknown one or two is probably CO and the other is probably methane. The CH 2 (OCH 3 ) 2 compound is a potentially very interesting material formed per:
CH 3 OH+catalyst→H 2 +CH 2 O
2CH 3 OH+CH 2 O→2H 2 O+CH 2 (OCH 3 ) 2
The methoxyacetal derivative represents a denser form of methanol and might actually be a better fuel if the fuel can be stored as the acetal and methanol recovered only on addition of water selectively at the anode. This would be helped by an acid catalyst, which would promote the reverse reaction.
Fourth, because the reactions are run, under dynamic conditions where the absolute amounts of MeOH and water do not change significantly, only buildup of the CO 2 peak represents a reliable measure of catalyst activity. For reactions that switch over to static it is possible to follow both MeOH and H 2 O consumption but not with the amounts of catalysts (50 mg) used for the synthesized catalyst studies.
Based on these provisos, catalyst numbers 24 and 25 (Table 2) and commercially available catalysts from ElectroChem and EBTech were tested. The catalysts tested are listed in Table 3.
TABLE 3
Catalyst activity tests for catalysts under standard conditions.
Catalyst
Amount
No.
(mg)
Pt source
wt % Pt
wt % Ru
Total
SSA
catalyst used
loading
loading
loading
m 2 /g
24
50
H 2 PtCl 6
5
5
10
1000
25
50
PtC1 2
5
5
10
1300
Electro-
500
?
20
10
30
200
Chem
EBTech
500
?
?
?
?
NA
The CO 2 data are likely to be the most reliable. FIG. 6 compares the CO 2 production rates for all of the catalysts at equal mass. This means that the data for the catalysts prepared according to the present invention have been multiplied by 10×. Hence, during dynamic flow, the rates of CO 2 production are too small to see. However, once the system goes static, CO 2 production is easily observed and comparable or slightly higher than the commercial catalyst data. This suggests that the synthesized catalysts within the scope of the present invention exhibit high activity.
FIG. 7 shows the hydrogen production data on an equal mass of catalyst basis. The data indicate that on a mass basis, the catalysts within the scope of the present invention are at least comparable in activity to commercially available catalysts.
An important observation of the foregoing results is the fact that the metals contents of the commercial catalysts and present invention catalysts are not the same. The ElectroChem catalyst is 30 wt. % 2:1 Ru:Pt and the EBTech catalyst is believed to be the 30 wt. % 1:1 Ru:Pt. FIG. 8 reconciles the catalyst activities on a moles of metal basis. As shown in FIG. 8, the catalysts prepared according to the present invention are about 5× more active than the commercially available catalysts.
Additional mixed metal catalysts were prepared, substantially in accordance with the procedure of Example 2. These catalysts are summarized below in Table 4:
TABLE 4
Pt/Ru, Pt/Ru/Cu, and Pt/Ru/Co mixed metal catalysts impregnated
coincidentally on activated carbon.
Cat-
Cu
Rxn.
alyst
PtCl 2
RuCl 3
(C 2 H 3 O 2 ) 2
CoCl 2
C*
Time
201
0.135 g
0.200 g
1.000 g
15 min.
(100 mL)
(100 mL)
(800 mL)
201a
0.135 g
0.200 g
1.000 g
15 min.
(100 mL)
(100 mL)
(800 mL)
202
0.270 g
0.400 g
2.000 g
15 min.
(100 mL)
(100 mL)
(800 mL)
203
0.675 g
1.000 g
5.000 g
15 min.
(100 mL)
(100 mL)
(800 mL)
203a
0.675 g
1.000 g
5.000 g
15 min.
(100 mL)
(100 mL)
(800 mL)
204
0.266 g
0.207 g
0.200 g
1.000 g
15 min.
(65 mL)
(65 mL)
(70 mL)
(800 mL)
205
0.266 g
0.207 g
0.130 g
1.000 g
15 min.
(65 mL)
(65 mL)
(70 mL)
(800 mL)
206
0.135 g
0.200 g
1.000 g
15 min.
(100 mL)
(100 mL)
(800 mL)
207
0.135 g
0.200 g
1.000 g
15 min.
(100 mL)
(100 mL)
(800 mL)
208
0.135 g
0.200 g
1.000 g
15 min.
(100 mL)
(100 mL)
(800 mL)
*Catalyst 201 through 205 used carbon with a surface area of 1500 m 2 /g
Catalyst 206 used Cabot Monarch 1300 carbon with a surface area of 560 m 2 /g
Catalyst 207 used Cabot Vulcan XC72R carbon with a surface area of 254 m 2 /g
Catalyst 208 used Cabot Monarch 1000 carbon with a surface area of 343 m 2 /g
FIG. 9 compares the CO 2 production rates for the commercially available ElectroChem catalyst (30 wt. % 2:1 Ru:Pt) with catalyst #202 defined in Table 4 at equal mass. As described above, during dynamic flow, the rates of CO 2 production are too small to see. However, once the system goes static, CO 2 production is easily observed. Catalyst #202 exhibits high activity. FIG. 10 shows the hydrogen production data on an equal mass of catalyst basis for the two catalysts shown in FIG. 9 . The data indicate that on a mass basis, catalyst #202 exhibits high activity.
FIG. 11 compares the CO 2 production rates for the commercially available ElectroChem catalyst (30 wt. % 2:1 Ru:Pt) with the catalysts defined in Table 4 at equal mass. During static operation CO 2 production is easily observed. The catalysts within the scope of the present invention exhibit high activity. FIG. 12 illustrates the static mode data of FIG. 11 with an expanded time scale.
From the foregoing, it will be appreciated that the present invention provides high activity, supported nano-sized mixed metal catalyst particles useful in methanol reforming reactions.
The present invention may be embodied in other specific forms without departing from its structures, methods, or other essential characteristics as broadly described herein and claimed hereinafter. The described embodiments are to be considered in all respects only as illustrative, and not restrictive. The scope of the invention is, therefore, indicated by the appended claims, rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope. | High activity, supported, nanosized metallic catalysts for methanol reformation and methods of fabricating such catalysts are disclosed. In one embodiment, soluble metal species are dissolved in a polyhydroxylic alcohol (polyol) solution. Platinum and ruthenium are preferred metal species. Other soluble metal species can be used, such as soluble Group 6, 7 and 8 metals. The polyol solvent is preferably a viscous alcohol, such as a diol, triol, or tetraol, to minimize particle diffusion and inhibit particle growth. The polyol solution is heated to reduce the metal(s) to a zero valent state. Typically, the heating temperature will range from 20° C. to 300° C., and the heating period will range from 1 minute to 5 hours. A high surface area conductive support material can be mixed with the polyol solution to form the supported catalysts in situ. Activated carbon, metals, and metal oxides, having a surface area from 20 to 2000 m 2 /g, are typical support materials. | 8 |
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to a device for needling a fibrous.
Description of Related Art
A device of the generic kind is disclosed in DE 10 2005 012 265 A1.
The device disclosed therein is used for strengthening and structuring fibrous layers. For this purpose, a fibrous web is pierced with a plurality of needles guided in an oscillating movement. During this process, the needles are guided with an oscillating vertical movement in order to strengthen the fibrous material contained in the fibrous web. During this process, the fibrous web is continuously moved forward by means of an advancing motion preferably carried out by means of rollers. Since the needles are not smooth but are provided with barbed hooks that are open in the piercing direction, individual fibers of the fibrous web are caught and realigned within the fibrous layers when the needles pierce the latter. This results in the desired fiber-mingling and bonding effects within the fibrous web. In order to prevent any undesirable deformations resulting, for example, in a draft of or slots in the needled fibrous material due to the advance of the fibrous web when the needles pierce the latter, the needles are guided in a horizontal movement that is superimposed on the vertical movement.
In the device disclosed in the aforementioned document, both the vertical and the horizontal movements of the needle beam are initiated by means of a crank mechanism drive. For this purpose, the crank mechanism drive comprises two crank drives having two driven crankshafts. By means of a phase-adjusting device, the crankshafts are formed so as to be adjustable in terms of their phase positions. Depending on the phase position of the crankshafts relative to each other, there thus results an ellipsoidal movement pattern, in which an oscillating movement of the needle beam is carried out.
In order to achieve the most stable possible piercing action of the needles into the fibrous web, a guiding device is additionally provided that engages the needle beam. However, in doing so, it is necessary to carry out the vertical and horizontal movements of the needle beam without any obstruction. In the device disclosed in the aforementioned document, the guiding device is formed by a guide rod that is guided on a guide bushing held on a machine frame. The guide bushing is held on the machine frame so as to be pivotable by means of a pivot bearing so that an inclined position of the beam carrier is possible by means of the pivot bearing of the guiding device depending on the phase position of the crankshafts. Depending on the degree of phase adjustment, there thus result various inclined positions of the beam carrier each of which leads to a horizontal movement with a defined stroke. The guide track of the beam carrier is determined by the fixed position of the pivot bearing of the guiding device. Thus, only relatively small horizontal strokes can be carried out since otherwise an excessive inclination of the beam carrier is achieved.
In principle, devices are also disclosed in the prior art in which the vertical movement of the needle beam is carried out by means of a vertical drive and the horizontal movement is carried out by means of a separate horizontal drive. Such a device is disclosed in DE 197 30 532 A1 by way of example. The separate horizontal drive of the device disclosed therein indeed enables larger amplitudes of motion in the horizontal direction, but suffers from the shortcoming of complicated mechanics resulting in insufficient stability and insufficient guidance of the needle beam, particularly at higher throughput speeds.
It is therefore the object of the invention to develop a device for needling a fibrous web of the generic kind such that the superimposed vertical and horizontal movements of the needle beam that are produced by a crank mechanism drive can be carried out with flexible adjustments in amplitudes of motion and stable guidance of the needle beam.
SUMMARY OF VARIOUS EMBODIMENTS
This object is achieved according to the invention by means of a device for needling a fibrous web in that the guiding device comprises a steering rod, one end of which is connected to the beam carrier by means of a swivel joint and the other end of which is coupled to a steering transmission by means of a second swivel joint.
Preferred developments of the invention are defined by the features and combinations of features described herein.
One particular advantage of the invention is that the beam carrier is linked to the machine frame by means of a steering transmission acting directly upon the beam carrier by means of a steering rod. Predetermined guide tracks for the steering rod can be produced by interposing the steering transmission, and these guide tracks are adapted to match the requirements of the needling process. Depending on the orientation of the steering rod, shear tensile forces can be absorbed both in the vertical and horizontal directions so that a stable guidance of the beam carrier is possible. Particularly, the pivot point on the beam carrier provides the beam carrier with a high degree of freedom to accommodate arbitrary phase adjustments of the crankshafts.
In order to considerably increase the range for adjusting a horizontal stroke, a development of the invention is particularly advantageous in which one of the transmission elements is formed as a drivable eccentric shaft that is mounted in the frame-rotary bearing and that is coupled to the steering rod by means of a connecting rod. Thus, in the case of an equiphase drive of the crankshafts, a horizontal stroke of the beam carrier can be initiated at a constant amount corresponding to the eccentricity of the eccentric shaft. This horizontal stroke can be increased or decreased by means of a phase adjustment of the crankshafts. It is thus possible to carry out relatively large horizontal strokes and thus high throughput speeds. The possible adjusting range of the horizontal stroke is doubled as a result.
Depending on the design of the steering transmission for guiding the steering rod, it is possible to implement a variety of guide tracks of the beam carrier. In a first variant, at least one of the transmission elements is formed as a rocker arm, the central portion of which is held on the machine frame by means of a rocker bearing. One end of the rocker arm is connected to the steering rod by means of a swivel joint and the opposite end of the rocker arm is connected to the connecting rod of the eccentric shaft by means of a second swivel joint. The guide track of the beam carrier produced by the steering rod can be formed so as to be straight depending on the adjustment of the lengths of the steering rod and the rocker arm.
Alternatively, it is also possible to form the connection of the steering rod by means of a rocker that is connected to the machine frame by means of a rotary bearing. The steering rod can thus be guided by means of the rocker and the connecting rod of the eccentric shaft.
In order to improve the guiding stability of the beam carrier, the steering rod is preferably connected to the center of the beam carrier by means of the swivel joint disposed on the beam carrier. The vertical and horizontal movements of the beam carrier can thus be transferred to the steering rod in a secure and stable manner.
In order to increase the flexibility in adjusting the horizontal strokes, particularly at varying throughput speeds of the fibrous web, the phase-adjusting device in a preferred development of the invention comprises two actuators that are assigned to the crankshafts of the crank drives and that can be controlled independently of each other by means of a control device. Thus, for example, in the case of a change of material, the machine settings can be adjusted rapidly and precisely to new specifications.
In principle, the phase-adjusting device can also be formed by a mechanical or hydraulic transmission system. The adjustment of the crankshafts can thus also be controlled by means of an actuator, for example.
The crankshafts can be adjusted both during operation when the shafts are being driven and when the shafts are idle. Thus other design solutions of the phase-adjusting device can also be utilized depending on the type of crankshaft adjustment.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
Some exemplary embodiments of the invention will be described below for explaining the invention in more detail with reference to the attached Figures, in which:
FIG. 1 schematically shows a side view of a first exemplary embodiment of the device of the invention
FIG. 2 schematically shows a side view of another exemplary embodiment of the device of the invention
DETAILED DESCRIPTION
FIG. 1 schematically shows a first exemplary embodiment of the device of the invention for needling a fibrous web. The exemplary embodiment of the device of the invention shown in FIG. 1 shows a beam carrier 2 , the lower side of which holds a needle beam 1 . The lower side of the needle beam 1 comprises a needle board 3 having a plurality of needles 4 . A bedplate 26 and a stripper 25 are assigned to the needle board 3 comprising the needles 4 , a fibrous web 27 being guided at a substantially constant feed rate between the bedplate 26 and the stripper 25 . An arrow indicates the direction of movement of the fibrous web 27 .
A crank mechanism drive 5 acts upon the beam carrier 2 . The crank mechanism drive 5 is formed by two crank drives 6 . 1 and 6 . 2 disposed parallel to each other. The crank drives 6 . 1 and 6 . 2 comprise two crankshafts 9 . 1 and 9 . 2 , which are disposed parallel to each other above the beam carrier 2 . The crankshafts 9 . 1 and 9 . 2 each comprise at least one eccentric section for receiving at least one connecting rod. FIG. 1 shows the connecting rods 7 . 1 and 7 . 2 , which are disposed on the beam carrier 2 and the big ends 10 . 1 and 10 . 2 of which are held on the crankshafts 9 . 1 and 9 . 2 respectively. The opposing small ends of the connecting rods 7 . 1 and 7 . 2 are connected to the beam carrier 2 by means of two connecting swivel joints 8 . 1 and 8 . 2 respectively. The crankshaft 9 . 1 together with the connecting rod 7 . 1 and the crankshaft 9 . 2 together with the connecting rod 7 . 2 form the crank drives 6 . 1 and 6 . 2 respectively in order to guide the beam carrier 2 in an oscillating movement.
A phase-adjusting device 11 is assigned to the crankshafts 9 . 1 and 9 . 2 . The phase-adjusting device comprises two actuators 12 . 1 and 12 . 2 that are assigned to the crankshafts 9 . 1 and 9 . 2 . The actuators 12 . 1 and 12 . 2 are connected to a control device 13 . The actuators 12 . 1 and 12 . 2 can be activated by means of the control device 13 independently of each other in order to rotate the crankshafts 9 . 1 and 9 . 2 in their bearings. A phase position between the crankshafts 9 . 1 and 9 . 2 can thus be adjusted in any desired manner. In addition to the purely vertical upward and downward movement of the needle beam 1 , a superimposed horizontal movement can thus also be effected on the beam carrier 2 . Thus, an approximately vertical upward and downward movement is carried out in the case of a phase balance of the crankshafts 9 . 1 and 9 . 2 and a synchronous drive of both the crankshafts. In the case of an offset in the phase positions of the crankshafts 9 . 1 and 9 . 2 , the connecting rods 7 . 1 and 7 . 2 bring about an oblique positioning of the beam carrier 2 , which, in the case of an advancing movement, generates a component motion that is directed in the movement direction of the fibrous web 27 . The amount of phase adjustment between the crankshafts 9 . 1 and 9 . 2 is directly proportional to the stroke length of the horizontal movement. The stroke of the horizontal movement can therefore be adjusted infinitely via the angle of phase difference of the crankshafts 9 . 1 and 9 . 2 .
It must be mentioned expressly at this point that the phase-adjusting device 11 could alternatively be formed by an actuator and an adjustment mechanism acting upon the crankshafts 9 . 1 and 9 . 2 . In this case, it is essential to drive the crankshafts 9 . 1 and 9 . 2 such that they are offset in relation to each other by a phase angle in order to also enable a horizontal movement for needling the fibrous web in addition to the vertical movement.
For guiding the movement of the beam carrier 2 , a guiding device 14 is provided that comprises, in this exemplary embodiment, a steering rod 15 connected to the beam carrier 2 by means of a first swivel joint 16 . 1 and to a steering transmission 17 by means of a second swivel joint 16 . 2 . The swivel joint 16 . 1 is formed at the center of the beam carrier 2 , the steering rod 15 being substantially oriented in the horizontal direction and being connected to the laterally disposed steering transmission 17 . In this exemplary embodiment, the steering transmission 17 is formed by an eccentric shaft 18 that is held in a frame-rotary bearing 19 on a machine frame 20 . The eccentric shaft 18 is connected to a free end of a rocker arm 22 by means of a connecting rod 21 . The connection of the rocker arm 22 to the connecting rod is carried out by means of the swivel joint 24 . In the central portion of the rocker arm 22 , a rocker bearing 23 is provided, on which the rocker arm 22 is held so as to be pivotable on the machine frame 20 . The steering rod 15 engages a lower free end of the rocker arm 22 by means of the swivel joint 16 . 2 .
In this exemplary embodiment, the guiding device 14 can optionally be operated by means of an actively driven eccentric shaft 18 or a freely adjustable eccentric shaft 18 . Alternatively, the eccentric shaft 18 can also be replaced by a swivel joint. However, the eccentric shaft 18 of the steering transmission 17 is preferably driven synchronously relative to the crankshafts 9 . 1 and 9 . 2 for increasing flexibility and stroke adjustments. It is thus possible to carry out a deflection of the steering rod 15 in the movement direction of the fibrous web 27 , which deflection is dependent on the magnitude of eccentricity of the eccentric shaft 18 . Apart from the guidance of the beam carrier 2 , a superimposed constant horizontal stroke of the beam carrier can be achieved by means of the steering rod 15 .
By means of a phase difference between the crankshafts 9 . 1 and 9 . 2 , it is thus possible to adjust both an increase and a decrease of the horizontal stroke predefined by the guiding device. The crankshafts 9 . 1 and 9 . 2 can be driven in the same or opposite direction. When the crankshafts are driven in the same direction, the phase adjustment is carried out in the opposite direction. In contrast, when the crankshafts are driven in the opposite direction, the phase adjustment is carried out in the same direction.
Irrespective of whether the guiding device is operated by means of a driven or non-driven eccentric shaft, the translatory movements of the beam carrier 2 are guided solely by means of the rotational movement of the transmission elements of the guiding device 14 . This represents a particularly cost-effective machine concept with a high degree of flexibility in terms of variable stroke adjustment in the case of superimposed vertical and horizontal movements of the beam carrier.
The exemplary embodiment of the device of the invention shown schematically in FIG. 2 represents an additional possibility of guiding the steering rod 15 for guiding the beam carrier 2 by means of a steering transmission 17 . The exemplary embodiment shown in FIG. 2 is identical to the one cited above in terms of construction and design of the crank mechanism drive 5 , the beam carrier 2 and the devices held by the beam carrier 2 so that reference is made to the above description.
As opposed to the exemplary embodiment shown in FIG. 1 , the guiding device 14 in the exemplary embodiment shown in FIG. 2 is formed above the beam carrier 2 between the crank drives 6 . 1 and 6 . 2 . In this exemplary embodiment, the steering transmission 17 of the guiding device 14 is formed by an eccentric shaft 18 and a rocker 28 . The eccentric shaft 18 is held in the frame-rotary bearing ( 19 ) in the machine frame 20 and is coupled to a drive system (not illustrated here). A connecting rod 21 connects the eccentric shaft 18 to the steering rod 15 by means of a swivel joint 16 . 2 . The rocker 28 is held on the machine frame 20 by means of a rotary bearing 29 , and a free end thereof is coupled to the steering rod 15 by means of an additional swivel joint 16 . 3 . When the eccentric shaft 18 is driven by a drive system synchronously to the crankshafts 9 . 1 and 9 . 2 , a translatory motion is superimposed on the steering rod 15 by means of the rocker 28 , and this translatory motion results in a superimposed horizontal movement of the beam carrier 2 by means of the swivel joint 16 . 1 with a constant horizontal stroke. The beam carrier 2 and thus the needle beam 1 carry out an elliptical movement. The rotational speed of the eccentric shaft 18 and that of the crankshafts 9 . 1 and 9 . 2 of the crank mechanism drive 5 are equal in this case so that a horizontal stroke of the needle beam can be adjusted depending on the eccentricity of the eccentric shaft 18 . According to requirements, this stroke can be decreased or increased by means of a phase adjustment of the crankshafts 9 . 1 and 9 . 2 .
However, it is alternatively also possible to lock the eccentric shaft 18 into position by means of the connecting rod 21 so that it would only be possible to carry out a rotational movement. In such a situation, the steering rod 15 exclusively acts upon the beam carrier 2 so as to guide the oscillating movement of the beam carrier 2 .
In the exemplary embodiments of the device of the invention shown in FIGS. 1 and 2 , the phase-adjusting device is represented by two actuators 12 . 1 and 12 . 2 . Such a phase-adjusting device is illustrated merely by way of example. The crankshafts can be adjusted both during operation when the shafts are rotating and during the idle period when the shafts are stationary. It is thus possible to assign a mechanical or hydraulic transmission system to the crankshafts for adjustment purposes. Thus, for example, a motor or an actuator can be used for initiating the adjustment of the shafts by means of the transmission system.
The device of the invention for needling a fibrous web thus offers a high degree of flexibility for guiding and driving a needle beam. In particular, it is possible to realize flexible stroke adjustments for carrying out horizontal movements.
LIST OF REFERENCE NUMERALS
1 Needle beam
2 Beam carrier
3 Needle board
4 Needles
5 Crank mechanism drive
6 . 1 , 6 . 2 Crank drive
7 . 1 , 7 . 2 Connecting rods
8 . 1 , 8 . 2 Connecting swivel joint
9 . 1 , 9 . 2 Crankshaft
10 . 1 , 10 . 2 Connecting-rod big end
11 Phase-adjusting device
12 . 1 , 12 . 2 Actuator
13 Control device
14 Guiding device
15 Steering rod
16 . 1 , 16 . 2 , 16 . 3 Swivel joint
17 Steering transmission
18 Eccentric shaft
19 Frame-rotary bearing
20 Machine frame
21 Connecting rod
22 Rocker arm
23 Rocker bearing
24 Swivel joint
25 Stripper
26 Bedplate
27 Fibrous web
29 Rotary bearing | An apparatus is described for needling a fibrous web having at least one needle bar. On its underside, the needle bar carries a needle board with a multiplicity of needles, wherein the needle bar is guided via a movably held bar carrier. The bar carrier is driven in an oscillating manner with a superimposed horizontal and vertical movement by a crank mechanism drive. To this end, a phase shifting device is provided, by which the crankshafts of the crank mechanism drive can be adjusted depending on the phase relation. Here, the movement of the bar carrier is guided by a guide device. In order to obtain stable guidance with high flexibility in every situation, according to the invention the guide device is formed by a steering rod which is connected at one end to the bar carrier by a rotary joint and which is coupled with the other end to a steering gear by a second rotary joint. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to the manufacture of tubular fibrous products or shells, intended particularly for the heat insulation of conduits and made of mineral fibers, for example of glass, agglomerated by a polymerized binder. The invention relates more particularly to techniques for winding of felts of mineral fibers around a mandrel of a predetermined length to produce cylindrical shells.
2. Discussion of the Art
According to these techniques, a felt of mineral fibers impregnated with a binder consisting of a polymerizable resin, for example of the melanin-formaldehyde, phenyl-formaldehyde or phenol-urea type, is cut into sections of a predetermined length. Each section of felt is wound around a revolving mandrel while the polymerization of the binder begins, which is then completed in a heated chamber.
This process is particularly known from U.S. Pat. No. 4,153,498 to which special reference is made. In this process the rvolving mandrel, around which the felt of mineral fibers is wound, is heated. This heating of the mandrel facilitates the anchoring of the first layer or wrap of felt. The temperature is selected so that an inner surface of the shell hardened by the polymerization of the binder in the vicinity of the mandrel is formed during the winding time. Thus, as soon as the winding ends, the shell can be separated from its mandrel and can be transferred to a device which assures the smoothing and hardening of the outside surface of the shell. At this stage, it exhibits hardened inner and outer surfaces while apart from these inner and outer surfaces, the polymerization of the binder remains incomplete. Polymerization is then completed homogeneously through the entire thickness of the shell in a heated chamber.
Also according to U.S. Pat. No. 4,153,498, the winding of the felt around the revolving mandrel is performed while maintaining the speed of the mandrel, leading to an accelerated tangential speed. Because of this, the thickness of the shell being formed increases with a constant speed.
This process is perfectly suited for the production of shells of small inside and outside diameters, for which only small lengths of felt of mineral fibers need be wound, for example less than 6 meters. Feeding the winding device should be performed at an accelerated speed, however it is impossible to increase the speed for feeding felt of mineral fibers too much without risking a tearing of the felt which is made more fragile by the fact that the mineral fibers are not yet bound to one another. The maximum feeding speed reached at the end of winding is a function of the outside diameter of the shell and of the rotation speed of the mandrel, and should be less than the speed beyond which the felt might be torn. This calls for a maximum rotation speed of the mandrel, to be inversely proportional to the outside diameter of the shaped shell at the end of winding. This limitation becomes particularly constraining for shells of large outside diameter. Thus, by way of example, if a feeding speed limited to 50 meters per minute is assumed, for a shell with an outside diameter of 400 mm, the mandrel should have a constant rotation speed less than 40 revolutions per minute. With layers of an average thickness of about 0.3 mm, a winding time for a shell of 100 mm total thickness is greater than 8 minutes. The rate of production according to this example would therefore be very low.
According to another important characteristic of U.S. Pat. No. 4,153,498, during the entire time of winding, pressing elements remain in contact with the shell being formed. These pressing elements consist, for example, of three counterrollers placed around the heated revolving mandrel. Simultaneously withdrawing from the axis of the mandrel as the shell is formed, these counterrollers assure, on the one hand, the uniformity of the winding and, on the other hand, the cohesion of the shell. Actually, these counterrollers define uniform lines of contact with the shell being formed, which define the general shape of the shell during the winding time. In addition, by the way their pressure is exerted, the counterrollers avoid any nonuniformity of the layers of wound felt.
In practice, three counterrollers are satisfactory for "small" shells, i.e., shells whose inside diameter is between 12 and 100 mm and whose outside diameter is less than 200 mm. When these limiting values are exceeded, for example for shells whose outside diameter reaches 500 mm, three contact points prove insufficient to define the shape of the shell correctly and the counterrollers no longer assure the desired cohesion. Since the squeezing of the shell is maintained by the counterrollers, the pressure exerted is all the greater if a large portion of the outside surface of the shell is in contact with the counterrollers; in other words, if the surface of each counterroller in contact with the shell is increased. However, this contact surface is limited by the fact that the diameter of the counterrollers cannot exceed such a value that the counterrollers are both tangential to one another and to the heated revolving mandrel which determines the value of the inside diameter of the shell. Of course, it would be possible to increase the number of counterrollers, but their diameter would then have to be reduced for the same reasons of bulk. Because of this, an installation well-suited to the production of shells of small inside diameter would provide shells of average inside diameter and/or of average thickness of poor quality while, reciprocally an installation well suited to the production of shells of average inside diameter would not be able to produce shells of small inside diameter, because no pressure would then be exerted on the first wound layers.
The use of this process of the art for the production of shells of average thickness also runs into an additional difficulty connected with the compressibility of the product. Actually, according to this process, the counterrollers are gradually withdrawn from the axis of the revolving mandrel so that during the entire winding phase, a constant force is exerted on the felt of mineral fibers by the counterrollers. Consequently, the first layers or wraps wound, whose outer surface remains not far from the completely rigid surface of the revolving mandrel, are more compressed than the last wraps which are separated from the rigid mandrel by considerable thickness of compressible felt. Because of the partial elasticity of the felt of mineral fibers, and because of this difference in compression, the pickup of thickness of the shell is greater at the end of winding; the result is a shaped shell whose outside diameter is imperfectly controlled and greater than the expected theoretical diameter.
SUMMARY OF THE INVENTION
This invention has as its object to improve the prior techniques for producing shells by winding a felt of mineral fibers impregnated with a binder around a revolving mandrel. In particular, the invention has as its object a process and an installation for manufacturing insulating shells whose inside diameter and thickness can vary within relatively wide limits.
According to the invention, there are continuously manufactured insulating shells made of mineral fibers agglomerated by a binder while winding a felt, impregnated with a binder in the nonpolymerized state, around a heated revolving mandrel whose temperature is such that an inner hardened surface is formed on contact during winding and while exerting a certain pressure on the shell being formed, on the one hand, by pressing elements consisting of main counterrollers which remain in contact with the outer surface of the shell during the entire winding phase and, on the other hand, by auxiliary pressing elements which come in contact with the shell only when the outside diameter of the shell reaches a given value during shaping.
Depending on whether the diameter of the mandrel is or is not greater than this value in question, the auxiliary counterrollers do or do not intervene as soon as winding begins. The choice of the dimension for which the auxiliary counterrollers intervene is a function of the maximum values of the inner and outer dimensions of the shells able to be shaped with the winding device. In any case, this choice is always the result of a compromise, the maximum effectiveness of the counterrollers being obtained at the beginning of their intervention.
For example, to produce insulating shells whose inside diameter, depending on needs, can vary between 12 and 400 mm and whose outside diameter reaches up to 500 mm, three main counterrollers are advantageously used which alone intervene as long as the outside diameter of the shell remains, for example, less than 200 mm, and three auxiliary counterrollers which additionally intervene as soon as the outside diameter of the shell reaches this 200 mm value, either because of the wound felt thickness or simply because the selected revolving mandrel itself has a diameter greater than or equal to 200 mm. The auxiliary counterrollers are placed in contact with the felt and controlled so that they withdraw from the axis of the heated revolving mandrel with the same instantaneous speed as that of the main counterrollers, thus exerting an identical pressure on the wound felt.
Preferably, according to the invention, the pressure exerted by the main, and possibly auxiliary, counterrollers is increased as the winding progresses by reducing the withdrawal speed, which makes it possible to obtain an approximately identical compression for all the wound felt wraps.
According to a preferred characteristic of the invention, the reduction of the withdrawal speed of the counterrollers is performed with a constant deceleration; the withdrawal speed at the end of winding being selected equal to the speed of increase of the diameter of a perfect shell, this theoretical speed being calculated for a diameter value equal to the outside diameter of the shaped shell obtained by the winding of a strip of incompressible material.
Also preferably, the felt of mineral fibers is wound at an approximately constant tangential speed which implies that the rotation speed of the mandrel, at any time, is a function of the outside diameter of the shell being formed. According to a particularly simple embodiment the rotation speed of the mandrel is reduced in a linear manner, the rotation speeds at the beginning and end of winding calculated on the assumption of a winding at constant tangential speed being taken as a reference.
It should be noted that a linear reduction of the speed of the revolving mandrel has the effect of bringing about a slight stretching of the wound felt which is thus compressed around the mandrel. This leads to a greater density for the shaped shell. On the one hand, this increase in the density of the product reduces the bulk of the product which facilitates its being placed around conduits; on the other hand, the shells made of glass fibers for thermal insulation generally have a density close to 60 kg/m 3 . The coefficient of thermal conductivity can be expressed as a function of the density of the product in the following manner λ=A+B·ρ+C/ρ, where A, B and C are variables that essentially depend on the temperature and the nature of the product. In the case of glass fibers, the thermal conductivity remains minimum for a density around 60-90 kg/m 3 . Therefore, a slight variation of the density here does not have a serious effect on the coefficient of thermal conductivity, i.e., on the insulating capability of the shaped shell.
The invention also has as its object a device for winding a felt of mineral fibers around a heated revolving mandrel that can produce shells whose inside and outside diameters can vary within wide limits while exhibiting a good uniformity of shape. Thus, according to an embodiment of the invention, the inside diameter varies between 12 and 400 mm, while the outside diameter remains less than 500 mm.
The device according to the invention essentially comprises a frame which, on the one hand, supports a revolving mandrel made of two half-mandrels driven together in rotation and equipped with electrical resistors that provide heating and, on the other hand, main counterrollers and auxiliary counterrollers each equipped with a device for driving the same in rotation and with a device that assures moving these counterrollers away or closer in relation to the axis of the revolving mandrel. In addition, a device makes it possible to retract the auxiliary counterrollers.
The winding device according to the invention makes possible automation and requires only a minimum of operations for the exchange from one given type of shells for another.
BRIEF DESCRIPTION OF THE DRAWINGS
Various other objects, features and attendant advantages of the present invention will be more fully appreciated as the same becomes better understood from the following detailed description when considered in connection with the accompanying drawings in which like reference characters designate like or corresponding parts throughout the several views and wherein:
FIG. 1 is a schematic view of a device for manufacturing insulating shells comprising a winding device according to the invention,
FIG. 2 is a schematic view of a winding device according to the invention in ejection position,
FIG. 3 is a schematic view of the winding device of FIG. 2 with the main counterrollers used while the auxiliary counterrollers are in a retracted position,
FIG. 4 is a schematic view of the winding device of FIG. 2 with the main and auxiliary counterrollers used,
FIG. 5a is a graph of the variation, during winding, of the outside diameter of the shell, during formation, for 3 types A, B and C of insulating shells,
FIG. 5b is a graph of the variation, during winding, of the instantaneous speed curve of the heated revolving mandrel, corresponding to shells A, B and C; and
FIG. 6 is a graph of the variation, during winding, of the instantaneous withdrawal speed of the counterrollers, for shells A, B and C.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 are represented the main elements constituting a device for forming insulating shells made of mineral fibers, particularly of glass, held by a binder. Each shell is formed from a section 1 of felt of mineral fibers, particularly of glass, in which a binder is dispersed in the nonpolymerized state. The section is obtained, for example, by a tearing of the felt caused by a sudden pull on it. Section 1 is brought by a feeding conveyor 2 to a winding device 3. To avoid any deterioration of the still very fragile felt, since the fibers are not fixed to one another by the polymerized binder, feeding conveyor 2 preferably has a polyvinyl chloride belt. In addition, according to a preferred embodiment of the invention, the feeding speed is selected to be constant; in this way any slipping of the sections against the conveyor which can cause losses of fibers are avoided. Moreover, this feeding speed can be selected relatively close to the production speed of the felt of mineral fibers.
Winding device 3 has a revolving mandrel 4 and counterrollers 5 which withdraw from the axis of the mandrel as felt 1 is wound. These counterrollers 5 exert a pressure on the shell being formed. Thus, they assure a good cohesion of the shell while inhibiting the formation of folds.
The revolving mandrel is heated to such a temperature that the inner surface of the shell is hardened by the polymerization of the binder in the vicinity of the mandrel. By way of example, for ordinary binders with a base of formaldehydephenolic resins, the mandrel may be heated to a constant temperature in the order of 350°-400° C., regardless of the thickness of the shaped shell. This makes it possible to obtain a polymerized thickness which is larger with a greater thickness of the shaped shell. Thus, independently of its size, the shell exhibits a certain rigidity which facilitates its ejection from the mandrel. As soon as the winding ends, shaped shell 6 is separated from mandrel 4 and transferred by device 7 with pivoting arms to smoothing device 8 which makes possible the formation of a "skin" on the outside surface of shell 6'. Smoothing device 8 comprises a hinged conveyor 9 and a smoothing plate 10 that can be raised or lowered to suit various outer diameters of shells, and is equipped with electrical resistors. Its temperature is regulated at about 400° C., for the type of binders considered by way of example.
Shell 6' is driven in rotation by contact with an upper portion of its generatrix on smooth plate 10 and with a lower portion of its generatrix on conveyor 9. In addition to the formation of a "skin", this smoothing device 8 also allows a possible surface treatment of the shaped shell.
After smoothing, the shell which has inner and outer hardened surfaces, while the binder has not yet completely polymerized between these peripheral surfaces, is brought to a polymerization oven 11 via a receiving table 12. For details of this polymerization oven, reference is made to French patent Nos. 2,325,007 and 2,548,586, the latter describing a microwave oven whose use is preferred here.
The polymerized shells are then brought to a cooling device, then placed lengthwise and finally cut lengthwise to make it possible to position them around conduits.
FIG. 2 shows, in greater detail, an embodiment of a winding device according to the invention. It includes a mechanically welded frame 13 which supports the various parts of the winder and their movement device.
Revolving mandrel 14 is composed of two axially spaced cylindrical half-mandrels, not separately shown, made for example of stainless steel, rotated together by a motor, preferably a direct current motor, or each independently driven in rotation, the two motors then being connected by a device for synchronization in relation to one another.
These two half-mandrels can be separated from one another to permit the ejection of a shaped shell. To do this, they are each equipped with a device for driving the same in translation along its axis, this device consisting of a hydraulic jack which controls the movement of the support of a half-mandrel and its motor.
Heating of the mandrel is provided by a bundle of electrical resistors distributed inside the mandrel and spaced as a function of its diameter.
While the felt is wound around the mandrel, counterrollers 15, 15', 15", 16, 16' and 16", exert a slight pressure on the outer surface of the shell. As FIGS. 2 and 3 in particular show, rotationally driven counterroller 15 is mounted on an axis fixed on a support plate 17, itself hinged for rotation around axis 18 which is connected to a stationary plate 19. Counterroller 15 can therefore describe the path of circle 20 passing through the axis of symmetry of the mandrel. This movement of support plate 17 is controlled by a rotary hydraulic jack 21. To do this, a point A of plate 17 is connected by a connecting rod 22 to an end D of a shaft 23 rotatable around fixed axis E. This rotation of shaft 23 is itself transmitted by shaft 24, rotatable around axis E and fixed to shaft 23. End F of shaft 24 is moved by the forward or backward movement of hinged jack 21, rotatable around fixed axis G, so that a movement of rod 25 brings about a movement of counterroller 15. The length of rod 25 is such that at the end of its travel, counterroller 15, placed at C, is in contact with the smallest mandrel that can be used. In practice, the mandrels used do not have a diameter less than 12 mm.
For greater clarity, so far we have mentioned only the case of the first counterroller 15. Counterrollers 15' and 15" are mounted in the same way on a support plates 17' and 17", hinged around axes 18' and 18" which are supported by frames 19' and 19". Plates 17' and 17" are controlled to move together with plate 17 by hinged arms 26' and 26".
In FIGS. 2, 3 and 4, each auxiliary counterroller 16, 16' and 16" is rotatably mounted and driven on an arm 27, 27' and 27" rotatable about a stationary axis H connected to one of the plates 19, 19' or 19". The rotation of each arm about axis H is controlled by a hydraulic jack 28, 28' or 28" mounted to support plate 17, 17' or 17" and which, through its arm 29, transmits to arm 27 the rotation movement of support plate 17, 17' or 17". It should be noted that hydraulic jack 28 must be sized and positioned such that when its piston rod is deployed, the generatrix of the auxiliary counterrollers 16, 16' or 16" closest to the axis of the mandrel is located on a cylinder 31 that also is tangent to the generatrices of primary counterrollers 15, 15' or 15", this cylinder 31 representing the outside envelope of the shell being formed, and shown more particularly in FIG. 4.
At the end of the counterrollers are placed flanges (not shown), mounted on a pivot and fixed to the rotary movements of support plates 17, 17' and 17". These flanges carry jacks identical with jacks 28, 28' and 28" and work in perfect synchronization with them, which makes it possible to retract auxiliary counterrollers 16, 16' and 16". These flanges also support hydraulic motors that drive the counterrollers in rotation.
The operation of the winder according to the invention is as follows. Initially, the main counterrollers 15 are brought together so that the central space left free between them is just enough to allow the passage of the two half-mandrels. The main counterrollers thus assure a guiding function for the half-mandrels, particularly important in the case of shell of small inside diameter, because a significant sagging effect otherwise occurs, since the half-mandrels are held only by one of their ends. It is noted that the diameter of the half-mandrels will preferably be 0.5 mm less than the inside diameter of the shaped shell. Thus, as soon as the first wrap of felt of mineral fibers is wound around the mandrel, counterrollers 15, 15' and 15" are in contact with the shell being formed. As the felt is wound, the outside diameter of the shell grows and counterrollers 15, 15' and 15" move away from the axis of the mandrel, their movement being controlled by the gradual backward movement of rod 25 of jack 21. When the outside diameter of the shell reaches, for example 200 mm, the auxiliary counterrollers--until then retracted--come into a work position, i.e., the piston rods of jacks 28, 28' and 28" are fully deployed (FIG. 4), which brings auxiliary counterrollers 16, 16' and 16" in contact with the shell. The movements of counterrollers 16, 16' and 16" are then controlled by those of support plates 17, 17' and 17" so that they exert a pressure identical with that of main counterrollers 15, 15' and 15".
Preferably, and as shown in FIGS. 2 to 4, auxiliary counterrollers 16, 16' and 16" have a diameter greater than that of the main counterrollers. Actually, to assure a compression distributed as well as possible over the outside surface of the shell, it is important to have a large contact surface. Now, it is clear that to be able to draw in the main counterrollers as soon as the winding phase begins, it is not possible to have main counterrollers with a diameter greater than ##EQU1## where d m is the diameter of the mandrel.
In a multipurpose installation as preferably envisaged according to the invention, the counterrollers must be able to exert a sufficient compression for all types of shells to be shaped by the installation, including shells with an inside diameter on the order of 12 mm, which means that the main counterrollers cannot have a diameter greater than 77.6 mm. The maximum diameter of the auxiliary counterrollers is, of course, also limited by the diameter of the shell. However, the calculations show that if according to an embodiment of the invention, the auxiliary counterrollers are put in contact with the shell only when it reaches 200 mm in diameter, with main counterrollers of 77.6 mm in diameter, the theoretical maximum diameter of the auxiliary counterrollers is greater than 700 mm. For practical reasons, and although this theoretically does not correspond to the most favorable conditions for a good shaping of the shells, auxiliary counterrollers of much smaller dimensions are used, for example with a diameter equal to 80 mm.
Now we come to the difficulties posed by the winding itself around a heated revolving mandrel of a section of mineral fibers whose length can amount to about twenty meters, for the purpose of shaping an insulating shell with an outside diameter that can reach up to 500 mm.
As already mentioned, to operate such a winding according to an increasing feeding speed of a felt of mineral fibers with a heated mandrel revolving at a constant speed leads to very great winding times as soon as the outside diameter of the shaped shell exceeds 200 mm, for example. Also according to the invention, operating with a constant feeding speed of felt is selected, and therefore a speed of rotation of the mandrel decreases as the winding progresses.
Theoretically, this rotation speed of the heated mandrel should be equal at each time t to: Vr=Va/πd where Vr is the rotation speed of the mandrel in revolutions per minute, Va the feeding speed of felt in meters per minute and d the outside diameter of the shell in meters at time t. If on the other hand, it is considered that overall, all the wound wraps of felt create an identical increase in the thickness of the shell, or in other words that all the wraps are compressed identically, the value of d is calculated in the following way: ##EQU2## where t e is the time necessary for the total winding of a shell, de the final outside diameter of the shaped shell and d m the diameter of the mandrel around which the felt is wound.
FIG. 5 illustrates the variation, during the winding time, of the outside diameter of the shell (FIG. 5a) and of the corresponding rotation speed of the mandrel (FIG. 5b). Curve 30 corresponds, for example, to the winding, with a constant feeding speed Va=30 m.s -1 for a time te A of a shell A with an inside diameter of d m =12 mm and with an outside diameter d e =50 mm. Curves 31 and 32 correspond respectively to the winding for a time t eB or t eC of a shell B or C, with d m =50 mm, d e =100 mm or d m =100 mm, d e =300 mm. It has been found in practice that for the thickness and outside diameter of the shells according to the invention, the representative curve of the diameter is practically a straight line.
From the instantaneous value of diameter d, it is deduced that the theoretical expression of the speed of the mandrel is equal to ##EQU3##
Thus, for each type of shell, the only variable in this expression is time. At 33, 34, 35 the representative curve of this rotation speed of the mandrel V R has been represented as a function of time, respectively for shells A, B and C. First of all, it is found that the production of shells of small inside diameters requires that the mandrel be able to be driven up to a rotation speed close to 800 revolutions per minute. On the other hand, at the end of winding of a shell with an outside diameter of 500 mm, the rotation speed is less than 20 revolutions per minute for a feeding speed of felt kept constant at 30 meters per minute. Such variations of rotation speed make a perfect correlation between the rotation speed of the mandrel and the instantaneous theoretical speed.
According to the invention, care is taken that the real rotation speed of the mandrel be equal to the theoretical rotation speed V R previously calculated at the beginning and at the end of winding. Thus, on the one hand, at the beginning of winding a good anchoring of the first wraps on the mandrel is facilitated and, on the other hand, at the end of winding the formation of folds or unesthetic waves are avoided. Between these two reference values, the speed decreases linearly. This choice is made possible by the elasticity of the material which allows a certain stretching thereof. Moreover, as already mentioned, the possible increase in the density of the shaped shell has virtually no effect on the conductivity for insulating shells made of glass fibers.
Concerning the counterrollers, we have already indicated that they are withdrawn from the axis of the mandrel as the diameter of the shell being formed increases, while exerting a slight pressure on the shell during the entire time of winding. The pressure exerted by the counterrollers should be such that the outside diameter of the shell conforms well to the desired diameter. To facilitate the anchoring of the first wraps, the counterrollers are preferably driven at a peripheral rotation speed equal to the feeding speed of felt of mineral fibers.
Since a felt of mineral fibers is a very compressible product, a certain pickup of thickness is observed at the end of winding. On the other hand, the more the thickness of wound felts increases, the more the shell being formed is soft and therefore the more it behaves like an elastic material. It is therefore all the more difficult to control the value of the outside diameter of the shell at the end of winding, if it exhibits a significant thickness of wound felt.
If the felts of mineral fibers behaved like a perfectly inelastic material, it would be easily calculated that at each time t, the withdrawal speed v of the counterrollers should be equal to v=(d e 2 -d m 2 ) / (4·t e d), where d, de and dm represents the outside diameter of the shell respectively at time t, at the end of winding and at the beginning of winding and te the time necessary for the winding of the shell. Curve 36 represents this withdrawal speed v as a function of time for the shells of the type B and C previously described.
According to the invention, fixing the real withdrawal speed ve of the counterrollers at the end of winding is selected as being equal to speed v calculated at time t e . Moreover, a linear variation of the withdrawal speed is necessary, slope x being obtained after linearization of the curve v=f(t) or ##EQU4## Curve 37 represents the straight line thus obtained. It is found that, at the beginning of winding, the withdrawal speed of the counterrollers is less than the theoretical speed which makes it possible to exert an overcompression which facilitates the formation of a hardened inner surface. It is also possible to increase this overcompression by varying the withdrawal of the counterrollers in relation to the beginning of the winding, as shown in FIG. 6, the counterrollers having a zero withdrawal speed from time t=0 to t=t'.
This measurement is especially important for shells of rather large thickness, on the order of 100 mm for example, because then the pickup of thickness of the shell becomes very significant as soon as the compression is stopped. To take this into account, it is proposed according to the invention to set a theoretical outside diameter less than the real diameter but which would be obtained after the same winding time. According to the invention, it has been found that in the case of shells of thickness less than 150 mm and of outside diameter not exceeding 500 mm very satisfactory results were obtained with a theoretical diameter equal to 88% of the outside diameter that is desired to be obtained after shaping. In this case, the necessary withdrawal speed of the counterrollers at the end of winding is equal to ##EQU5## and the slope α' equal to: ##EQU6## Thus v'<v, which means a slight overcompression at the end of winding but also α'>α means a compression smaller at the beginning of winding compensated for by the delay of the withdrawal of the counterrollers.
This servocontrol obtains an excellent result, i.e., a very good conformity between the measured value of the outside diameter of the shaped shell and the desired value, this of course for outside diameters according to the invention less than 500 mm, and of thicknesses less than 150 mm.
Of course, if shells of greater thicknesses must be shaped with a device of the type described in the invention which is however not preferred, it would then be necessary to select a smaller theoretical value of the outside diameter which will be determined after tests.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein. | In the manufacture of insulating shells formed by a felt of mineral fibers wound around a mandrel, main pressing elements intervene as soon as the winding begins and remain in contact with the surface of the shell during the entire winding phase. Auxiliary pressing elements intervent only when the shell, during shaping, has reached a given outside diameter of, for example, 200 mm. The process applies particularly to the insulation of conduits of small and average outside diameters. | 3 |
FIELD OF THE INVENTION
The present invention relates to the field of controlling characteristics of drawn wire, and more particularly to an apparatus for consistent control of the cast and the helix of drawn wire.
BACKGROUND OF THE INVENTION
Metal wire is a material that has a wide variety of uses in many applications. One method of producing wire products involves drawing a wire stock through one or more dies to provide a wire having a desired outer diameter However, in the drawing process, the molecular arrangement of the atoms in the wire may be affected so that the drawn wire product may have certain undesirable characteristics.
More specifically, the drawn wire may not have a desirable "cast". Also, the drawn wire may have an undesirable "helix" characteristic. To one of ordinary skill in the art of wire drawing, the term "cast" refers to the characteristic of a short piece of drawn wire to assume a curved orientation of a specific radius of curvature. Even for drawn wire wound on a spool, if a short piece of the wire were cut from the spool and permitted to sit undisturbed on a flat surface, such as a tabletop, the short piece of wire would inherently curve to a radius of curvature indicative of its "cast".
Also, to one familiar with the art of wire drawing, the "helix" characteristics of the wire may be of great importance. If a short piece of drawn wire is placed on a flat surface, the ends of the wire may lie flat on the surface, or the ends may tend to bend either upward or downward out of the plane of the flat surface. The degree to which the ends of the wire bend out of the plane of the flat surface is referred to as the "helix" characteristic of the wire. If the tendency of the ends of the wire to bend out of the plane of the flat surface is eliminated, then the helix of the wire is said to be eliminated. When the helix is eliminated, the two ends of the piece of drawn wire placed on the flat surface lie in the same plane, and could abut one another if pushed together in the same plane.
Various applications for drawn wire (e.g. for conveyor belts and radial tires) have stringent requirements with respect to the cast and the helix of the wire in addition to the diameter of the wire. More specifically, some applications for drawn wire call for elimination of the helix characteristic. However, conventional wire drawing processes do not provide for consistently eliminating the helix characteristic.
Presently, steps taken to eliminate the helix characteristic of drawn wire are inconsistent and not reproducable. For example, in a production run of drawn wire, at the beginning of the run, a sample of wire may be taken and tested for its helix characteristic. If the helix characteristic is not as desired, then adjustments are made in the drawing or cast control steps to adjust the helix to the desired degree. Once the desired helix is obtained, the production run is continued. However, at intervals during the production run, if new samples are taken and tested for helix, often the helix characteristics will have changed and be out of required specifications. Under present conditions, vast quantities of wire are wasted because of unpredictable and uncontrolled variations in wire helix characteristics of drawn wire. Presently, there is a great need for a device that can provide consistent helix control for drawn wire.
With respect to the characteristic of cast, a drawn wire is often pulled through a series of rollers which impart a desired cast to the wire. Different rollers may be used for different wires. Furthermore, optimum spacing and alignment of the rollers may be attained only after a time-consuming and expensive series of trial and error. So when one wire is substituted for another, a given set of rollers may have to be changed, or a given set of roller alignment and spacing parameters may have to be changed, followed by extensive trial and error to obtain optimum spacing and alignment characteristics for producing desired wire. It would be desirable to be able to change roller sizes, alignment, and spacing without requiring extensive trial and error to obtain desired cast characteristics in drawn wire.
Also, the prior art merely bows the wire and does not consistently (and substantially) break down the molecular structure or composition of the wire, so that the cast of the wire is not uniformly maintained using the prior art method.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to alleviate the disadvantages and deficiencies of the prior art by providing consistent helix control for drawn wire.
Another object is to provide consistent helix control for drawn wire that is easily adjusted manually by an operator.
Another object of the invention is to provide means to be able to change roller sizes, alignment, and spacing without requiring extensive trial and error to obtain desired cast characteristics.
In accordance with the principles of the invention, a novel apparatus is provided for controlling the helix characteristic of wire drawn from a wire source by means for pulling the wire. The novel apparatus is comprised of: means, located between the wire source and the means for pulling the wire, for guiding the pulled wire in a first plane; and means, located between the guide means and the means for pulling the wire, for selectively exerting forces on the pulled wire in a direction outside the first plane, whereby helix characteristics are controlled.
Preferably, the means for exerting out-of-plane forces on the pulled wire include means for selectively shifting the pulled wire from the first plane to a second plane. The plane shifting means are manually adjustable.
Preferably, the plane shifting means include an assembly comprised of a rotatable sheave and a movable block.
The apparatus of the invention implicitly provides a method for controlling the helix characteristic of drawn wire by employing the steps of: guiding the wire in a first plane; and selectively exerting forces on the wire which are in a direction outside the first plane. Preferably, the wire is shifted from the first plane to a second plane.
The apparatus of the invention also implicitly provides a method for controlling both the cast and the helix characteristics of the drawn wire. This method includes the steps of: guiding the wire in a first plane around a set of rollers, thereby selectively imparting a cast to the wire; and selectively shifting the wire from the first plane to a second plane, whereby the helix characteristic of the wire is selectively controlled.
More specifically, with respect to the sheave and movable block assembly, the sheave includes means for guiding the pulled wire in a selected second plane, and the sheave further includes an opening oriented substantially perpendicular to the second plane. A movable block supports the sheave, and the block includes an opening aligned with the opening in the sheave. A guide is provided for guiding the movement of the movable block. A fastener passes through the opening in the sheave and the opening in the movable block for fixing the sheave to the movable block. The assembly also includes a hollow bolt for securing the sheave to the movable block. The movable block includes an orifice extending from the bottom of the hollow bolt to the bottom of the block.
Manually adjustable means are provided for selectively adjusting the sheave and movable block assembly. The selective adjustment means may include: a threaded shaft; a handwheel connected to the threaded shaft; a stationary block having threads complementary to the threaded shaft; and a threaded adjustment nut located on the threaded shaft below the stationary block. The threaded shaft passes through the hollow bolt, the sheave, the movable block, the adjustment nut, and the stationary block. By turning the handwheel, the threaded shaft is selectively moved up or down with respect to the stationary block, and the adjusting nut respectively pushes the assembly up or permits the assembly to ride down, whereby the sheave is selectively moved outside the first plane.
In accordance with another aspect of the invention, an apparatus is provided for controlling both the cast and the helix characteristics of wire drawn from a wire source by means for pulling the wire. The cast and helix controlling apparatus includes both cast control means operating on the wire in one plane and wire shifting means serving to shift the wire from one plane to a second plane, whereby the helix characteristic of the wire is selectively controlled.
In accordance with yet another aspect of the invention, there is provided (in an apparatus for controlling the cast characteristic of a drawn wire) a universal framework having an opening means formed therein to accommodate a selected one of a plurality of base plates, and means are provided for securely receiving a selected base plate in the opening means in the framework. Each base plate carries a set of rollers having a given size and being arranged in a predetermined configuration. With this arrangement, different sizes or configurations of rollers are provided by the base plates, respectively, thereby providing for reduced tooling and maintenance cost and improved flexibility in production.
In a preferred embodiment, the framework includes a receiving plate having ledges adapted to receive the base plate therein. Preferably, the base plate includes at least one adjustment screw, lying in the plane of the base plate, for adjusting at least one roller along the surface of the base plate.
Preferably, the receiving plate includes at least one channel in registration with the adjustment screw. The channel is capable of receiving means for turning the adjustment screw, e.g. an Allen wrench, when the base plate is in position in the receiving plate.
In accordance with yet still another aspect of the invention, an apparatus for controlling the cast characteristic of drawn wire includes a plurality of sets of rollers and associated base plates. Each set of rollers and associated base plate defines a roller assembly, and the plurality of sets of rollers and respective associated base plates define a plurality of interchangeable roller assemblies. A single framework interchangeably supports each of the roller assemblies, one at a time. The framework includes a receiving plate adapted to receive each of the interchangeable roller assemblies.
The present invention further constitutes an improvement (over the known prior art) in that the movable rollers may be individually and selectively adjusted to extend beyond the center line of the fixed rollers, such that each movable roller may be disposed on either side of the center line of the fixed rollers, as desired. This arrangement and flexibility assures that the molecular structure of the wire may be broken down substantially, thereby assuring that the wire will maintain its desired given cast.
In accordance with a still further improvement of the present invention, a frame is provided having an opening therein; The first and second sets of rollers are mounted on respective base plates; and a selected one of the base plates is adapted to be received in the opening in the frame, thereby providing for reduced tooling costs and improved flexibility in production.
These and other objects of the present invention will become apparent from a reading of the remainder of the specification taken in conjunction with the enclosed drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic drawing showing the apparatus of the invention used in conjunction with a system of drawing wire.
FIG. 2 is a close-up side view of an apparatus of the invention.
FIGS. 2A, 2B and 2C are schematic sequence views, showing (substantially) the extent of vertical adjustability of a sheave for imparting a "positive" or "negative" helix to the wire.
FIG. 3 is an enlarged end view of the apparatus of FIG. 2 having a cover plate removed and showing a manually adjusted mechanism for adjusting the helix controlling sheave.
FIG. 4 is an exploded view of the helix control adjustment mechanism shown in FIG. 3.
FIG. 5 is a close-up, top view of the apparatus shown in FIG. 2.
FIG. 6 is a cross-section of the apparatus in FIG. 5 taken along the line 6--6.
FIG. 7 shows an interchangeable roller assembly about to be placed in a framework support.
FIG. 8 is a partially exploded view of the apparatus shown in FIG. 7.
FIG. 9 and 10 depict alternate interchangeable roller assemblies.
FIG. 11 is a schematic drawing of a prior art base plate having a plurality of fixed rollers and further having a plurality of movable rollers interspersed between the fixed rollers, wherein the fixed rollers are disposed on a given centerline, and wherein the extent of movement of the movable rollers is limited and falls short of the center line of the fixed rollers.
FIG. 12 is a further schematic drawing, corresponding substantially to that of FIG. 11, but showing an improvement of the present invention, wherein the movable rollers may selectively extend beyond the center line of the fixed rollers for substantially improved flexibility in production.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, the cast and helix control apparatus 10 of the invention is employed in conjunction with drawing stages 12, 14, and 16 for drawing wire 11. Drawing stages 12, 14 and 16 may be provided with their own means for pulling wire 11 through dies (not shown) in the drawing stages 12, 14, and 16. A finish block 18 includes a spool 20 which is powered by its own electric motor (not shown). The finish block serves to pull the wire 11 through the apparatus 10 of the invention toward itself in the direction of arrows 22.
With reference to FIG. 2 the embodiment of the apparatus 10 from FIG. 1 is shown in greater detail. For descriptive purposes the last drawing stage 16 in FIG. 1 serves as a source for wire 11 moving to the apparatus 10. Furthermore, the finish block 18 contains the motorized spool 20 and serves to pull the wire 11 through the apparatus 10. A set of cast control rollers 28, 30, 32 and 34 serve as means, located between the wire source and the means for pulling the wire 11, for guiding the pulled wire 11 in a first plane depicted by line 36.
A helix control assembly 38 is located between the guiding rollers 28-34 and the means for pulling the wire 11, for selectively exerting forces on the pulled wire 11 in a direction outside the first plane 36. More specifically, the forces exerted by the helix control assembly 38 pull the wire 11 into a second plane depicted by broken line 40. Even more specifically, rotatable sheave 42 pulls the wire 11 into the second plane 40. Once the helix control assembly 38 is set at the desired second plane 40, a set screw 63 is turned to lock the helix control assembly 38 in the desired setting.
Referring to FIG. 3, the cover plate 61 and set screw 63 shown in FIG. 2 have been removed and details of the helix control assembly 38 are shown. More specifically, the helix control assembly 38, which serves to shift the plane of the wire 11, includes an assembly comprised of a rotatable sheave 42 and a movable block 44 and means for selectively adjusting the location of the assembly. The sheave and block assembly includes a hollow bolt 46 securing the sheave 42 to the movable block 44. The movable block 44 includes an orifice 48 extending from the bottom of hollow bolt 46 to the bottom of the block 44. A shim 67 is placed between bearing 69 of the sheave 42 and the movable block 44 to assure that the sheave 42 does not rub against either the top of the movable block 44, or the top of the framework 62, or the top of the housing 77 of the helix control assembly 38.
The wire 11 may be given a "positive" or "negative" helix, as shown schematically in FIG. 2A.
The selective adjustment means includes a threaded shaft 50, a handwheel 52 connected to the threaded shaft 50, a block 54 having threads complementary to the threaded shaft 50, and a threaded adjustment nut is located on the threaded shaft 50 below the stationary block 54. In a preferred embodiment, the assembly includes a pair of lock nuts 56 separated by a lock washer 56A, as shown more clearly in FIG. 3. However, other assemblies are equally feasible (such as threaded locking collars, not shown) consonant with the teachings of the present invention. The handwheel 52 is connected to the threaded shaft 50 and is capable of turning the shaft 50 when manually operated. The threaded shaft 50 passes through the hollow bolt 46, the sheave 42, the movable block 44, the adjustment nut 56, and the stationary block 54. By turning the handwheel 52, the threaded shaft 50 is selectively moved up or down with respect to stationary block 54. As the threaded shaft 50 moves upwardly, the lock nuts 56 push the sheave and movable block assembly upward. Or, as the threaded shaft 50 moves downward, the internally-threaded stationary block 54 causes the assembly to ride down. The extent of the downward movement of the assembly is limited by the engagement of the lower lock nut 56 with the top of the stationary internally-threaded block 54, thereby providing a stop means, so that the sheave 42 will not bottom out on the top surface of the guide blocks 65. When the sheave and block assembly moves up or down, the sheave 42 is selectively moved outside the first plane 36. A pair of outer stationary guide blocks 65 serve to guide the motion of the movable block 44 in a straight line.
In the view depicted in FIG. 4, the elements of the helical control assembly 38 shown in FIG. 3 are shown in exploded view.
In accordance with another aspect of the invention, as depicted in FIGS. 5-10, an apparatus for controlling the cast characteristic of wire is provided. The cast controlling apparatus includes a plurality of cast control rollers 28, 30, 32 and 34, a base plate 60 retaining the rollers, and a framework 62 supporting the base plate 60 and the rollers. The framework 62 includes a receiving plate 64 adapted to receive the base plate 60 therein. More specifically, the receiving plate 64 includes ledges 66 adapted to receive the base plate 60. The base plate 60 has three holes 60A for respective screws 60B that are received in corresponding tapped holes 66A in the ledges 66 of the receiving plate 64. The base plate 60 includes at least one adjustment screw 68 (and, preferably, two aligned adjusting screws 68A and 68B) lying in the plane of base plate 60, for adjusting at least one roller along the surface of the base plate 60. U-shaped clearance channels 64A are formed in the receiving plate 64 to accommodate the adjustment screws 68A and 68B. Adjustable cast rollers 30 and 34 are adjusted by adjustment screws 68 within slots 70. The receiving plate 64 includes at least one channel 72 in registration with the adjustment screw 68 wherein the channel 72 is capable of receiving means for turning the adjustment screw 68, when the base plate 60 is in position. An Allen wrench 74 is shown engaging an adjustment screw.
The framework 62 may be bolted onto a stationary support such as the support for the last drawing stage.
As shown in FIG. 5, a commonly utilized routing of wire 11 is as follows. The wire 11 comes from the wire source, e.g. drawing step 16 in FIG. 1, and takes a right angle turn on rotatable guide sheave 13. After passing stationary roller 28, the wire 11 is routed past adjustable roller 30. From adjustable roller 30, the wire 11 passes by stationary roller 32 and then into rotatable sheave 42 and onto the spool 20 of finish block 18 in FIG. 1. Adjustment of adjustable roller 30 is a key factor in control of cast. It is noted that in the routing of the wire 11 shown in FIG. 5, the roller 34 is not utilized.
Other wire routings are possible with the rollers shown in FIG. 5. For example, instead of using two stationary rollers 28, 32 and one adjustable roller 30, one may employ two adjustable rollers 30 and 34 and one stationary roller 32.
Preferably, the contact points (or tangent points) of the wire 11 with guide sheave 13, with stationary rollers 28 and 32, and with sheave 42 lie on a straight line 33 shown in FIG. 5, when viewed from above. However, when viewed from the side, as shown in FIG. 2, the portion of the wire 11 which contacts sheave 42 of the helix control assembly 38 lies in second plane 40 which is outside the first plane 36 wherein the contact points of the wire 11 guide sheave 13 and stationary rollers 28 and 32 are located.
In FIG. 6, two adjustment screws 68 and 68a coming from opposite sides of the base 31 of roller 30 serve to secure roller 30 into an adjusted position. This structure provides back-up for the respective rollers and assures that the adjusted predetermined position of the respective rollers is maintained.
As shown in FIG. 7, a person is placing a casting roller assembly 78 onto the receiving plate 64 of the framework 62. The casting roller assembly 78 includes two stationary rollers 28 and 32 and two adjustable rollers 30 and 34. The base plate 60 has three openings 60A to receive respective screws 60B which are received in tapped holes 66A in the ledges 66 on the receiving plate 64. There are two screws 60B on one side of the base plate 60, and one screw 60B on the other side (intermediately of the two screws 60B on the one side, as shown more clearly in FIG. 7) thereby assuring proper alignment and positioning of the base plate 60.
Additional casting roller assemblies 80 and 82 are shown in FIGS. 9 and 10, respectively. The rollers 28, 30, 32 and 34 in roller assembly 78 are of a different size than the rollers 90, 92, 94, and 96 in roller assembly 80 in FIG. 9. In addition, the rollers 100, 102, 104, and 106 in roller assembly 82 in FIG. 10 are of a different size that those in either of the roller assemblies 78 and 80. Yet, the size of the base plate for each of the roller assemblies 78, 80 and 82 is the same, thereby providing interchangeability.
It is noted that the size of the rollers, the spacing between the rollers, and the selected adjustments for the adjustable rollers can be fixed for each of the roller assemblies 78, 80 and 82. In this way, when different size wire or wire requiring different casting characteristics is required, one casting roller assembly can be swapped for another interchangeable roller assembly. The capability to swap interchangeable roller assemblies helps reduce time consuming and expensive trial and error when different cast characteristics are desired.
By employing the principles of the invention, numerous objects are realized and numerous benefits are obtained. For example, consistent helix control is provided for drawn wire, whereby scrap losses due to unsuccessful production runs are greatly reduced. Adjustment of the helix is obtained by a simple turning of a handwheel that controls a helix control assembly. By employing interchangeable sets of cast controlling rollers, much undesirable trial and error is eliminated when different wire cast characteristics are needed and different rollers are needed.
With reference to FIG. 11, a prior art base plate BP is illustrated schematically, wherein a plurality of fixed rollers FR is disposed along a center line CL, and wherein a plurality of movable rollers MR is interspersed between the fixed rollers FR for movement transversely thereof. As will be readily appreciated, the maximum alternate position of the movable rollers MR falls short of the center line CL of the fixed rollers FR. As a result, the base plate BP with its fixed rollers FR and movable rollers MR do not have the desired flexibility for economical production.
The improvement thereto is illustrated schematically in FIG. 12, wherein the movable rollers 34 are arranged to have alternate positions on either side of the center line CL. The result is increased flexibility for more economical production.
Obviously, many modifications may be made without departing from the basic spirit of the present invention. Accordingly, it will be appreciated by those skilled in the art that without the scope of the appended claims, the invention may be practiced other than has been specifically described herein. | An apparatus consistently imparts a desired cast characteristic and a desired helix characteristic to drawn wire. A set of interchangeable rollers imparts the cast characteristic to the wire in a first plane, and a helix control assembly imparts helix control by shifting the wire leaving the rollers into a second plane. The helix control assembly includes a rotatable sheave and a movable block. The plane in which the sheave resides and to which the wire is shifted is manually controlled by a handwheel. The rollers and the helix control assembly are supported by a common support. The rollers may be mounted in respective universal base plates, a selected one of which is received in an opening in the frame, thereby greatly reducing tooling and maintenance costs and providing improved flexibility in production. Moreover, the rollers include movable rollers interspersed with fixed rollers, wherein the movable rollers may be individually adjusted on either side of the center line of the fixed rollers. | 1 |
FIELD OF THE INVENTION
The present invention is directed toward a method for manufacturing an emulsion of alkenylsuccinic anhydride (ASA) in an aqueous solution of a cationic starchy material, it being understood that the oily phase consists of the ASA, the starchy solution acting as a support for said emulsion. The term “aqueous solution of a cationic starchy material” means a composition containing at least one cationic starch in aqueous solution.
BACKGROUND OF THE INVENTION
The process described in the present patent application does not use a recirculation loop of the product in the emulsification unit. The emulsion thus manufactured has both a fine and monodisperse particle size, and does not show any heating that might lead to detrimental hydrolysis of the ASA. An efficient process that is simple to perform, especially on a papermaking production site, for producing an emulsion that will advantageously be used as a sizing agent in the manufacture of paper sheets is thus provided.
In the field of papers and other cardboards, “sizing” operations are aimed to give these supports improved properties, especially in terms of hydrophobization and resistance to the penetration of hydrophilic species such as water and aqueous inks. In this regard, use is made of “sizing” compositions that contain hydrophobic substances.
Such compositions are equally used as a mixture with the fibrous mass of cellulose that constitutes the structure of cardboard or paper (internal sizing) or as an application to at least one of the faces of this structure (external sizing, sizing, surfacing or coating). The present invention relates here to the exclusive field of internal sizing. For terminological convenience, the simple term “sizing” will denote the term “internal sizing” as defined above.
One of the compounds frequently used in sizing compositions is alkenylsuccinic anhydride or ASA. This chemical species, which is immiscible in water, must be emulsified in order to be used advantageously in the form of a liquid product: good contact between the ASA and the cellulose fibers is thus allowed.
To perform this emulsification, it is known practice to use concomitantly aqueous solutions of cationic starchy materials of different nature, the starchy material being optionally modified; the function of such compositions is to avoid coalescence of the ASA particles by positive ionization of the surface of the particles, and to bring the ASA particles close to the fibers via an ionic mechanism. Broadly speaking, a cationic starchy material/ASA dry weight ratio of between 0.2 and 4 is used.
Such liquid compositions based on ASA and cationic starchy material are especially reported in documents WO 96/35840 A1 and WO 97/35068 A1. They optionally contain surfactants that increase the dispersibility of the ASA, these substances nevertheless being able to interact negatively with the ASA according to the teaching of document WO 97/35068 A1.
Besides the capacity of giving improved properties to the final product, the emulsion of ASA in the aqueous solution of cationic starchy material must have a certain number of characteristics. It must especially have great acuteness of particle sizes, and also a narrow distribution spectrum of these sizes (“monodisperse” product). As explained in document WO 97/35068 A1, these parameters condition the efficacy of the sizing composition with regard to the hydrophobicity properties that it is supposed to impart.
In this respect, it is well known that the presence of “coarse” particles is a source of fouling, especially of the various items of equipment in which the sizing composition transits, but also of the dryer section of the paper machine by steam entrainment of these coarse particles (which may occasionally lead to fires). Conversely, particles of said composition that are too “fine” will pass through the fibrous mattress and will be carried away in the process waters during draining. It is thus necessary to have a sizing composition in the form of an emulsion that has a maximum number of particles whose diameter is centered on an optimum size that a person skilled in the art estimates at between 1 μm and 1.5 μm.
In order to determine the particle size distribution, use is generally made of a laser particle size analyzer which allows counting, by number or by volume, the particles having a certain diameter, or having a mean diameter within a certain range: this is then referred to as particle size distribution and particle population as a function of the range under consideration. In the present patent application, the term “narrow particle size distribution” will be used when at least 80% by volume of said particles have a diameter of less than 2 μm, and when the mean diameter is between 1 μm and 1.5 μm.
The first of these characteristics reflects a reduced proportion of “coarse” particles (diameter greater than 2 μm). By specifying that the mean diameter is within a range which excludes particles that are too fine (whose mean diameter is less than 1 μm), a “narrow” and “monodisperse” particle size distribution is clearly defined, this distribution being centered on the range from 1 μm to 1.5 μm. Moreover, it is specified that in the present patent application, the particle sizes are always measured using a laser particle size analyzer sold by the company Malvern under the name Mastersizer® 2000. The corresponding measuring procedure is reported in the experimental section of the present document.
The prior art mentions a certain number of documents relating to devices and methods for producing emulsions of ASA in an aqueous solution of cationic starchy material. The general principle is as follows: preparing in a first stage an aqueous solution of cationic starchy material, mixing it homogeneously with ASA, and finally preparing an emulsion from this mixture of ASA and of this aqueous solution of cationic starchy material in an emulsification unit. This unit is characterized by the presence of mechanical means of milling or shearing, which micronize and disperse the particles.
In order to prepare such an emulsion having a narrow particle size distribution, the person skilled in the art has for a long time realized that one of the keys of the process was based on the energy employed for the actual emulsification operation, but also in a system for recirculating this emulsion in the emulsification unit. Intuitively, it is understood that this recirculation loop allows many passes of the product into the emulsification unit, which facilitates the micronization process and thus increases the particle dispersion.
As examples illustrating this concept, reference may be made notably to documents U.S. Pat. No. 6,207,719 and U.S. Pat. No. 5,653,915, which directly concern the preparation of an ASA emulsion, using various devices. It clearly appears that the principle of recirculation of the product in the emulsification means is information that has been acquired and integrated by the person skilled in the art (see notably step D of claim 1 of the first document, and step C of claim 1 of the second document). As regards the documents already mentioned, document WO 96/35840 A1 remains silent regarding the devices used, whereas document WO 97/35068 A1 mentions a Gaulin mixer in its examples, this mixer being known to have a recirculation loop.
SUMMARY OF THE INVENTION
Now, and surprisingly since it is in contradiction with what is taught by the prior art, the Applicant has now developed a process for manufacturing an emulsion of ASA in a composition of cationic starchy material, without a loop for recirculating the product into the emulsification unit. This process leads to a product having the required granulometric characteristics, namely a narrow particle size distribution centered on a range between 1 μm and 1.5 μm.
One of the things that the Applicant can be credited with is that it looked beyond the received idea that a recirculation loop was necessary in such a process. It is also to the Applicant's credit to then have known how to adapt said process so as to ensure the stability and the granulometric properties of the manufactured emulsion, while at the same time getting rid of a recirculation loop. In concrete terms, the Applicant has demonstrated that it is the selection of a certain solids content ranging from 5.5% to 11.5% for the initial solution of cationic starchy material which makes it possible not only to get rid of a recirculation loop, but which leads to a particle size distribution that is even narrower than that observed according to the prior art. Knowing that this parameter conditions the future performance of the product in terms of paper sizing, it may be understood that the process according to the present invention leads to an emulsion that potentially proves to be very efficient in terms of final application.
Furthermore, and advantageously, the person skilled in the art is thus provided with a process that is simple to use, notably directly in a papermaking factory, and free of a recirculation loop: it is a continuous process, which leads to the desired product in a single pass in the emulsification unit.
In addition, the emulsion obtained from the process according to the invention has a temperature that is very close to those of the starting products (i.e. ASA and the solution of cationic starchy material), the slight increase being due to the heating caused by the single pass through the emulsification unit. Conversely, the prior art systems which have a recirculation loop lead to large temperature increases (occasionally greater than 40° C.) due to the principle of recirculation itself: this increase is harmful to the final product, since it accelerates the hydrolysis of the ASA.
Furthermore, the Applicant has demonstrated that said process, which is thus a continuous process, can be performed for several hours, without modification of the granulometric characteristics of the emulsion. Finally, it has also demonstrated that this process allows the use of surfactants without impairing the final product, either as regards its stability or as regards its granulometric characteristics. This is another substantial advantage, since problems of negative interaction between ASA and surfactants have been reported in the prior art (as already discussed in document WO 97/35068 A1).
DETAILED DESCRIPTION OF THE INVENTION
Thus, a first subject of the present invention consists of a process for manufacturing an emulsion of ASA in an aqueous solution of cationic starchy material, comprising the steps of:
a) preparing an aqueous solution of cationic starchy material, b) mixing the ASA and the aqueous solution of cationic starchy material obtained from step a), so as to obtain a cationic starchy material/ASA dry weight ratio of less than 1, preferentially between 0.2 and 0.6 and very preferentially between 0.3 and 0.5, c) preparing in a single pass in an emulsification unit an emulsion from the mixture obtained from step b),
characterized in that:
the process does not involve recirculation of the emulsion obtained from step c) in the emulsification unit, and in that the solids content of the aqueous solution of cationic starchy material obtained from step a) is between 5.5% and 11.5% and preferentially between 7% and 10% of its total weight.
Step a) of preparing the aqueous solution of cationic starchy material consists either in providing an aqueous solution of cationic starchy material, as commercially available, or in diluting the latter with water, so as to obtain the desired solids content. This content, between 5.5% and 11.5% and preferentially between 7% and 10% of the total weight of the solution prepared is the essential parameter to be adjusted for this first step.
For all intents and purposes, it is pointed out that the term “cationic starchy material” denotes a starchy material obtained via any of the known processes for cationization in aqueous medium, in solvent medium or in the dry phase, provided that this process allows one or more nitrogen groups of electropositive nature to bind to said starchy material. Reference may be made notably to document WO 2005/014709 A1. As examples of aqueous solutions of cationic starchy materials that may be used according to the present invention, mention may be made of the products sold under the range Vector® SC and IC (Roquette), Raisabond® 15 (Chemigate), Licocat® P (Suedstaerke), Lyckeby® LP 2145 and LP 1140 (Lyckeby), Redisize® 205 and Redibond® 4000 (National Starch) and Raifix® 25035 and 01035 (Ciba Raisio).
Step b) consists, starting with standard mixing means, which notably allow regulation of the mass concentrations of the constituents, in preparing the mixture between the aqueous solution of cationic starchy material derived from step a) and ASA. Said mixture and ASA are placed in a mixer, which is ideally a static mixer, but may also consist of a dynamic mixer, or a “venture” mixer, according to the term well known to those skilled in the art.
Step c) consists in circulating in a single pass the mixture that was obtained in step b), in an emulsification unit. This unit denotes any device that is well known to those skilled in the art, and which notably has mechanical means whose purpose is to micronized and homogeneously disperse the liquid that it is desired to emulsify. Such devices are notably the Process Pilot DR 2000/4 (IKA) or Ytron Z (Ytron) machines.
The unit in which the aqueous solution of cationic starchy material (a′) is prepared, the mixer (b′) and the emulsification unit (c′) are entirely standard devices, connected to each other ideally via pipes, enabling the circulation of the various liquids. For the purposes of the present invention, the devices should be considered as being devices that are suitable for performing the process according to the invention, at the industrial scale. The emulsification unit (c′) is notably linked to the paper machine such that the emulsion that is useful for sizing paper or cardboard can be introduced in wet-end, in general at one or two points of introduction. Typically, the manufacture of the emulsion consumes at least 5 liters of ASA per hour and preferentially at least 10 liters of ASA per hour.
Thus, a subject of the present invention is in particular a process for manufacturing an emulsion of ASA in an aqueous solution of cationic starchy material as described above, which is performed in a device consisting of:
a unit a′ for storing an aqueous solution of cationic starchy material to perform step a), a unit b′ for mixing ASA and an aqueous solution of cationic starchy material, connected to the unit a′, to perform step b), a unit c′ for emulsifying the mixture of ASA and of the aqueous solution of cationic starchy material, connected to the unit b′, to perform step c),
said device not containing a recirculation loop in the emulsification unit c′.
The process according to the present invention is also characterized in that the ASA is preferentially a product of synthetic origin; it is actually modified oils which result from C16-C18 fractions. Among the commercially available ASAs that may be used in the present invention, mention may be made of the product Chemsize® A 180 (Chemec).
This process is also characterized in that the aqueous solution of cationic starchy material has a content of fixed nitrogen of less than 3.5%, preferentially between 0.3% and 3.5% and very preferentially between 0.7% and 2% by dry weight of nitrogen relative to the total weight of cationic starchy material.
This cationic starchy material may optionally be modified by means of an operation chosen from hydrolysis, chemical and physical, mechanical, thermomechanical or thermal transformations. A hydrolysis operation, which very directly targets the reduction of the molecular mass and, in the majority of cases, the reduction of the viscosity, may be performed via various means such as chemical means, commonly via the action of an acid, a base or an oxidizing agent or via enzymatic action, most commonly with amylase. The common chemical modifications are of various nature, such as oxidation, especially with hypochlorite, esterification, such as acetylation, etherification, for example, by cationization, carboxymethylation or hydroxypropylation. The physical treatments may be performed via thermomechanical means, such as extrusion or pregelatinization, or thermal means, such as those known to a person skilled in the art under the name Hot Moisture Treatment (HMT) or annealing.
Another subject of the present invention consists of a device consisting of:
a′) a unit for storing an aqueous solution of cationic starchy material, b′) a unit for mixing ASA and the aqueous solution of cationic starchy material, connected to the unit a′), c′) a unit for emulsifying the mixture of ASA and of the aqueous solution of cationic starchy material, connected to the unit b′),
said device being free of a recirculation loop in the emulsification unit.
The various units have been described previously. They are connected together by means of pipes and pumps that ensure the circulation of the products in these pipes. A person skilled in the art will know how to adapt said device for its implementation in a paper production factory.
Another subject of the present invention consists of an emulsion of ASA in an aqueous solution of cationic starchy material, having:
a cationic starchy material/ASA dry weight ratio of less than 1, preferentially between 0.2 and 0.6 and very preferentially between 0.3 and 0.5, a particle size distribution such that at least 80% by volume of said particles have a diameter of less than 2 μm, and a mean diameter of between 1 μm and 1.5 μm as determined by laser granulometry using a device sold by the company Malvern under the name Mastersizer® 2000.
This emulsion is also characterized in that the ASA it contains is a product preferentially of synthetic origin.
It is also characterized in that the cationic starchy material it comprises has a content of fixed nitrogen of less than 3.5%, preferentially between 0.3% and 3.5% and very preferentially between 0.7% and 2% by dry weight of nitrogen relative to the total weight of cationic starchy material.
Said cationic starchy material may optionally be modified by means of an operation chosen from hydrolysis, chemical and physical, mechanical, thermomechanical or thermal transformations, as indicated previously.
A final subject of the present invention consists of the use of said emulsion in an operation for sizing a sheet of paper or cardboard.
The examples that follow make it possible to appreciate better the nature of the present invention, without, however, limiting its scope.
EXAMPLES
In all the examples, the granulometry of the emulsions is analyzed using a laser particle size analyzer sold by the company Malvern under the name Mastersizer® 2000, with the following parameters:
800 ml of demineralized water stirring at 1900 rpm background measurement: 10 s 3 consecutive measurements per sample (interval between the measurements: 0 s) duration of each measurement: 10 s laser obscuration: between 8% and 13% refractive index: 1.5 dispersant (water) refractive index: 1.33 absorption: 0.01 particle shape model=spherical
Example 1
The aim of this example is to illustrate the manufacture of an emulsion of ASA in an aqueous solution of cationic starchy material in a device according to the invention not containing a recirculation loop in the emulsification unit, and with a device according to the prior art. It also has the object of illustrating the influence of the solids content of the initial aqueous solution of cationic starchy material on the granulometry of the emulsion prepared.
An aqueous solution of cationic starchy material sold by the company Roquette under the name Vector® SCA 2015 is used. The ASA which is the product Chemsize® A180 sold by the company Chemec is also used. This product contains 0.5% by weight of sodium dioctyl sulfosuccinate as surfactant (also known as DOSS).
Feeding with water is performed using an existing distribution network. The transfers and metering of the ASA and of the aqueous solution of cationic starchy material to this emulsification platform are performed from their respective mobile container or storage tank, by means of pipes and volumetric pumps, the rotation speeds of which are regulated at the desired nominal flow rates and at the target cationic starchy material (dry)/ASA ratio.
The aqueous solution of cationic starchy material is diluted online. The flow rate of dilution water is regulated by the flow rate of the commercial aqueous solution of cationic starchy material, as a function of the desired solids content. A static mixer homogenizes this dilute aqueous solution. The ASA is then introduced online, into the homogeneous dilute aqueous solution of cationic starchy material.
This “aqueous solution of cationic starchy material/ASA” mixture is then conveyed via a pipe to the emulsification unit. This continuous single-pass emulsification system has a series of 3 consecutive rotors/stators, each rotor and each stator of which is composed of 3 rows of concentric toothed crowns. This process operates at variable speed; the rotation speed depends on the passing hydraulic flow rate, on the nature of the constituents and the proportions thereof, on the pressure in the emulsification chamber, and also on the desired fineness of the emulsion. The emulsification unit outlet is equipped with a temperature sensor, a pressure sensor, a valve for maintaining pressure of 3 bar in the process, and a flowmeter.
In this example, the dry content of the aqueous solution of cationic starchy material was varied from 3% to 20%, the cationic starchy material/ASA dry ratio from 0.3 to 0.5, the flow rate at the emulsification unit outlet from 80 to 140 kg/h, the peripheral speed of the emulsification unit rotor being set at 40 m/s.
In all the tests, the temperature T° C. of the emulsion leaving the emulsification unit is determined, and a granulometric analysis is performed according to the protocol already presented, so as to determine the mean diameter and the parameter %<2 μm. In all the tests, except test 6, the emulsion at the emulsification unit outlet is recovered, whereas in test 6, the emulsion is recirculated at least once more in said unit.
The results are collated in Table 1, with the following abbreviations:
Flow rate (kg/h): flow rate at the emulsification unit outlet
SM/ASA: cationic Starchy Material/ASA dry weight ratio
SC SM (%): solids content of cationic starchy material in the initial solution
T° (° C.): temperature of the final emulsion leaving the emulsification unit
%<2 μm: volume percentages of particles less than 2 μm in diameter
d mean (μm): mean particle diameter
TABLE 1
Flow rate
SC SM
T°
% < 2
d mean
Tests
(kg/h)
SM/ASA
(%)
(° C.)
μm
(μm)
1
125
0.5
5
40
64.9
2.03
2
80
0.3
5
44
77.0
1.80
3
125
0.3
3
39
39.1
2.58
4
110
0.3
3
38
34.7
2.80
5
125
0.3
8
46
80.2
1.43
6*
125
0.3
8
63
75.4
1.55
7
100
0.3
20
83
47.0
2.36
8
140
0.3
13
56
58.2
2.04
9
125
0.3
7
43
82.5
1.46
10
125
0.5
7
42
84.9
1.48
11
125
0.5
6
41
81.7
1.49
11**
125
0.5
6
41
82.0
1.50
*2 circulations in the emulsification unit, by ordered and consecutive passings
**granulometric analysis performed after 90 minutes of storage at room temperature
Tests 1 to 4 demonstrate that, at two given SM/ASA ratios and for an excessively low solids content of cationic starchy material (3% and 5%), an excessively high mean diameter is obtained (notably very much higher than 2 μm for tests 3 and 4) and/or an excessively low value of %<2 μm is obtained. This therefore does not give an optimal amount of particles whose diameter is between 1 μm and 1.5 μm, which means that particles of larger size are generated, which may give rise to fouling problems.
Similarly, tests 7 and 8 performed with a large solids content of starchy material do not give the desired granulometry. In addition, they lead to high emulsion temperatures which run the risk of facilitating detrimental hydrolysis of the ASA.
As regards test 6*, it demonstrates that the 2 ordered and consecutive passings of the emulsion through the emulsification unit cause a very large increase in temperature.
In summary, only tests 5, 9, 10 and 11 lead to a final product characterized by a mean particle diameter of between 1 μm and 1.5 μm, with a %<2 μm index of greater than 80%, and with a low increase in temperature. This thus gives an emulsion that is potentially very efficient as a sizing agent by virtue of its granulometry, and which is advantageously free of any detrimental hydrolysis phenomenon. Test 11** demonstrates that, over a long storage period, the manufactured emulsion conserves its granulometric characteristics.
Example 2
The aim of this example is to illustrate the manufacture of an emulsion from ASA and from an aqueous solution of cationic starchy material in a device according to the invention without a recirculation loop. It notably illustrates the influence of the solids content of the initial aqueous solution of cationic starchy material on the granulometry of the emulsion prepared, and on the hydrophobic nature of a paper manufactured with this emulsion.
This example is performed under the same conditions as the preceding example, the only difference being that the continuous single-pass emulsification system has only one rotor/stator, each of the two parts of which is composed of 3 rows of concentric toothed crowns.
Tests 12 to 16 use, in a device according to the invention, an aqueous solution of cationic starchy material sold by the company Roquette under the name Vector® SCA 2015 and of ASA which is the product Chemsize® A180 sold by the company Chemec. The cationic starchy material (SM)/ASA dry weight ratio here is equal to 0.3. The peripheral speed is set at 40 m/s and the flow rate at the emulsification unit outlet is equal to 140 kg/h. Tests 12, 13, 14, 15 and 16 use, respectively, a solids content of 2%, 7%, 9%, 12% and 16% cationic starchy material in the initial aqueous solution.
In all the tests, the temperature T° C. of the emulsion at the emulsification unit outlet is determined, and a granulometric analysis is performed according to the protocol already presented, so as to determine the mean diameter d and also the parameter %<2 μm. All the results are given in Table 2, the abbreviations remaining unchanged.
TABLE 2
SC SM
T°
% < 2
d mean
Tests
(%)
(° C.)
μm
(μm)
12
2
34
39.1
2.70
13
7
41
81.3
1.48
14
9
43
80.8
1.42
15
12
47
69.6
1.79
16
16
70
52.5
2.61
It is clearly seen that the product obtained according to test 16 underwent a very large increase in its temperature: it is thus subject to ASA hydrolysis that is prohibitive to its use as a sizing agent, as will be demonstrated later.
For these emulsions, laboratory sheets of paper known as handsheets are prepared using a FRET machine (handsheet retention tester) sold by the company Techpap. These handsheets have characteristics close to that of client industrial paper, notably as regards flocculation and retentions.
The process for manufacturing the handsheet uses a paper pulp which is a pulp of virgin fibers (50% coniferous, 50% broad-leaved) with a refining level of 35° Schopper (SR). 35% (by dry weight relative to the total weight of the pulp) of natural calcium carbonate sold by the company Omya under the name Omyalite® 50 is added. The charged fibrous suspension has a concentration of 2.5 g/l. 0.3% (dry equivalent/paper) of a size Hicat® 5163AM (Roquette) is then added. Finally, 0.35% (relative to the paper) of the ASA emulsion is added. A handsheet with a basis weight of 70 g/m 2 is thus prepared.
After manufacture of the handsheet, it is placed between two sheets of blotting paper and the assembly is passed twice through a Techpap brand roll press. The handsheet is then separated from the blotting papers and is placed in a Techpap brand dryer for 5 minutes at 100° C. Maturation of the handsheets is then performed, by placing them for 30 minutes in an oven at 110° C., to allow the sizing agent to give the paper its hydrophobic nature. The handsheets are then placed for a minimum of 24 hours in an air-conditioned room at 23° C. (±1° C.) and 50% relative humidity (±2%) (standards ISO 187: 1990 and Tappi T402 sp-08).
A Cobb 60 measurement (standards ISO 535: 1991 and Tappi T441 om-04) is then performed, which relates to the hydrophobicity of the paper: the smaller the amount of water absorbed, the more hydrophobic the paper (Table 3). For the handsheets made from the emulsions according to tests 12 to 16, a mean Cobb value equal to 47, 28, 25, 45 and 51 g/m 2 is found, respectively. It is thus demonstrated that it is indeed the handsheets made according to the invention (tests 13 and 14) which have the highest hydrophobicity.
Example 3
The aim of this example is to illustrate the manufacture of an emulsion from ASA and from an aqueous solution of cationic starchy material in a device according to the invention not containing a recirculation loop. It notably demonstrates that the granulometric characteristics of the manufactured emulsions are constant over time.
The tests use the aqueous solution of cationic starchy material Vector® SCA 2015 and the product Chemsize® A180. They are performed using a device identical to that described in the preceding example.
This example is performed under the same conditions as those of Example 2. Here, the solids content was set at 8%, the cationic starchy material/ASA dry ratio at 0.32 and the flow rate at the emulsification unit outlet at 220 L/h and the peripheral speed at 40 m/s.
3 granulometric analyses are formed here on 3 samples collected at 45 minutes, 3 hours and 5 hours. Besides the mean diameter d and the parameter %<2 μm, the volume percentage of particles whose diameter is within a certain range was also determined: the corresponding results are given in Tables 3, 3a and 3b.
TABLE 3
(after 45 minutes of running)
% (volume)
between (μm)
100.00
0.48
3.80
99.73
0.55
3.31
82.15
0.83
2.19
75.32
0.83
1.90
48.50
1.10
1.66
25.37
1.26
1.44
81.5
% < 2 μm
Mean diameter
1.43
TABLE 3a
(after 3 hours of running)
% (volume)
between μm)
100.00
0.48
3.80
99.86
0.55
3.31
97.89
0.63
2.88
92.18
0.72
2.51
75.72
0.83
1.90
48.62
1.10
1.66
25.43
1.26
1.44
12.82
1.30
1.41
87.8
% < 2 μm
Mean diameter
1.41
TABLE 3b
(after 5 hours of running)
% (volume)
between (μm)
100.00
0.55
3.31
98.77
0.63
2.88
93.39
0.72
2.51
76.74
0.83
1.90
49.46
1.10
1.66
25.89
1.26
1.44
88.3
% < 2 μm
Mean diameter
1.42
Not only is the consistency of the manufactured emulsions in terms of granulometric characteristics demonstrated, but also it is clearly demonstrated afterward that the particle size distributions are monodisperse. | A method for producing an emulsion of ASA in an aqueous solution of a cationic amylaceous substance, without having to use a loop for recirculating the product at the emulsification unit. The produced emulsion is characterized by both a fine and monodisperse particle size, and no overheating is involved that could lead to negative phenomena of hydrolyzing the ASA. The corresponding production device is also described. | 3 |
FIELD OF THE INVENTION
This invention relates to devices adapted to dispense a water soluble or dispersible additive into a flushable toilet cistern and bowl thereof. More particularly, the present invention relates to such a device having no moving part that is able to minimize the amount of additive that is flushed to waste and is present in the cistern water during quiescent periods, whilst maximizing the amount of additive present in the water of a toilet bowl after flushing.
BACKGROUND TO THE INVENTION
The prior art is replete with devices for use in dispensing an additive into a toilet cistern and a bowl thereof, which require no moving parts to facilitate their action. These range from relatively simple devices, such as those in which a block of additive material is held within a container having an opening into which the water in the cistern enters and dissolves or disperses the additive and by diffusion through the opening produces a concentration of additive in the cistern water, to relatively complex devices having air locks, baffles and the like to facilitate controlled delivery of additives.
An example of the latter mentioned type is disclosed in UK patent application No. GB2114623-A. Although dispensers of the latter type have the ability to provide a substantially constant concentration and volume of additive to the cistern and bowl, their complex design and resultant relative high costs generally have made these devices unattractive in large scale consumer use.
Similarly, whilst the relatively simple dispensers of the first mentioned kind have achieved wide consumer acceptance, because the additive is present in the cistern water, when a toilet is flushed, a substantial proportion of the additive will be flushed to waste. As the additive is generally required to produce an effect in the water of the toilet bowl, the amount of additive not remaining in the bowl after flushing is clearly wasted. Moreover, in most cases, the presence of additive in the cistern water during quiescent periods serves no useful purpose. Further, by allowing the relatively large volume of cistern water to remain in continuous contact with the additive during quiescent periods, this results generally in increasing concentration of additive in the cistern water with time.
To minimize the amount of additive wasted, additives have been incorporated into various solid matrices that allow the additive to be dissolved or dispersed in the cistern water at a controlled rate. Whilst this approach may achieve some reduction in the maximum concentration of additive in the cistern water, nevertheless, during prolonged quiescent periods, the concentration of additive in the cistern water will become excessive. More importantly, this approach will have no effect on the proportion of additive that is flushed to waste.
SUMMARY OF THE INVENTION
The present inventor has recognized these difficulties inherent in the prior art and in the present invention seeks to provide a dispenser that is relatively simple in design but which is able to minimize the proportion of additive that is flushed to waste, so that the major proportion of additive that is dispensed remains in the toilet bowl water after flushing.
Accordingly, the present invention consists in a passive dispenser for use in dosing a toilet bowl with an additive comprising a first chamber and a second chamber separated by a common wall having an opening therein, a second wall extending upwardly from a base of a second of the chambers and spaced apart from the common wall opening to define a cavity having an open upper end to permit fluid communication between the chambers, the first chamber being adapted to hold the additive, the second chamber having a filling means to admit water thereinto during filling of the cistern and a discharge means to discharge additive-containing water into the toilet bowl when a toilet is flushed.
DETAILED DESCRIPTION OF THE INVENTION
In order to allow water in the cistern to enter the dispenser, it is immersed in the cistern to an extent sufficient to ensure that when the cistern is full, water will enter the first chamber through the passage. This may be achieved by suspending the dispenser from an upper portion of the cistern, for example, from one of the sidewalls or cover. The first chamber must, however, always have an opening to the atmosphere through which water must not enter when the dispenser is placed in the cistern.
If the dispenser is to be suspended from a sidewall, a hanger having means to attach to an upper edge of a sidewall and apportion connectible to the dispenser may be used. Such a hanger will preferably be further adapted to permit the adjustment of the dispenser vertically in the cistern and hence the extent to which it will be immersed. This may be achieved through the use of an elongate portion dimensioned to co-operate with a connecting means on the dispenser in a manner such that the dispenser is adjustable therealong.
The additive may be in the form of a solid and if so, desirably it will be present in the form of a block in admixture, for example, with components to control the rate at which the additive is released into the surrounding water. Compositions for such blocks are well known in the art and require no elaboration in this specification. However, to assist in attaining the controlled release of additive, the dimensions of the block may be controlled together with its density.
In those cases where the additive is in the form of granules or the like, their size and density should be sufficient to prevent them from being carried over into the second chamber.
The additive may also be in the form of a gel, paste, emulsion, viscous dispersion, viscous solution, or dispersed or dissolved in water-immiscible liquid(s), provided that the additive in the form selected is capable of being dissolved or dispersed into the cistern water at an appropriate rate.
The additive itself may be a variety of substances present singularly or in combination. These include dyestuffs, fragrances, disinfectants, deodorants and the like. Depending on the nature of these substances, they may be dissolved or dispersed into the water contained within the first chamber.
The dispenser may be sold with or without the additive present in the chamber. Additive may also be sold separately to allow for replacement once the additive in a dispenser is used up.
The volume of additive-containing water dispensed will be determined by a number of factors, excluding the volume occupied by the additive in solid form. These are:
(a) the extent to which the dispenser is immersed, which will in turn determine the level of water in the chambers;
(b) the volume of the second chamber below the level of water therein; and
(c) the volume of the first chamber defined between the height of the second wall and the level of the water therein.
It is preferred that the chambers are formed side by side with the common wall dividing them. In this way, a common base may be used, from which the common wall upwardly extends. In such an arrangement, another upwardly extending wall may be formed around the periphery of the base.
The upper end of the second chamber may be closed by the use of a wall extending from the outer wall surrounding the first chamber to connect with the common wall.
The dimensions of the cavity formed between the walls, particularly the size of the opening in its upper end, will affect the diffusion of additive between the chambers. The rate of filling of the first chamber is not as critical as the control of the extent of diffusion. Clearly, if diffusion is excessive, then by further diffusion through the filling means and the discharge means into the cistern during quiescent periods, the effectiveness of the dispenser will be diminished.
The dimensions of the cavity will be such that the rate at which additive containing water is transferred from the first chamber to the second chamber when additive is dispensed is determined by the rate at which additive-containing water is dispensed through the discharge means. Provided that the rate of this transfer is the same or greater than the rate additive is dispensed, the dimensions of the cavity may be varied accordingly. However, as mentioned above, the dimensions of the passage should not be so large as to produce an unacceptable rate of diffusion.
The discharge means is preferably located at the lowest portion of the second chamber to maximize the efficiency of the discharge of additive and water. In an embodiment wherein the chambers have a common base, the discharge means comprises an aperture in a portion of the base of the second chamber. It will be appreciated that the dimensions of the aperture may be adjusted in accordance with the rate of discharge required.
To achieve maximum effectiveness of the dispenser of the invention, the dimensions of the aperture should be adjusted so that the rate of discharge is substantially less than the rate at which the level of water falls in the cistern during flushing. Most preferably, the rate of discharge should be such that the relatively concentrated additive-containing water held in the first chamber is dispensed into the cistern water immediately prior to emptying. In this way, a minimal amount of additive will be flushed to waste whilst a maximal concentration of additive in the toilet bowl water will be achieved.
The filling means must be located in a position that permits water to enter the second chamber when the cistern is full or during filling. Accordingly, the filling means may constitute an aperture located in an outer wall or in the base of the second chamber. If it is located in an outer wall, it will be located below the level of the water in the cistern when full.
Preferably, the filling means will also constitute the discharge means. Most preferably, such means will comprise an aperture in the base of the second chamber.
In use, the dispenser is partially immersed in the cistern water to a depth sufficient to cause water to enter the first chamber from the second chamber via the opening in the upper end of the cavity. Both of the chambers will be filled to a level somewhere above the height of the second wall, the exact level being determined by the extent of immersion.
At equilibrium, the level of water in the chambers of the dispenser and the cistern will be equal.
Once water enters the first chamber, additive will become dispersed or dissolved in the water. Some of the additive will diffuse into the water of the second chamber as the chambers are in fluid communication via the cavity. However, the concentration of additive in the water of the first chamber will be substantially greater than that of the second chamber.
When the cistern is emptied, water containing additive will be dispensed into the cistern water once the level of water in the cistern begins to fall. Discharge will continue until the level within the first chamber reaches the top of the second wall and the second chamber is empty. However, the greatest concentration of additive will be dispensed when the cistern is near empty. This will include the water from the first chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
Two embodiments of the invention will now be described with reference to the accompanying figures in which:
FIG. 1 is a perspective view of a dispenser of the invention;
FIG. 2 is a perspective sectional view about 2--2 of FIG. 1 (with the hanger removed);
FIG. 3 is an inverted plan view of a dispenser shown in FIG. 1; and
FIG. 4 is a perspective view of another embodiment of the dispenser of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The dispenser 10 comprises two chambers 11, 12 separated by a common wall 13. A wall 14 is spaced apart from an opening in wall 13 to form a cavity 15 having an open upper end.
In this embodiment, the volume ratio of chamber 11 to chamber 12 is 2.1:1, whilst the cross-sectional dimensions of the cavity 15 are 5×5 mm.
At an upper end of chamber 11 is an opening 16 to the atmosphere, through which a solid additive contained in the form of a block (not shown) is to be placed. In this embodiment, the block contains a dyestuff as additive.
In base 18 of chamber 12, there is a small, circular opening 17 that permits the discharge of water containing additive. The same opening 17 permits water to enter chamber 12. An opposing end 19 is closed.
In an opening 20, adjacent the open end 16 of chamber 11, there is a hanger 21 that permits the dispenser 10 to be located within a cistern. The hanger 21 has an elongated portion 22 dimensioned to fit within the opening 20. Notches, not shown, on the elongated portion allow the hanger to be positioned in the dispenser. At an upper end of the hanger 21 is a U-shaped portion 23 adapted to fit over the side of a cistern and be held there by a resiliently biassed portion 24.
All of the components of the dispenser 10, including the hanger 21, may be injection moulded using a thermoplastic material. The dispenser may be moulded with the hanger if it is, for example, aligned longitudinally as shown in FIG. 4.
In use, a block of solid additive is placed in chamber 11 prior to the immersion of the dispenser 10 in the water of a cistern. The hanger 21 is slid through opening 20, with the U-shaped portion 23 facing away from the chamber 11. The dispenser 10 is then immersed whilst the U-shaped portion 23 is placed over the upper edge of a wall of the cistern, being held there by the resilient bias of portion 24 acting on an inner surface of the wall.
By moving the dispenser 10 along the hanger 21, the position of the dispenser may be adjusted in the water until water enters chamber 11 through opening 17 and cavity 15.
The dispenser will then function as follows:
Once immersed, water will enter and fill chamber 12 through opening 17. When the water level reaches the top of wall 14, water will enter chamber 11 through cavity 15. Water will continue to enter chamber 11 until it reaches the level of the water in the cistern. The level of the water in the chambers 11, 12 will be somewhere above the top of wall 14, thereby ensuring that chambers 11, 12 will remain in fluid communication.
During immersion, additive will be dissolved or dispersed in the water in chamber 11. By virtue of the fluid communication with the water in chamber 12, some additive will diffuse into chamber 12. However, the concentration of additive will be substantially greater in chamber 11.
Naturally, the greater the contact time between the water held within chamber 11 and the additive block, the greater the resultant concentration of additive in the water.
During flushing, the water level falls in the cistern thereby causing the level of water in the dispenser to fall and additive to be dispensed. As the rate of discharge from opening 17 is substantially less than the rate of fall of water in the cistern, water containing additive from chamber 11 will be discharged when the cistern is near empty.
When the cistern is empty and discharge is completed, water will remain in chamber 11 to the height of wall 14. The volume of additive-containing water discharged will be equal to the volume of additive-containing water contained in chamber 12 together with the volume contained in chamber 11 above the top of wall 14.
The embodiment of the dispenser 10 of the invention shown in FIG. 4 is essentially as that described with reference to FIGS. 1, 2, 3, except that hanger 21 is affixed to a side of the dispenser by a lug 25. In this configuration, the dispenser and hanger may be injection moulded together in the one mould.
In use, the lug 25 is broken by twisting hanger 21. It is then inserted into opening 20 in the manner previously described. | A passive dispenser, adapted to be positioned in the cistern of a toilet, useful for dosing a toilet bowl with an additive such as a disinfectant, cleaning agent, colorant, perfume or the like, has a first chamber and a second chamber separated by a common wall having an opening therein, a second wall extending upwardly from a base of a second of the chambers and spaced apart from the common wall opening to define a cavity having an open upper end to permit fluid communication between the chambers, the first chamber being adapted to hold the additive, the second chamber having a filling means to admit water thereinto during filling of the cistern and a discharge means to discharge additive-containing water into the toilet bowl when the toilet is flushed. | 4 |
COPYRIGHT NOTICE
A portion of the disclosure of this patent contains material that is subject to copyright protection. The copyright owner has no objection to the reproduction by anyone of the patent document or the patent disclosure as it appears in the Patent and Trademark Office patent files or records, but otherwise reserves all copyright rights whatsoever.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to air cleaning systems for welding chambers. In particular, the present invention relates to an air cleaning system booth, a small footprint and the ability to have many units in a confined area without substantial air handling problems.
2. Description of Related Art
The welding of metal parts and welding to build products is an inherently dangerous endeavor. Not only are the sparks and hot metal pieces easy to start fires, cause burns, and the like, but the gases and dust created during the welding process can be toxic, as well as detrimental, to the product being produced. Generally, welding is carried out in a welding chamber, which controls dust and particulate matter generated by the process of circulating and filtering the air that enters the welding chamber before returning it to the surrounding environment.
Older welding chamber air filtration systems consist of an air cleaning system, which is positioned on the floor just outside the welding chamber. They are connected to the air flow from the welding chamber by one or more air hoses. Not only does this older system waste valuable floor space, but it adds considerably to the maintenance and cleaning of a welding system.
A more recent approach to air handling systems for welding chambers, which is superior in many ways to the side mounted units, has been the introduction of the overhead air cleaning system for welding stations. These air cleaning systems have the ability to be in direct connection with the interior of a chamber, eliminating the need for ducting, and also eliminate many of the other problems associated with side mounted air systems and lengthy ducted systems.
The air cleaning systems contain one of a variety of different types of air filtration devices. One cleaning filter method, in addition to standard charcoal, HEPA and other filter units, is the self cleaning pulsed air filter. These filters comprise a paper or cloth filter, which air moves through trapping particles. At desired intervals, a pulse of reverse flow air is blown through the filter, releasing the trapped particles for collection below the filter. Typically, air cleaning systems provide a door, which must be opened and a collector below the air filter also must be handled and cleaned. These work well, but expose the worker who cleans the unit to the filter and interior of the filter chamber every time the tray needs to be cleaned, exposing the worker and surrounding environment to a higher level of contaminants. In U.S. Pat. No. 4,359,330 issued Nov. 16, 1982 to Copley, there is disclosed a self cleaning pulsed air cleaner designed for use in air cleaning systems. The system describes methods for preventing the recontamination of the air filter after it has been pulsed but, nothing to prevent exposure to the filter every time the collection tray is cleaned.
In addition to a wide variety of filters, there are several different approaches to the air cleaning system. In U.S. Pat. No. 6,036,736 issued Mar. 14, 2000 to Wallace, et al., there is disclosed a ventilating method wherein an air blower, suitable for fumes filtered by a contaminate filter, a charcoal filter, and a HEPA filter is disclosed. The device is mounted on top of a framed box and includes spark arrestor means. In U.S. Pat. No. 4,606,260 issued Aug. 19, 1986 to Cox, there is disclosed a movable welding station with a top frame mounted exhaust hood, including charcoal filters. In U.S. Pat. No. 6,758,875 issued Jul. 6, 2004 to Reid et al., there is disclosed a top frame mounted air cleaning system. The system includes a blower housing, frame, filters, shields, and a spark arrestor. This particular air cleaning system has a framing system for supporting the air cleaning on top of the cabinet. The support consists of corner posts with a top corner to corner cross member of long, heavy, metal “beams”. The beams are indicated as relatively tall, and in some embodiments, must be further supported by cross posts (i.e., cross members like the upright posts which add support to the heavy beams of the invention, FIG. 1 and FIG. 2 ). Upright posts and cross beams are a fairly standard construction method for framing systems in general, and as with any older technology, present a variety of problems including their size and greater weight.
These booths all tend to take up much room on the floor, and are not very cost effective for smaller welding jobs. The problems of the present state of the art would be a greatly reduced different type of welding chamber than currently in use.
BRIEF SUMMARY OF THE INVENTION
The present invention relates to a new type of welding chamber that, while it can stand alone, allows for a reduced space when multiple chambers are used. The particular configuration is designed such that either side-to-side, back-to-back, or both configurations can be achieved with multiple booths of the present invention.
Accordingly, in one embodiment of the present invention, there is disclosed a welding booth designed to attach to one or more like welding booths comprising:
a) a left and right side panel wall; b) a back work panel wall comprising one or more adjustable slots and a duct support mounted to a top surface of the panel; c) a plurality of leveling feet; and d) a roof positioned on the top surface of the side and back panels with a roof mounted exhaust extraction port;
wherein the side and back panels are adapted, such that a side or back panel can become the side or back panel of a second welding booth attached to the welding booth.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front perspective view of a welding booth of the present invention.
FIG. 2 is a back perspective view of a welding booth of the present invention.
FIG. 3 is a front view of the back panel.
FIG. 4 is a perspective view of two connected booths with one booth comprising a fume arm.
FIG. 5 is a perspective view of multiple booths positioned side-by-side and back-to-back with ducting connected to duct supports on the booth.
FIG. 6 is a perspective view of roof mounted ventilation.
DETAILED DESCRIPTION OF THE INVENTION
While this invention is susceptible to embodiment in many different forms, there is shown in the drawings, and will herein be described in detail specific embodiments, with the understanding that the present disclosure of such embodiments is to be considered as an example of the principles, and not intended to limit the invention to the specific embodiments shown and described. In the description below, like reference numerals are used to describe the same, similar, or corresponding parts in the several views of the drawings. This detailed description defines the meaning of the terms used herein, and specifically describes embodiments, in order for those skilled in the art to practice the invention.
The terms “a” or “an”, as used herein, are defined as one or as more than one. The term “plurality”, as used herein, is defined as two or as more than two. The term “another”, as used herein, is defined as at least a second or more. The terms “including” and/or “having”, as used herein, are defined as comprising (i.e., open language). The term “coupled”, as used herein, is defined as connected, although not necessarily directly, and not necessarily mechanically.
Reference throughout this document to “one embodiment”, “certain embodiments”, and “an embodiment”, or similar terms means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearances of such phrases or in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments without limitation.
The term “or”, as used herein, is to be interpreted as an inclusive or meaning any one or any combination. Therefore, “A, B or C” means any of the following: “A; B; C; A and B; A and C; B and C; A, B and C”. An exception to this definition will occur only when a combination of elements, functions, steps, or acts are in some way inherently mutually exclusive.
The drawings featured in the figures are for the purpose of illustrating certain convenient embodiments of the present invention, and are not to be considered as limitation thereto. Term “means” preceding a present participle of an operation indicates a desired function for which there is one or more embodiments, i.e., one or more methods, devices, or apparatuses for achieving the desired function, and that one skilled in the art could select from these or their equivalent in view of the disclosure herein, and use of the term “means” is not intended to be limiting.
As used herein, the term “welding booth” refers to a chamber enclosed on 3 sides used for welding and for containing the sparks and/or air emissions caused by the welding activity. In the present invention, they are designed for smaller welding jobs, and unlike large cabinets designed for large robotic welding jobs that are enclosed on 4 sides. These booths typically have a relatively small footprint on the floor of around 3 or 4 feet on a side to no more than about 10 or 12 feet on a side. Where appropriate, these chambers could also be used for welding by either a small robotic or a non-robotic means, but in general, designed for operator welding small items because of the smaller size. The welding booth can accommodate smaller jobs than high volume booths, and have the advantage of operating in a smaller warehouse floor area. The welding booth normally consists of an enclosure, consisting of 3 panel sides and a roof mounted on the panels to form and define the enclosure. There is no frame structure like larger welding chambers designed for large robotic applications. In some embodiments, the paneling is solid metal or the like. In one embodiment, the panels are welding steel that is optionally powder coated. As will be shown in the figures, the booths have the advantage of being placed next to one another, or even wall sharing to take up even less floor space.
The “left and right side panel walls” are essentially identical. A panel is essentially a welded steel (tubing and sheet), powder coated panel wall. Other materials can be utilized, however, steel is presently cost effective and works in this environment. By making them essentially identical inside, two booths can use a common side panel if desired, though walls can be single or double as desired, thus, saving on materials, and not wasting floor space by needing floor space in-between each booth. While a single booth could be free standing, the great advantage of the present invention is the shared wall option. In the shared wall option, two welding booths of the invention share a wall. The left and right walls of the two booths are the same wall. This can be clearly seen in the drawings of the present invention. The panels each have leveling feet. These feet create a space underneath the bottom of the side panels for air circulation, and in addition allow for leveling of the booth on uneven surfaces.
The “back work panel wall” is the third center panel of the booth. The present booth has no front wall. The back wall and left and right side walls can be attached to one another to create a free standing three wall structure. In other embodiments, the roof attaches to the top surface of the side and back panels to hold them together, and in yet another embodiment, both methods are used to hold the panels together and the structure upright and in a squared off configuration. The back wall is also optionally outfitted with one or more adjustable slots for regulating air circulation in and out of the booth. This can be used to balance air flow and air pressure within the booth. The slots can also be positioned in the roof, but the booth is fitted with at least one of these slots in the back wall or roof. An adjustable slot is an opening that can be adjustably opened or closed to the opposite outside of the panel to allow air circulation to pass through the back panel (or roof) as desired. The back panel also is outfitted with leveling feet, which accomplish the same function as the side panels. Note that in one embodiment, the back wall as well as the side walls can be predrilled for side-to-side or back-to-back use, where the walls are used together and not shared. The back wall is engineered to support overhead ducting, wiring, gas lines and the like, without additional structures and/or hanging anything from the ceiling for support.
The roof of the present invention is outfitted with a means of resting on the top surface of the two sides and one back panel. As can be seen in the figures, which accompany, the bottom of the roof can be fitted with a slot or bracket, so that the roof stays in place when placed on the 3 walls. The roof can also be screwed, welded, or otherwise attached to the walls as desired. The roof can be a flat type roof, or can be a built up roof as is typical in many welding cabinets of larger size. The recess in the roof can be outfitted with lighting, ductwork, or the like, as well as air flow pass through slots as in the back wall. The roof on its top surface has a vent exit, which passes down to the booth interior. In order for several booths to be used together and to string exhaust tubing along the top of the booths, the back panel is outfitted with a support bracket for supporting exhaust vents (tubing) along the width of the booth while some attachment can partially be to the roof, the back wall placement allows for better support and better usage for booths placed back to back. By supporting the vents on the back wall instead of the roof, they can be strung together easier, and provide more support than those mounted directly on the roof. Multiple connected booths can then be attached by sharing a common side wall or back wall, as desired. While they can also be attached without sharing a common wall, the sharing allows for a reduction in expense, when utilizing the booths together. In other embodiments it's possible to utilize a roof mounted filtration system, such as filters. These systems are known in the art however it's possible to use a single filtration unit mounted to span two or more booths thus saving money and equipment, something not achieved in previous welding system enclosures.
Now referring to the drawings, FIG. 1 is a front angle perspective of the welding booth of the present invention. Welding booth 1 consists of left panel 2 and right panel 3 . Panels 2 and 3 are constructed of a square tubing frame 5 covered with a steel sheet coating 5 a , and the entire exposed surface powder coated as desired. As can be seen, the frame left panel 2 supports a CO2 bracket 6 for placing a CO2 canister and positioned between left panel 2 and right panel 3 is shelf 7 .
Likewise, back panel 10 is tubing and sheet metal covered with a powder coating, but has several additional accessories. There are quick connectors 12 for gas, such as CO2 or air. There is also an open shelf 13 , and right above that, a dust clean out drawer 15 for collecting heavier dust. The adjustable air slots 20 with adjustment handles 21 can be seen in this view. The roof 30 is supported on tops 8 of the left 2 and right 3 panels as well as the top of back panel 10 not seen in this view. The roof 30 has electrical connection box 31 positioned in the back right corner for routing electrical and for a working light. The back left corner has quick connect inlets 34 for attaching gas to feed connectors 12 inside the booth 1 . Also seen in this view is exhaust port 32 . This connector can be attached to exhaust tubing and a motor to suck air out of the booth 1 . The exhaust tubing brace 32 a is shown in this embodiment as spanning the entire width of the booth along the back wall 10 , and supported on the top of that wall as well as attached to the roof 30 of the invention booth 1 . In order to further brace this embodiment, triangular braces 33 are placed on roof 30 , and welded in place to give lateral support to the brace 32 .
FIG. 2 shows a back angle perspective view of booth 1 . In this view, the top of back panel 10 can be seen. It is noted that while the two side panels are the same height in this view, the back panel 10 is taller. Note that the top of back panel 35 can also be seen in this view. FIG. 3 is a full frontal view of the present invention, in addition to multiple adjustable slots 20 . This view shows the entire interior portion of booth 1 . In this view, electrical outlets 38 and electric light switch 39 can be seen. The light is recessed up inside the roof in this embodiment.
FIG. 4 depicts an embodiment with side-to-side configuration of two units sharing a single side wall. Note wall 40 , which is the left wall of booth 45 and the right wall of booth 46 . This view is from a lower perspective than the previous figures, such that one can see up into the roof, where recess or hanging light fixture 48 can be seen. This view has booth 45 equipped with a retractable fume arm 50 . This arm has the ability to be repositioned as necessary during use, and the small suction head 51 positioned next to the job. Typically fume arms have about a 4 to 8 inch capacity in this environment. With one embodiment being a 6 inch fume arm (referring to diameter). It is clearly designed for small welding jobs as is the entire booth of the present invention.
FIG. 5 shows a large series of booths in both side-to-side and back-to-back configuration. Booths 60 a and 60 b are positioned back-to-back, and thus, the exhaust tubing braces 32 a are touching and a single exhaust connection 62 is used. As can be seen, the main tubing 63 exhausts to the outside with each pair of booths connected along the main tubing route. Electrical is provided, using conduit 64 with connections to each booth. One can clearly see that in this configuration, several booths can be positioned in a relatively small space on the floor, and conveniently be exhausted at the same time.
FIG. 6 depicts a perspective view of an embodiment of the present invention where there is a roof mounted filtration system spanning two booths of the present invention. In this embodiment roof 30 has roof mounted filter system 70 . The roof mounted filter system 70 can contain paper filters screens or any other type of filtration unit or means normal for welding type environments. Access to the filter is by door 71 and particulate clearing can be accessed by drawers 72 . By using a single filtration system 70 a further benefit of the present invention is obtained.
It is clear to one skilled in the art that the drawings herein, are not intended to be limiting. Variations on materials number of attached booths accessories in the booth and the like are within the skill in the art in view of the present disclosure. Nothing in the claims is therefore intended to be limited by the drawings. | The present invention relates to a welding booth that has a small foot print and can be joined to other booths for maximization of floor space use. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This is a continuation application, under 35 U.S.C. §120, of copending international application No. PCT/EP2013/067676, filed Aug. 27, 2013, which designated the United States; this application also claims the priority, under 35 U.S.C. §119, of German patent application No. DE 10 2012 215 151.6, filed Aug. 27, 2012; the prior applications are herewith incorporated by reference in their entireties.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] The invention relates to a beam assembly having a generally rectilinear beam which is arranged between two bearings, extends along a longitudinal direction and is made up of at least three segments, that is to say a central segment and two outer segments, which are arranged one behind the other in the longitudinal direction and are connected to one another via two head-plate joints. The bearings are obstructed from displacement in the longitudinal direction. The invention also relates to a construction, in particular a steel construction, erected with such a beam assembly.
[0003] It is often the case that steel beams cannot be produced, and transported to the use location, in one piece in the length which is necessary for the intended use purpose. Rather, prefabricated segments of smaller length are connected to one another on the building site. This often takes place using so-called head-plate or end-plate joints, in the case of which head plates which are formed, or joined, onto the ends of the actual beam profiles are screwed to one other. It is usually the case that such head plates are oriented perpendicularly to the longitudinal direction of the beam.
[0004] Steel constructions in nuclear facilities, but also in other fields of use, in particular main beams which are subjected to high levels of loading, often have to be configured to withstand pronounced constraint effects resulting from the influences of temperature. On the other hand, they have to be configured, and mounted, such that all of the external loads, such as imposed loads and induced vibration, e.g. from earthquakes, can be dissipated as uniformly as possible. This is often incompatible with the desire for mounting which is as free from constraint as possible so as to compensate for thermal expansion. In general, the reduction in strength also involves a reduction in load-bearing capacity.
[0005] It has therefore been the case in the past that thermal constraining forces have been taken into account predominantly by axial displace ability of the connection (constraint-free mounting) being realized using movable bearings or floating supporting bearings. In the case of external dynamic stressing, this type of connection lacks a sufficient amount of axial strength in order to distribute the loads homogeneously throughout the system. As a result, these constructions are unsatisfactory from an economic point of view.
SUMMARY OF THE INVENTION
[0006] It is an object of the invention to specify an alternative beam assembly which allows a controlled reduction of thermal constraining forces while, at the same time, maintaining the load-dissipating function and with external forces being distributed uniformly within the construction.
[0007] Accordingly, a beam assembly has a generally rectilinear beam disposed between two bearings and extends along a longitudinal direction. The rectilinear beam is made up of at least three segments, that is to say a central segment and two outer segments, which are arranged one behind the other in the longitudinal direction and are connected to one another via two head-plate joints. The bearings are obstructed from displacement in the longitudinal direction. The central segment has a central-segment head plate at each of its two ends and each of the two outer segments has an outer-segment head plate at its end directed toward the central segment. The respective outer-segment head plate is oriented in a complementary manner in relation to the central-segment head plate located opposite it, such that, together, they form a head-plate joint. The two head plates of each head-plate joint are connected to one another via connecting screws or connecting bolts which are guided through apertures in the head plates. The apertures in at least one of the head plates of each head-plate joint are configured in the form of slots. The two head-plate joints are inclined in opposite directions in relation to a plane normal to the longitudinal direction and the slots are arranged, and oriented, such that, in the case of thermal expansion or contraction of the segments, the central segment can be displaced laterally relative to the two outer segments, that is to say transversely to the longitudinal direction.
[0008] The problem on which the invention is based is thus solved by a straightforward and cost-effective steel construction. All that is required is to have metal sheets, rolled profiles and screws in a slot connection; there is no need for any special components. The straightforward combination of the aforementioned components achieves constraint-reducing mounting under the action of temperature and, at the same time, maintains the load-bearing capacity for external loads. The axial expansion of the segments under thermal loading is compensated for by lateral yielding of the construction in a direction perpendicular to the longitudinal direction. The high constraining forces here overcome the static friction between the head plates, the static friction being realized by partial prestressing of the screw-connection. Lateral yielding of the central segment of the beam as a result of external static and/or dynamic loads, in contrast, is not possible, for design reasons. After the action of temperature has ceased, the segments contract again, and this results automatically in a laterally directed restoring force, which pushes the central segment back again into the starting position.
[0009] The customary scenario will be one in which the segments of the beam, at normal ambient temperature, are in line/alignment, and in which the central segment pushes out sideways in the case of a significant increase in temperature. It is also possible, however, to have a system design which reacts correspondingly to decreases in temperature, and thus to contractions of the segments, and in which, to a certain extent, the displaced state is the basic state. If, in the basic state, the connecting screws or connecting bolts are located approximately in the center of the slots and the central segment, accordingly, has been pushed some way out of alignment, there is—depending on the kind of change in temperature—freedom of movement in both directions.
[0010] It is advantageously the case that the inclination axis of the respective central-segment head plate—and, accordingly, also the inclination axis of the outer-segment head plate located opposite it in the head-plate joint—is oriented perpendicularly to the longitudinal direction. Furthermore, the inclination axes of the two central-segment head plates are oriented preferably parallel to one another, and the two central-segment head plates are preferably at an equal angle of inclination in relation to a plane normal to the longitudinal direction. This angle of inclination preferably ranges between 30° and 60° and is preferably 45°. This provides optimal assistance for the above described, automatic lateral displacement of the central segment as a result of thermal expansion of the segments, while the load-bearing capacity is maintained in the best manner possible. Relatively small deviations from the aforementioned details relating to direction and angle are nevertheless possible, for example as a result of slight twisting or torsion of the inclination axes or as a result of slightly different inclination of the head-plate joints.
[0011] The slots acting, during lateral displacement of the central segment, and to a certain extent as guide rails for the connecting screws or connecting bolts of the respective head-plate joint are, of course, arranged, and oriented, in the corresponding head plate so as to provide for the displaceability. In expedient coordination with the above described geometry, the slots are oriented perpendicularly to the inclination axis of the respective central-segment head plate.
[0012] In a preferred variant, the apertures in the central-segment head plates of a head-plate joint are configured in the form of slots and those in the outer-segment head plates are configured in the form of round holes. However, the reverse may also be the case. The connecting screws or connecting bolts here are guided/inserted expediently through the two apertures, that is to say through the two head plates of the head-plate joint, and secured from the outside by nuts and/or by screw heads which engage laterally over the peripheries of the apertures and rest on the head plates. In a possible modification, however, the connecting bolts may also be formed, or jointed (for example welded), onto at least one of the two head plates of a head-plate joint, inserted through the slots in the other head plate and secured from the outside by a nut.
[0013] The slots are advantageously closed over the entire circumference, that is to say they are surrounded on all sides by the head plate and are not open for example in the direction of their outer surrounding. This limits the lateral displaceability of the central segment, and the central segment cannot fall laterally out of the beam. The maximum lateral displacement path of the central segment here lies within a design-compatible range. This ensures that the stability and load-bearing capacity of the beam are not lowered below a critical value.
[0014] As already indicated the two head plates of a head-plate joint, during installation of the beam, are expediently braced or clamped against one another by releasable force-fitting connecting elements. For this purpose, use is made preferably of connecting bolts, in particular in the form of threaded bolts and/or in the form of cap screws or similar elements which are suitable for forming a screw-connection and have an essentially cylindrical stem which is secured customarily by associated nuts—possibly in combination with washers—or, as an alternative, by a dowel pin or the like and are subjected to tensile loading in the process. The two head plates are advantageously braced against one another so as to maintain, for example by appropriately firm tightening of the screws or of the nuts, the lateral displaceability of the central segment under the action of temperature (partial prestressing).
[0015] In an expedient configuration, the beam is a steel beam, of which the individual segments are produced for example in the form of rolled profiles with head plates formed or joined, in particular welded, onto the end sides. As an alternative, it is also possible for the beam, or at least individual constituent parts thereof, to be produced from other materials, in particular from modern composite materials or the like. The individual beam segments, for their part, may be segmented in a customary manner, that is to say may be made up of originally separate sub-segments—for example with head-plate joints oriented perpendicularly to the longitudinal direction. It is also possible, in principle, to produce a beam which is made up, for example, of five segments and in which the second and fourth segments, as seen in the longitudinal direction, are designed for lateral displace ability in the manner described. Since, in this case, the combination of the first to third segments or the combination of the third to fifth segments may be considered to be a single segment, such a configuration is also covered by the wording of the claims.
[0016] The head plates have preferably planar contact surfaces which allow tilt-resistant and torsionally rigid support in relation to their respective connecting partner, and also connection thereto, and which form sliding surfaces when the central segment of the beam is displaced laterally. In an alternative configuration, the contact surfaces may also have a stepped formation oriented along the displacement direction, and this creates a guide rail for the lateral displacement. In particular in the case of solid beams, or in the case of closed box profiles, the head plates may have flanges projecting laterally beyond the beam profiles, in order to facilitate the fitting of the connecting elements and access thereto for installation and maintenance purposes. As an alternative, in the case of closed and/or solid profiles, it is also possible for appropriate access openings to be introduced into the material.
[0017] The beam assembly described is expediently a constituent part of a steel construction or of a structure, in particular of a steel platform or of a supporting frame, for example in a nuclear facility or in some other industrial plant.
[0018] The concept according to the invention is suitable for new steel constructions and also for upgrading existing ones. The geometry of the structure here is not influenced in practical terms, and the beam connection can be largely prefabricated in the workshop.
[0019] The advantages achieved by the invention reside, in particular, in that the segmented configuration of a beam of which the individual segments are connected to one another by partially prestressed head-plate joints with slot/screw-connections and with a specific connection geometry makes it possible for a controlled reduction in stressing caused by thermal constraint effects to be realized by lateral yielding, with the bending load-bearing capacity for external loads being simultaneously maintained, in constructions which are subjected to thermal, static and dynamic loading, to be precise using straightforward steel-construction principles without any special components.
[0020] This results in a) a flexurally rigid, load-bearing connection in the operating or installation position, b) an additional design option for reducing constraint-induced stressing in steel constructions, c) a more cost-effective design than has been the case hitherto, on account of the amount of material used in the construction as a whole being reduced, and d) a single construction combining expansion under thermal stressing and the load-bearing capacity for external loads being maintained at the same time.
[0021] Other features which are considered as characteristic for the invention are set forth in the appended claims.
[0022] Although the invention is illustrated and described herein as embodied in a beam assembly and a construction erected therewith, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
[0023] The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0024] FIG. 1 is a diagrammatic, longitudinal sectional view through a first configuration of a beam according to the invention at ambient temperature;
[0025] FIG. 2 is a sectional view through the beam according to FIG. 1 taken along the section line designated therein by II-II;
[0026] FIG. 3 is a sectional view through the beam according to FIG. 1 taken along the section line designated therein by III-III;
[0027] FIG. 4 is a longitudinal sectional view through the beam according to FIG. 1 in a second configuration, at increased temperature; and
[0028] FIG. 5 is a sectional view through the beam according to FIG. 4 taken along the section line designated therein by V-V.
DETAILED DESCRIPTION OF THE INVENTION
[0029] The same parts are provided with the same designations in all of the figures. Referring now to the figures of the drawings in detail and first, particularly to FIG. 1 thereof, there is shown a beam 2 illustrated in a longitudinal section at ambient temperature (ΔT=0), is configured in the form of an elongate, rectilinear steel beam which, in the example here, is clamped in vertically between an upper bearing 4 and a lower bearing 6 . The overall length of the beam 2 in a longitudinal direction 8 is designated by L. The two bearings 4 , 6 are obstructed from displacement in the longitudinal direction 8 , for example by a surrounding construction or anchoring means. In particular, the bearings may be fixed bearings. In other designs, it would also be possible for the beam 2 to be arranged horizontally or obliquely.
[0030] The beam 2 is constructed from three originally separate segments 10 , 12 , 14 , that is to say a central segment 10 , an upper outer segment 12 and a lower outer segment 14 , which are prefabricated in a workshop and put together, and connected to one another, at the construction site. Each of the three segments 10 , 12 , 14 has a beam element 16 formed for example from a symmetrical I-beam profile. The profile of the beam 2 is constant essentially over the entire length of extent. Of course, it is also possible to use other profiles. If appropriate, the three segments 10 , 12 , 14 may also have different profiles and/or profiles which vary in the longitudinal direction.
[0031] In order to create the connections, the central segment 10 is provided, at both ends, with a respective flat central-segment head plate 18 , which is welded onto the beam element 16 . The two outer segments 12 , 14 , of corresponding design, have an outer-segment head plate 20 in each case at their end which is directed toward the central segment 10 , this giving rise, in the definitively installed state, to two head-plate joints 22 . In each of the two head-plate joints 22 , the outwardly directed contact surfaces of the connecting partners involved rest flatly on one another over the entire lateral extent.
[0032] So that, while maintaining a high bending load-bearing capacity, the beam 2 is mounted between the two bearings 4 , 6 in a manner which is as free from constraint as possible, the head-plate joints 22 are configured with a specific inclination. To be precise, the two central-segment head plates 18 are arranged in a state in which they are inclined/tilted in opposite directions in relation to the horizontal about an imaginary inclination axis 24 in each case. The two inclination axes 24 run parallel to one another and perpendicularly to the longitudinal direction 8 , here, in FIG. 1 , perpendicularly to the image plane and through the axis of symmetry of the beam profile. Each of the two central-segment head plates 18 assumes an angle of inclination α of 45° in relation to the horizontal (and thus also in relation to the vertical) or, expressed in more general terms, in relation to a plane normal to the longitudinal direction 8 . As a result of being inclined in opposite directions, in the section view according to FIG. 1 the two central-segment head plates 18 would form a V lying on its side if they were extended appropriately to the left. The outer-segment head plates 20 are inclined in a coordinated, complementary manner. For this purpose, the beam elements 16 of the three segments 10 , 12 , 14 are cut in an appropriately inclined manner (in a manner similar to miter-cut corner connections) at the end connections, and the head plates 18 , 20 are welded onto the end edges of the beam elements 16 . Accordingly, in FIG. 1 , the central segment 10 has the outline of an isosceles, symmetrical trapezoid.
[0033] The head plates 18 , 20 , which are located opposite one another in the respective head-plate joint 22 , are connected on a permanent basis by screw-connection. For this purpose, the head plates 18 , 20 according to the illustration in FIGS. 2 and 3 are provided with suitably positioned apertures 26 or bores, through which threaded bolts 28 , preferably with two oppositely directed threaded portions in the two end regions, are inserted and are secured from both sides by screwed-on nuts 30 , which engage laterally over the apertures and rest on the head plates. As an alternative, it is also possible to use cap screws, each secured by a single nut.
[0034] In specific terms, in the present exemplary embodiment, the apertures 26 in the respective outer-segment head plate 20 are configured in the form of round holes 32 with the diameter which is slightly larger than the diameter of the threaded bolt 28 , or screw stem, which is to be inserted through in each case ( FIG. 2 ). The apertures 26 in the respective central-segment head plate 18 are configured in the form of slots 34 , of which the width is likewise slightly larger than the diameter of the threaded bolt 28 , or screw stem, which is to be inserted through in each case, the length of the bolt or screw stem nevertheless being considerably larger than the width ( FIG. 3 ).
[0035] In the definitively installed position, the longitudinal direction 36 of the slots 34 in the respective central-segment head plate 18 runs perpendicularly to the inclination axis 24 of the central-segment head plate, in this case parallel to the image plane of FIG. 1 . The slots 34 are positioned in relation to the round holes 32 such that, in the case of the configuration which is illustrated in FIG. 1 , and in which the three segments 10 , 12 , 14 are located in line/alignment, as seen in the longitudinal direction 8 , the threaded bolts 28 or screw stems tend to be positioned at that end of the slots 34 which is directed toward the long base side of the trapezoid, that is to say at the right-hand end in FIG. 2 .
[0036] As a result of the construction described, in the case of an increase in temperature (ΔT>0), the accompanying attempts, on the part of the three segments 10 , 12 , 14 to be expanded in the longitudinal direction 8 and the fact that the two outer segments 12 , 14 are clamped in firmly between the two bearings 4 , 6 give rise to the central segment 10 being subjected to a resultant force in a direction transverse to the longitudinal direction 8 , in the direction of the long base side of the trapezoid—that is to say to the right in this case.
[0037] In the case of the prestressing of the screw-connections being set at an appropriate level, this means that, when a minimum temperature difference ΔT in relation to the initial state on which FIG. 1 is based, the minimum temperature difference being necessary to overcome the static friction between the head plates 18 , 20 of the two head-plate joints 22 , is exceeded, the central segment 10 is displaced in the aforementioned direction, that is to say it yields laterally. The touching contact surfaces of the head plates 18 , 20 here, on the one hand, give rise to force deflection in a direction transverse to the longitudinal direction 8 and, on the other hand, form mutual sliding surfaces. The slots 34 in the central-segment head plates 18 provide for the necessary degree of translator-movement freedom and, in addition, form a guide rail for the threaded bolts 28 or screw stems which are being displaced relative to them in the direction of the free space depicted in FIG. 2 , that is to say in the left in this case.
[0038] The higher the temperature difference ΔT, the greater the lateral displaceability of the central segment. The displacement distance is limited by the finite longitudinal extent of the slots 34 , which are closed at both ends.
[0039] The state of maximum displacement is illustrated in FIG. 4 (ΔT>>0). The threaded bolts 28 or screw stem, in this case, are located at those ends of the slots 34 which are directed toward the short base side of the trapezoid, wherein the remaining material crosspieces between the slots 34 and the outer surround of the central-segment head plates 18 act as end stops ( FIG. 5 ). The sum of the overall length of the three segments 10 , 12 , 14 , measured in each case along the axis of symmetry of the beam profile, has increased from originally L1+L2+L3 to what is now (L1+ΔL1)+(L2+ΔL2)+(L3+ΔL3). The difference between these two length dimensions is designated in FIG. 4 by f a . However, the lateral displacement of the central segment 10 by the distance f a causes the overall length L of the beam 2 to remain the same. In the present, special case, L1=L3 and it is therefore the case, at least approximately, that ΔL1=ΔL3, but this symmetry is not generally imperative.
[0040] It is only if the temperature were to increase further that the beam 2 would be subjected to a significant level of constraint, which could result in corresponding pinching compression or bending deformation of the beam 2 or in the bearings 4 , 6 loosening or in the threaded bolts 28 or screw stems shearing.
[0041] The displacement of the central segment 10 is reversible. It is also possible for the configuration illustrated in FIG. 4 to be used as an initial state for a subsequent decrease in temperature and corresponding contraction of the segments 10 , 12 , 14 which then results in the configuration illustrated in FIG. 1 .
[0042] The following is a summary list of reference numerals and the corresponding structure used in the above description of the invention:
2 Beam 4 Upper bearing 6 Lower bearing 8 Longitudinal direction (of the beam 2 ) 10 Central segment 12 Upper outer segment 14 Lower outer segment 16 Beam element 18 Central-segment head plate 20 Outer-segment head plate 22 Head-plate joint 24 Inclination axis 26 Aperture 28 Threaded bolt 30 Nut 32 Round hole 34 Slot 36 Longitudinal direction (of the slots 34 ) Δ Angle of inclination | A beam assembly contains a substantially straight beam, which is arranged between two bearings and extends in a longitudinal direction. The beam assembly contains at least three segments, which are arranged one behind the other in the longitudinal direction and which are connected to each other by two head plate joints. The three segments include a middle segment and two outer segments. The bearings are prevented from moving in the longitudinal direction. The beam assembly permits controlled relief of thermal constraining forces while the load-transferring function is simultaneously maintained and while external dynamic forces are evenly distributed within the construction. Accordingly, this is achieved in that the middle segment has a middle segment head plate at each of the two ends of the middle segment and each of the two outer segments has an outer segment head plate at the end of the outer segment directed toward the middle segment. | 4 |
RELATED APPLICATIONS
This application is a continuation-in-part of PCT international application Ser. No. PCT/MY2009/000203, filed Dec. 4, 2009, designating the United States, which claims the benefit of Malaysan Application No. PI 20097019, filed Oct. 1, 2009. The entire contents of the aforementioned patent applications are incorporated herein by this reference.
FIELD OF INVENTION
The present invention generally relates to a spacer building system and more particularly to an architectonic spacer building system which allows flexibility in form of design and flexibility in assembly of physical building components using pre-cut materials.
BACKGROUND OF INVENTION
Prefabricated or Industrialised Building System (IBS) component has been widely used in the housing construction sector that facilitates mass production. An IBS building uses ingredients like prefabrication, standardisation, methods of production and quality control (Gann, 1996). The engineering advantageous in using IBS in construction include elimination of waste, precision and quality control in production, optimisation of time and sustaining and protecting the environment during construction. These benefits encourage IBS as a construction technique and this factor is one of the prime factors for promoting the IBS building system around the world. Unfortunately, designers still have problem to creatively experiment with IBS components during a building project's design phase and prefabrication.
The level of standardisation and prefabrication process is considered very low (Noguchi, 2003). Despite its premature growth in the construction industry, IBS construction is a preferred construction method in developing countries. The targeted benefit of IBS implementation is its objective to minimise dependency on foreign labour in construction projects. However, IBS implementation meets the supply demand barrier. Economic volume, general readiness and social acceptability of IBS make the construction technology less appealing (Zuhairi 2008). Moreover, although the prefabrication building process puts emphasis on the mass production, repetitive design layout is blamed for causing monotonous barrack-liked complex (Thanoon 2003).
Gib (1999) identified three categories of offsite prefabrication; namely, non-volumetric, volumetric, and modular building, but he argued that the line dividing each type is flexible. When Gib's concepts are applied into prefabricated house design in term of architectural perspective, there is a miss-coordination between the spatial dimensioning of physical building element and the functional building design element therefore making it not appropriately moulded into fabrication of the house's space design. Yet Gib's system also did not address the assembly and disassembly of industrialised building systems. It is also noted that there is no timber building system existing for prefabrication since the conventional wooden construction joints have been used in the prefabrication process. Additionally, there is nil assembly of industrialised building system in the form of non-volumetric pre assembly for volumetric pre assembly and/or modular building.
Schindler was reported attempting to develop new construction system for housing whereby the construction system enables to reduce construction cost, improve in building efficiency, increase speed of fabrication interchangeability of parts, reduce number of labours, provide durability and provide better design (Jon Ho Park 2004). Schindler had identified the needs of building assembly in prefabrication but his construction system was complicated that it reduced prefabrication flexibility of the designed assembly. To date, there is a lack of pre assembly system that is flexible enough to simplify the assembly in prefabricated timber building construction, especially when the assembly system is applicable only in precast concrete panel systems and more so in the less developed timber building assembly.
Historically those taking standardisation seriously have always struggled to resolve the conflict between uniformity and variation, between standardisation and flexibility (Gibb 2004). This conflict still not been solved.
In one of the prior art, it discloses a modular building system which includes a prefabricated desk system having a plurality of rectangular flooring modules. However, the system is modular form but not in the form of building component assembly. Moreover, the floor modules of this prior art are sandwiched with joist and connector.
Another prior art discloses a joint connector device and a method for assembling prefabricated building panels. This prior art invention includes an L-shaped cove channel joint connector device for joining prefabricated structural building panel and its method of assembly. However, it does not have flexibility for angular or radial walls construction.
The invention of this study focused on the design assembly for an industrialised building system in which degree of flexibility in design form can be rejuvenated. This invention stating the prefabricated building assembly is not only an engineering process. It is an amalgamation of both design cum engineering methods and mechanics.
SUMMARY OF INVENTION
The present invention relates to an architectonic spacer building system which allows flexibility in form design and flexibility in the assembly of prefabricated modular components using pre-cut building materials. Accordingly, it relates to physical building components design assembly principle for industrialised building system.
In accordance with preferred embodiments of the present invention, the architectonic spacer building system for skeleton construction which is used for developing design assembly for physical building components in a modular industrialised building system (IBS), characterised in that the architectonic spacer building system includes spacer having predetermined shape for use in constructing modular form of building component; wherein said spacer has a length of at least 0.1 m (100 mm) used to construct modular floor joist assembly, corner and crisscross junctions assembly; and wherein said spacer has a thickness of at least 0.001 m (1 mm); the spacer acts as an anchored dowel connector, composite key roof connector and/or a bracing of adjoining wall panel; and wherein the spacer is used in modular wall panel of a predetermined size to form a “flexi-shape” of angular, radiated wall, or polygonal wall; wherein the spacer is also a piece of physical building assembly component to integrate with various physical building components in prefabrication.
Accordingly, the spacer can be of rectangular, square, triangular or polygonal in shape. The spacer can be a solid, hollowed or extruded form of different shape profile.
Accordingly, the spacer is a floor joist dowel connector, composite key roof connector, a bracing of adjoining and/or intersecting wall panel. The composite key roof connector includes of modular hip rafter, key bracket spacers, key plate spacers and key ties.
It will be appreciated that the spacer is used to attain a required cross section for structural stability in vertical and horizontal physical building components such as floor joist, wall panel, and roof truss formation. Accordingly, the spacer can also be used to extend the length or a connector for making long span horizontal physical building components such as beam or joist.
It will also be appreciated that the spacer can be served as an interlocking jigsaw piece in method of playing with the modular physical building components to knit armature of sub- and super-structure of prefabricated building structures. The spacer also tends to act as a shock absorber for any structural mechanisms of the building such as impact load, lateral movement or floor vibration of the building structure.
Accordingly, the spacer used in modular wall panel creates slit between two sectional building materials while joining at corner or crisscross junction of the wall panel that allow conduit of services to be accommodated thereof.
Accordingly, the spacer can be in multi dimensional shape to form an angular and polygonal wall panel. The spacer can also be develop as principle for flexible assembly of roof, such as pyramid roof, mansard roof (double slope) and cone roof by using the composite key roof connector to hold main rafters to form longer span truss. Said composite key roof connector can easily form a two-tier roofing and cupola on top for admitting light. Utilisation of architectonic spacer building system would save the volume of materials used in prefabricated industrialised building system such as wood, metal, etc.
BRIEF DESCRIPTION OF DRAWINGS
The accompanied drawings constitute part of this specification and include an exemplary or preferred embodiment of the invention, which may be embodied in various forms. It should be understood, however, the disclosed preferred embodiments are merely exemplary of the invention. Each assembly form may be fastened together with a preferred method of fastening such as with nails, screws, caulking, etc. Therefore, the figures disclosed herein are not to be interpreted as limiting, but merely as the basis for the claims and for teaching one skilled in the art of the invention.
In the appended drawings:
FIGS. 1( a )-1( e ) show various geometrical shapes of spacer and interlocking spacer used in architectonic spacer building system in accordance with preferred embodiment of present invention, and the spacers may be hollowed, solid or extruded in its form;
FIGS. 2( a )-2( c ) show the examples of various assemblies of wall panels that are formed by different architectonic spacers, whereby the spacers are used as bracing for adjoining wall panel;
FIG. 3 shows an example of grid modular floor joist assembly, whereby the spacers are used as anchorage dowel connector at upper and lower layers of modular floor joist assembly;
FIG. 4 shows an example of wall panel corner assembly and crisscross junction assembly, whereby the spacers are used to create a corner or wall junction assembly in a prefabrication wall panel;
FIGS. 5( a )-5( b ) show the assembly of key roof connector for the pyramid roof, whereby the spacers are used as composite key roof connector;
FIGS. 6( a )-6( d ) show physical building components of key roof connector, which includes key bracket spacers, key plate spacers and key ties respectively.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
A detailed description of preferred embodiments of the invention is disclosed herein. It should be understood, however, the disclosed preferred embodiments are merely exemplary of the invention, which may be embodied in various forms. Each assembly form may be fastened together with a preferred method of fastening such as with nails, screws, caulking, etc. Therefore, the details disclosed herein are not to be interpreted as limiting, but merely as the basis for the claims and for teaching one skilled in the art of the invention.
The invention relates to physical building components design assembly principle for industrialised building system. This system uses various geometrical shapes of spacer such as rectangle, square, triangular or polygon in shape for construction of flexible design form. For instance, FIGS. 1( a )-1( e ) show various possible geometrical shapes of spacer ( 2 , 4 , 6 , 10 ) and interlocking spacer ( 8 ) used in architectonic spacer building system. The space can be of, but not limited to rectangular, square, triangular or polygonal in shape either as a single part or two separate interlocking parts, depending on the use of the spacer.
It is to be noted that the spacer works as key accessories in physical building components such as bracing of adjoining wall panel ( 12 ), dowel connector ( 2 , 10 ) and also composite key roof connector ( 22 , 24 , 26 ). FIGS. 2( a )-2( c ) show the examples of various possible assemblies of wall panels that can be formed by different spacers ( 2 , 4 , 6 ), whereby the spacers are used as bracing for adjoining wall panel ( 12 ). FIG. 3 shows an example of grid modular floor joist assembly whereby the spacers ( 2 , 10 ) are used as anchored dowel connector at upper and lower layers ( 14 , 16 ) of modular floor joist assembly ( 18 ).
It is to be noted that the spacer ( 2 ) can also be used to form interlocking component or spacer-adjuster ( 3 ), by having unequal size of elements ( 3 a ) configured to form a horn/L-shape lock ( 3 b ) with predefined depth to interlock both end of modular floor joist. Said interlocking component or spacer-adjuster ( 3 ) can be used for floor component assembly of multi-layers. Accordingly, the spacer-adjuster ( 3 ) is one of the architectonic forms in modular interlocking component for floor component assembly that is formed by either two or three layer of unequal size of spacer elements joined together with or without slit ( 3 c ). The purpose of slit ( 3 c ) in the spacer-adjuster ( 3 ) is to increase the depth to hold the joist firmly. It will be appreciated that the spacer-adjuster ( 3 ) is an alternative component to ease the assembly of floor components.
FIG. 4 shows an example of wall panel corner assembly ( 17 ) and crisscross junction assembly ( 19 ) whereby the spacers ( 2 ) are used to create a corner or wall junction assembly in a prefabricated wall panel. FIGS. 5( a )-5( b ) show the assembly of key roof connector for the pyramid roof ( 20 ), whereby the spacers ( 22 , 24 , 26 ) are used as composite key roof connector. Accordingly, the physical building components for key roof connector includes key bracket spacers ( 22 ), key plate spacers ( 24 ) and key ties ( 26 ) as respectively shown in FIGS. 6( a )-6( d ) .
It will be appreciated that the length of the spacer should not be less then 0.1 m (100 mm) with minimum thickness of at least 0.001 m (1 mm) to make negligible slit for the conduit of services to run in between and also to allow flexible rotation and tolerance for wall panels and roof connection. For spacers interval based on the span, it requires minimum of two spacers for span of 1.8 m (1800 mm) centre to centre of the two spacers. Spacers or anchorage dowels are used to anchor the grid type modular spacer floor joist, wall panel and key roof connector. It will also be appreciated that the spacer can be used to fill up the residual length left over by modular wall panel due to dimensional variation of the functional space. In addition, the spacer also enables to attain a required cross section for structural stability in vertical and horizontal physical building components such as floor joist, wall panel, roof like truss formation, etc. Said spacer added engineering advantage to optimise the use of heavy cross section of building material used in prefabricated building construction.
The spacer can also served as a modular or pre-cut physical building component which can be used as a development length or a connector for making long span of building components such as beam, joist or rafter. Said spacer enables to modularise the physical building components as an assembly parts for easy handling and mobilisation. Preferably, various shapes of the spacer such as rectangle, square, triangular or polygon wherein whose profile can be hollowed, extruded or solid and can be used in modular wall panel of predetermined size, preferably of 1.8 m×2.7 m (1800 mm×2700 mm) to form “flexi-shape” of angular or radiated wall. Accordingly, the spacer can be served as an interlocking jigsaw piece ( 25 ) in method of playing with the modular physical building components to knit the armature of sub- and super-structure of prefabricated building structures. The spacer may also tend to act as a shock absorber for any structural mechanisms of the building such as impact load, lateral movement or floor vibration of the building structure. The spacer used in modular wall panel creates slit between two sectional elements while joining at corner or crisscross junction of the wall panel that allow conduit of services to be accommodated thereof.
By the implementation of spacer system, it enables to eliminate complex conventional joints and thus improves the efficiency and precision in constructability. The spacer can be in multi dimensional shape (e.g. triangle, polygon, rectangular and square) to form an angular and polygonal wall panel. Therefore, the degree of flexibility in form of the industrialised building system is increased. The spacer system also develop principle for flexible assembly of roof, such as pyramid roof, mansard roof (double slope) and cone roof by using the composite key roof connector to hold the main rafters and it also can form longer span truss. Moreover, the spacer system for roof principle in the composite key roof connector can easily form a two-tier roofing and cupola on top for admitting light.
To make crisscross junction, radiated walls and angular wall, various shapes of spacers and interlocking spacer can be placed in any angular degree to sides of wall panel. Accordingly, this spacer system helps to provide assembly of the wall panel that obtains appropriate right angle clear corner for mounting any type of cladding. In addition, composite key roof connector which includes of modular hip rafter ( 21 ), key bracket spacers ( 22 ), key plate spacers ( 24 ) are held with four vertical key ties ( 26 ) to keep the pyramid roof ( 20 ) in intact.
It will be appreciated that, the architectonic spacer building system provides modular assembly system that allows flexibility in design form and flexibility in the assembly of physical building components using pre-cut materials. Architectonic spacer building system supports a design assembly for physical building components in a modular industrialised building system. Accordingly, spacer is a key physical building component for assembly system to integrate the various physical building components in prefabrication and on-site installation, which is termed as architectonic. The architectonic is defined as a blend of organised structure and form in which physical building component are knitted by spacer. The knitting design assemble is the key invention for various physical building component such as grid modular joist, slit wall panel and composite key roof connector.
It will also be appreciated that the architectonic spacer building system is complete pre made assembly of flexible design integrated industrialised building system. In this design assembly system, spacer used as key accessories for various physical building components such as anchorage dowel for floor joist, development length-connector for long span beams, corner and crisscross junction wall panel, unique roof assembly system using long span truss, pyramid roof and their derivatives. The spacer-designed assembly system has not used any complex conventional joints for the assembly and disassembly. The use of spacer system optimises utilisation of materials (such as lumber was reduced by 25%) as compared to conventional prefabrication method such as post and beam. This spacer system lightens the weight of the building. It also claims that in the super structure, one type of cross sectional building material can be used all over, and it achieves required cross section by spacer for the structural stability.
While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation and various changes may be made without departing from the scope of the invention. | The architectonic spacer building system is a simplified prefabrication assembly using industrialized building system concept. The architectonic spacer building system for skeleton construction includes a spacer ( 2, 4, 6, 8, 10 ) having a predetermined shape for use in constructing modular form of building components, including a modular floor joist assembly ( 18 ), corner and crisscross junctions assembly ( 17, 19 ). The spacer acts as an anchored dowel connector ( 2, 10 ), composite key roof connector ( 22, 24, 26 ) and/or a bracing ( 2, 4, 6, 8 ) of adjoining wall panel ( 12 ). | 4 |
This is a continuation-in-part of U.S. application Ser. No. 08/876,143 filed Jun. 13, 1997, now U.S. Pat. No. 5,806,204 the disclosure of which is incorporated herein.
FIELD OF THE INVENTION
This invention relates to a material dryer, and in particular to a dryer incorporating a condenser within a vacuum sealed chamber for drawing moisture at moderate temperatures.
BACKGROUND OF THE INVENTION
There is a large variety of materials that require a low moisture content for usage, such as clothing. Clothing can be reused indefinitely if properly washed and dried. For this reason, this application will illustrate its usage as a clothes dryer, however, it will be obvious to one of ordinary skill in the art that the instant invention can be used for drying any type of material. The scope of the invention is defined by the claims appended hereto.
A clothes dryer is a modern material dryer used in conjunction with a washing machine which allows a consumer to quickly launder clothing. The conventional clothes dryer employs a rotating chamber which receives damp clothing directly after the wash cycle. Air is drawn into the rotating chamber at atmospheric pressure past a heating element. The heated air is used for drawing moisture from the clothes and the moisture laden air is continually exhausted from the clothes dryer.
The conventional material dryer expends a large amount of energy as the air drawn into the dryer must be heated. The amount of air drawn into the chamber and amount of energy expended during the process is further dependant upon the condition of the air being drawn into the dryer and amount of clothes to be dried. This process is not efficient due to the amount of thermal energy required to heat the air for a drying cycle which may take upwards of an hour to complete. In addition, if a clothes dryer is placed inside a home, the process may cause additional energy loss as the air is drawn from inside the home and expelled outside.
Should the air being drawn have been previously cooled, such as in an air-conditioned home, the cooled air must be heated for the dryer while new air drawn into the home must be cooled. If the home was heated, the conventional dryer again draws treated air requiring the home to replace the air. In this example the heater of the home must operate to replace the air expelled by the dryer.
Should a clothes dryer be placed outside the home, typical of many southern homes, operation of the clothes dryer is affected by the amount of moisture in the air. A high amount of moisture will require the clothes dryer to operate for a longer period of time in order to complete a drying cycle. In addition, most clothes dryers operate on a timing cycle making it impossible to predict an accurate time to discontinue the heating process due to the various conditions of air make-up. Depending upon the weight of the clothes and moisture content therein as well as the type of air being drawn into the clothes dryer, the drying cycle may take upwards of an hour to complete.
It is generally known that the evaporation temperature of a liquid decreases as the pressure of the surrounding air decreases. Thus, water can be drawn from a material at lower temperatures in a near vacuum environment thereby expending less energy if a lower temperature can be utilized. As a result, a number of prior art devices are directed to the modification of clothes dryers which have been developed to incorporate a vacuum or vacuum like chamber. However, these devices lose efficiency in that they constantly pump air into a chamber for purposes of discharging a volume of air and water vapor out of the device by use of a vacuum pump. Such devices require additional power as the incoming air must be circulated and in most cases heated.
For instance, U.S. Pat. No. 3,425,136 discloses a clothes dryer having an interior drum heater and vertical air ducts wherein the device continuously draws air and water vapor from inside a chamber by use of a vacuum pump. Similarly, U.S. Pat. No. 4,041,614 discloses a device which passes air and water vapor through an exit duct to the exterior of a cabinet. U.S. Pat. No. 4,257,173 discloses a "no heat" clothes dryer which simply incorporates a vacuum source coupled to an exhaust port.
U.S. Pat. No. 4,305,211 discloses a clothes drying chamber whereby air and moisture particles from within the chamber are discharged by creation of a suction on the chamber. U.S. Pat. No. 4,615,125 discloses yet another vacuum chamber with a perforated rotatable drum and vacuum pump which draws air and water vapor from the vacuum chamber and contained drum.
U.S. Pat. No. 5,131,169 discloses a clothes dryer with a drum enclosed in a shell having a compressor to remove air and water vapor from the shell. A cyclic operation of pumping heated air into the shell and removing saturated air is employed. U.S. Pat. No. 5,430,956 discloses a clothes drying device employing a turbo engine for drawing air from a drying room and condensing the liquid thereby reducing the volume of air produced by the drying process. U.S. Pat. No. 5,459,945 discloses a vacuum assisted system for drying clothes which includes an evaporation chamber which is located inside a condensation chamber. In this manner the device extracts water from the evaporation chamber by use of a condensation chamber to condense extracted vapor on the outer surface of the evaporation chamber. While the condenser is used, air is continually circulating out of the vacuum chamber by use of the vacuum pump.
Thus what is lacking in the art is a material drying device that eliminates the constant draw of air into the device, lowers the drying temperature, eliminates a constant evacuation by a vacuum pump, and decreases the amount of time to perform a drying cycle thereby reducing energy and operating costs.
SUMMARY OF THE INVENTION
The present invention teaches an energy efficient material drying method and device. The material dryer of the present invention employs a sealed chamber that allows a near vacuum to be drawn on material, such as clothing, placed within the chamber. Water in the form of vapor is drawn from the material placed within the device by use of a condenser placed within the chamber. The condenser operates to condense the water vapor evaporated from the material. The material is heated to increase the rate of evaporation and to provide the required heat of vaporization. Because the boiling temperature of water decreases as the pressure in the chamber decreases, evaporation can be maximized while maintaining a safe temperature of the material being dried. The material is placed in contact with the heating elements, such as heated surfaces located above and below the material. Movement of the water vapor from the heated material to the condenser Can be enhanced by the use of a fan or similar device if the condenser cannot be located close to the material. The condensed water can be stored within the chamber until the drying cycle is complete or can be purged during the cycle if desired. The operation of the dryer can be controlled by a timer or by sensors which monitor the amount of moisture left in the material, permitting not only full dry operation but also damp dry suitable for operations such as ironing and pressing for material such as clothing.
In one embodiment, a conveyor belt or paddle assembly allows for movement of the material and a circulation fan operates to enhance operation of the condenser. Condensed water is stored within the chamber until a drying cycle is complete, and excess water can be purged during the cycle if necessary. In operation, the interior environment of the material dryer is evacuated of air by use of a vacuum pump to a point which causes the evaporating temperature of water contained within the material to be lower than that at atmospheric pressure and at a safe level for the material. As a result, liquid evaporates into the chamber in the form of water vapor. The water vapor is circulated past the condenser where it re-condenses on the cold surface back into liquid form. The liquid drains off and flows to a holding area where it can be purged before, during, or after the drying cycle.
The inner surface of the chamber is smooth allowing ease of movement of material while allowing for maximum contact with the sides of the chamber. The outer surface of the chamber can be heated by use of coolant coils that operate from the compressor. In this manner excess heat generated by the operating system can be returned to the chamber. A conveyor on the inside of the dryer rotates around a central axis for purposes of moving the material thereby providing uniform drying. Alternatively a paddle may also be used and drive a circulation fan for air circulation.
The heat of vaporization needed for evaporation to occur is supplied by heated surfaces placed in thermal contact with the material. The surfaces are heated from the hot side of an air-conditioner compressor either directly by the freon itself or indirectly by water heated by the freon in a heat exchanger. Similarly, the condenser surfaces are cooled from the cold side of the air-conditioner compressor (after the freon has passed through the expansion valve) either directly by the freon itself or indirectly by water cooled by the freon in a heat exchanger. The efficiency of the air-conditioning cycle used to provide simultaneously the heat needed for vaporization and the cold needed for condensation provides a great energy saving over other methods and is an important part of the present invention. For the most part, the energy supplied for heat of vaporization is not lost but rather recovered in the condenser and recycled, reducing the overall energy consumption.
In another embodiment, the material dryer employs a plurality of flat drying chambers placed in a stacked arrangement. Each drying chamber is hermetically sealed and operates independently, but uses use common vacuum and water systems. Inside of each chamber are heating and cooling surfaces. A removable drawer fits within the chamber and is used to support the clothing or other material to be dried. The drawer rests on a heated surface with an additional heating surface located above the material to be dried. Preferably this upper material is flexible for use in pressing against the material to increase heat transfer and efficiency.
Monitoring of the material dryer is performed by use of conductivity sensors to measure the moisture content of the material being dried. Temperature probes are used to measure various temperatures and pressure sensors are used to measure pressure inside the chamber. The parameters are preset and allow for operation of the heating/cooling compressor. Activation of the compressor will cause heat to be built up and be distributed through the hot coils surrounding the dryer bin or, alternatively, heating elements not associated with the compressor placed around the drying bin may be activated. In any event the increase of heat speeds up the evaporation of liquid from the material to be dried. The newly released water vapor will thereby condense on the condenser coils and be routed to a liquid collection tank. If the liquid collection tank is filled, the tank may be purged either before, during, or after the drying operation. Sensors can also be used to report the moisture content which is indicative of the amount of drying that has occurred allowing the consumer to remove material, such as clothing to be pressed, before complete drying if preferred.
It is noted that liquid in the collection tank is relatively cool due to its inner action with the cold condenser coil. As a result, a set of cooling coils may be routed from the vacuum pump and through the collection tank so as to provide cooling action for the vacuum pump without the system consuming more energy. The cooling action extends the life of the vacuum pump and increases the overall efficiency of the system.
An objective of the present invention is to provide a material dryer based upon the drawing of a partial vacuum on a sealed chamber with a condensate coil placed within the chamber for use in drawing moisture from clothing placed within the chamber.
Another objective of the present invention is to provide a material dryer that is shaped in the form of a drum that may provide a tumble style drying.
Another objective of the present invention is to provide a material dryer that is shaped in the form of one or more drawers that may provide a press style drying.
Another objective of the present invention is to provide a material dryer that eliminates the need for an in-flow of air.
An advantage of the present invention is to provide a material dryer capable of speeding the drying process by approximately fifty percent while using approximately fifty percent less energy over conventional drying devices.
Other objectives and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow schematic of the instant invention;
FIG. 2 is a cross sectional side view of the instant invention;
FIG. 3 is a cross sectional end view of FIG. 2;
FIG. 4 is a cross sectional pictorial side view of a conveyor belt transport;
FIG. 5 is a cross sectional pictorial side view of a second embodiment directed to a plurality of drawers;
FIG. 6 is a cross sectional side view of a drawer assembly; and
FIG. 7 is a partial end view of FIG. 6.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Although the invention will be described, in terms of a specific embodiment, it will be readily apparent to those skilled in this art that various modifications, rearrangements and substitutions can be made without departing from the spirit of the invention. The scope of the invention is defined by-the claims appended hereto.
Referring to FIG. 1, set forth is a simplified flow schematic for the material dryer device of the instant invention. The material dryer includes a housing 10 having a cylindrically shaped chamber 12 mounted horizontally within the housing 10. The chamber 12 is hermetically sealed defining an interior 14 and an exterior 16. The interior 14 is fluidly coupled to a vacuum pump 18 capable of a drawdown vacuum of approximately 28 inches Hg. The vacuum pump 18 operates initially to withdraw air from the chamber through exhaust check valve 19 for maintaining a low pressure environment during the drying cycle with minimum pump operation. In the preferred embodiment, the air is drawn through an internal collection tank 31 through check valve 19 and delivered to a second collection tank 30 for holding and eventual discharge to drain. The second collection tank 30 may allow an overflow to drain, or include a solenoid 32 for purging the collected water to drain 34. The second collection tank 30 providing a ready source of fluid for creation of a water seal for operation of vacuum pump 18.
The interior 14 of the chamber 12 is accessible through a door 20 hingedly coupled to one end of the housing 10 and maintaining a pressure seal to the chamber 12 when closed. A paddle assembly 22, extending substantially along the longitudinal length of the chamber 12, is used to rotate the positioning of clothes placed within the chamber. The paddle assures the clothing contacts the inner surface of the chamber in such a way as to enhance heat transfer through the sidewall of the chamber which is heated along the exterior surface 16 of the chamber.
The chamber may be heated by an electric coil, utilize hot water preheater lines or the hot fluid line 24 as provided by a compressor system. The pressurized fluid is directed through an expansion valve before being directed through a condensate coil 28. The condensate coil 28 condenses moisture from clothing placed within the chamber with the condensed moisture collected in an internal collection tank 31. The condensate is held until the drying cycle is complete, or if full during the cycle, purged by vacuum pump 18 through check valve 19 to collection tank 30. A set of cooling coils 36 may be routed from the condenser 28 and through the collection tank so as to provide cooling action for the vacuum pump 18 without the system consuming more energy. The condensate in the collection tank is relatively cool due to its inner action with the cold condenser coil 28 and will also provide cooling action. The cooling action extends the life of the vacuum pump and increases the overall efficiency of the system.
Sensors 38 are available for determining the relative humidity within the chamber, pressure of drying chamber and temperature for operation of the compressor cycle and temperature control providing operation for only the time needed to complete a drying cycle.
In operation, wet clothing is placed into the chamber 12 through door 20 wherein the vacuum pump 18 draws down the environment within the chamber 12 in about one minute. The compressor 26 then becomes operational in a format similar to a conventional air conditioner with the condensate coils 28 placed within the chamber 12. The compressor pressurizes freon or the like refrigerant material to approximately 265 psi at a temperature of about 220 F. Instead of being used directly, the high pressure liquid from the compressor may be passed through a hot water preheating tank. The preheating tank water may then be used to heat the chamber exterior. The pressurized fluid is drawn through an expansion valve before placement through condensate coils 28. The condensate coils 28 draw the moisture out of the clothes wherein the condensate liquid drains into the collection tank 31. In this manner, 30 pounds of water can be evaporated in approximately 30 minutes, the system utilizing between 30,000 and 60,000 BTU's per hour. Sensors 38 may be used to monitor the time of operation or automatically determine the length of operation by determining moisture content, pressure and temperature of the chamber.
Referring now to FIGS. 2 and 3, the material dryer device of the instant invention consists of a housing 10 sized to support the operating components of the system including a cylindrically shaped chamber 12 mounted horizontally within the housing 10. The chamber 12 is hermetically sealed defining an interior 14 coated with teflon or the like non-stick coating material and an exterior 16. A rear cage end plate 50 is positioned at the back of the chamber 12 for positioning of clothing placed within the chamber. The chamber includes pusher bars or paddles 22 (shown in FIG. 1) for movement of the clothing around the chamber. The paddles 22 are coupled to a drive shaft support structure 52 held by drive shaft 54. The drive shaft 54 is rotated by a timing belt and pulley assembly having pulleys 58 coupled together by belt 60. The lower of pulley 56 and 58 is rotated by drive motor 62. The paddles 22 assure clothing contact with the inner surface 14 of the chamber 12 allowing the clothing to enhance heat transfer through the sidewall of the chamber.
A centrifugal fan 64 allows for circulation of water vapor through the chamber and past condensate coils 28. The fan 64 is driven by a fan motor 66 supported by back plate 70. Alternatively the fan 64 can be driven by the paddle motor 62 by use of an additional pulley or modification of the pulley into a fan shape. The condensate coils are enclosed in a shroud 72 causing direction flow of the circulation air past the coils 28.
The interior 14 of the chamber 12 is accessible through a door 20 hingedly coupled to one end of the housing 10 along a front door end plate 74 and maintaining a pressure seal to the chamber 12 when closed. The door includes a handle 76 for ease of access. The front of the chamber includes a front cage end plate 78 which is operatively associated with the inner surface of the door 20 for securely positioning the clothes within the chamber.
The interior of the chamber is fluidly coupled to a vacuum pump 18 capable of a drawdown vacuum of approximately 28 inches Hg. The vacuum pump is water sealed with a water inlet 80 drawn through strainer 82 and controlled by inlet solenoid 84. The vacuum pump 18 operates initially to withdraw air from the chamber through exhaust check valve 19 and associated piping 86 for maintaining a low pressure environment during the drying cycle. The vacuum pump exhausts air through the air silencer 87 out of outlet 93. The pump includes a trap 89 to further seal as well as prevent back flow of water discharged to the drain 91.
The chamber may be heated by an electric coil or utilize hot water preheater lines 90 provided by the compressor system 92 wherein the compressor 92 operates at a pressure between 250 and 280 psi. The pressurized fluid is directed through the hot water preheating tank 94 by input pipe 96 through a coiled wrap 98 wherein the input temperature to the compressor at exit pipe 100 is between 220 and 250 F. The heated water is transferred by pump from tank 94 through preheater lines 90 which engage at least a portion of the chamber. The pressurized refrigerant from the compressor 92 is then directed through precooling coils 106 and into expansion valve 108 as it is introduced into the condensate coils 28. Low pressure refrigerant 110 is returned to the compressor motor 92. Condensed moisture is collected along the bottom of the condensate shroud 72 and directed through solenoid valve 112 and into water collector tank 114. The solenoid valve 112 is used to maintain a vacuum in the chamber until the condensate is ready to flow into the water collector tank 114. The water collector tank is purged by a dump valve 118 when the drying cycle is complete, should excess water be present in the collection tank during the drying cycle.
As further illustrated in FIG. 3, the door includes a view area 120 and a solenoid operated latch opener 122 which allows access to the chamber only when the vacuum is removed. The door is mounted along hinge 124 providing a pivotal opening. The chamber heating coil 90 is placed around a portion of the chamber and in particular the area that the wet clothes will contact during rotation. Control panel 126 provides operational control of the system.
FIG. 4 depicts a conveyor belt means 150 depicted along a portion of interior surface 152 of the chamber. In this embodiment, the conveyor belt consists of a continuous flexible belt 154 placed over rollers 156 wherein at least one of the rollers 156 is rotated by an electric motor to cause rotation of the belt. The belt may include paddles 158 to assist is transferring material along a portion of interior surface 152 along directional arrow 160. This embodiment has a particular application for clothing as the belt 154 causes the clothing to maintain a close proximity to the interior surface which, as previously described, allows heat transfer into the clothing to provide heat of vaporization. The entry area 162 may be enlarged to accommodate the type of material circulated wherein paddle 158 provides an enlarged grasp of the material for placement into the entry area 162. The conveyor assembly 150 can be supported by brackets 164 and 166. Bracket 164 may be made adjustable to accommodate various size loads.
Now referring to FIGS. 5-7, set forth is a second embodiment of the invention which employs a plurality of flat drying chambers 211 placed in a stacked arrangement. Each drying chamber 211 is hermetically sealed and operates independently, but uses common vacuum and water systems. Inside of each chamber are heating and cooling surfaces. A removable drawer fits within the chamber and is used to support the clothing or other material to be dried. The drawer rests on a heated surface with an additional heating surface located above the material to be dried. Preferably this upper material is flexible for use in pressing against the material to increase heat transfer and efficiency.
In this embodiment, housing 10 includes multiple drying units of chamber 211, the illustration depicting five drying units stacked in above each other. The chambers operate independently but use common vacuum and water systems. Each chamber 211 is hermetically sealed and connects to the common vacuum system 18. At the start of a cycle, the chamber is drawn down to a vacuum of approximately 28 inches of Hg by the vacuum pump. The vacuum system can then be shut off until needed. If the vacuum pump can handle water, e.g. a liquid-ring pump, the pump can also be used to drain the condensate water.
Inside each chamber 211 are heating surfaces 201 and 203 and condensing surfaces 204. A removable basket 202, drawer, or combination thereof containing the material to be dried is placed over the heating surfaces. In particular, the drawer 202 is inserted though a door, not shown, and placed on the heated surface which consists of a number of aluminum strips 203 through which the hot water is circulated from a hot water tank 94 by use of pump 209. The aluminum strips 203 are mounted on plastic supports 215 which maintain the strips in a fixed position with a small gap 216 between adjacent strips. The gap 216 allows evaporating water vapor to pass from the material being dried through the bottom of the drawer down to the condenser plate 204 mounted at the bottom of the chamber. The condenser plate 204 is made of aluminum strips with integral tubes through which cold water is circulated from a cold water tank 114 by means of water pump 210 through manifold 219.
Additional heating of the material is accomplished by a second heated surface located above the material. It is desirable that this upper surface is made flexible so that it can be pressed down onto the material in the drawer, thereby increasing the heat transfer and efficiency of the surface. In the present embodiment, this upper surface is a tubular blanket 201 constructed of connected neoprene tubes through which hot water is circulated along manifold 218. To ensure efficient thermal contact is made between this tubular blanket 201 and the material to be dried, the upper surface of the drying unit includes a neoprene membrane 200. The membrane 200 is pressed down on the tubular blanket 201 and the material in the drawer 202 as shown by the dotted line 300 in FIG. 6 by action of the atmospheric pressure outside the chamber. This pressure does not harm the unit because it is transmitted through the material, the heated aluminum strips 203, the plastic supports 215, and the cold condenser aluminum strips 204 to the bottom of the unit which is experiencing a balancing upward force from the atmospheric air beneath it. Condensate outlet of the unit is through coupling 220. The drying unit becomes effectively a sandwich in which the material is pressed, maximizing the thermal contact with the heated surfaced above and below.
It is to be understood that while we have illustrated and described certain forms of my invention, it is not to be limited to the specific forms or arrangement of parts herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown in the drawings and described in the specification. | A material drying apparatus having a sealable chamber for receipt of wet material, such as clothing. Material placed into the chamber is dried upon the evacuation of air from the chamber wherein moisture drawn from the material is condensed on a condensate coil placed in the chamber. Heating coils placed around the chamber or beneath a drawer elevate the temperature to enhance condensate operation providing an energy efficient material dryer requiring no make-up air. Drum or thermal blanket enhances temperature elevation. Condensed water is purged after the drying process although provisions provide for an interim purge should excess liquid be drawn from the material. | 3 |
U.S. GOVERNMENT RIGHTS
[0001] The invention was made with U.S. Government support under contract no. N00019-02-C-3003 awarded by the U.S. Navy. The U.S. Government has certain rights in the invention.
BACKGROUND OF THE INVENTION
[0002] (1) Field of the Invention
[0003] The invention relates to turbine engines. More particularly, the invention relates to variable throat turbine engine exhaust nozzles.
[0004] (2) Description of the Related Art
[0005] There is well developed field in turbine engine exhaust nozzles. A number of nozzle configurations involve pairs of relatively hinged flaps: a convergent flap upstream; and a divergent flap downstream. Axisymmetric nozzles may feature a circular array of such flap pairs. Exemplary nozzles are shown in U.S. Pat. Nos. 3,730,436, 5,797,544, and 6,398,129.
SUMMARY OF THE INVENTION
[0006] Accordingly, one aspect of the invention involves a turbine engine nozzle subassembly. A downstream flap is pivotally coupled to an upstream flap for relative rotation about a hinge axis. An actuator linkage is coupled to the downstream flap along a forward half thereof for actuating the upstream and downstream flaps between a number of throat area conditions.
[0007] In various implementations, an external flap may be pivotally coupled to the downstream flap and to an environmental structure. A span between respective coupling locations with the downstream flap and environmental structure may be extensible and contractable responsive to aerodynamic forces. Means may restrict an extensibility range of the external flap. The means may include a secondary link having a first pivotal coupling location to the environmental structure and a second pivotal coupling location to the divergent flap. The second pivotal coupling location may be intermediate coupling location of the downstream flap to the external flap and a coupling location of the actuator linkage to the downstream flap. The secondary link may have a restricted free float range relative to the downstream flap.
[0008] Another aspect of the invention involves a turbine engine nozzle having a number of flap subassemblies coupled to a static structure. The subassemblies each include an upstream flap pivotally coupled to the static structure for relative rotation about an axis essentially fixed relative to the static structure. Each subassembly further includes a downstream flap pivotally coupled to the associated upstream flap for relative rotation about a hinge axis. Means actuate articulation of the upstream and downstream flaps within a range of areas of the throat while minimizing mode change-induced throat area changes at a given design point.
[0009] In various implementations, the subassemblies may be axisymmetrically arranged about an engine centerline. The articulation may be simultaneous for each of the subassemblies. Each of the subassemblies may further include an external flap pivotally coupled to the associated downstream flap.
[0010] Another aspect of the invention involves a means for retrofitting a turbine engine or reengineering a turbine engine configuration which has or has previously had a first nozzle subassembly having a convergent flap, a divergent flap, an external flap and an actuation linkage coupled to the convergent flap. A second subassembly is installed or engineered. The second subassembly has a second convergent flap, a second divergent flap, and a second actuation linkage, optionally sharing one or more components with the actuation linkage of the first nozzle subassembly. The second actuation linkage is coupled to the second divergent flap so as to permit an aerodynamically-induced mode change articulation of the second divergent flap to rotate the second divergent flap about a non-fixed instantaneous center of rotation while simultaneously rotating the second divergent flap relative to the second convergent flap about a non-fixed hinge axis.
[0011] In various implementations, the second subassembly may provide an aerodynamic throat which has a throat area that is less sensitive to changes associated with said mode change articulation than was an area of a throat of the first nozzle subassembly. The method may entail replacing a circumferential array of such first nozzle subassemblies with a circumferential array of such second nozzle subassemblies.
[0012] The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a cutaway longitudinal view of a turbine engine nozzle in a first condition.
[0014] FIG. 2 is a view of the nozzle of FIG. 1 in a second condition.
[0015] FIG. 3 is a view of the nozzle of FIG. 1 in a third condition.
[0016] FIG. 4 is a view of the nozzle of FIG. 1 in a fourth condition.
[0017] Like reference numbers and designations in the various drawings indicate like elements.
DETAILED DESCRIPTION
[0018] FIG. 1 shows a turbine engine nozzle 20 . The exemplary nozzle comprises an axisymmetric circular array of convergent/divergent flap pairs about a nozzle axis or centerline 500 . A given flap pair has a convergent flap 22 upstream/forward extending from an upstream end 23 to a downstream end 24 and a divergent flap 26 downstream/aft extending from an upstream end 27 to a downstream end 28 . The flaps are hinged relative to each other by a hinge mechanism 30 for relative movement about a hinge axis 502 proximate the convergent flap downstream end and divergent flap upstream end. The inboard surface of the divergent flap 26 has a longitudinally convex surface portion 40 near its upstream end for forming an aerodynamic throat (i.e., the location of smallest passageway cross-section) of the nozzle of instantaneous throat radius R T and an essentially longitudinally straight portion 42 extending aft therefrom toward the downstream end for forming an exhaust outlet of instantaneous outlet radius R O . For each convergent/divergent flap pair, the nozzle further includes an external flap 50 , the outboard surface 52 of which forms an exterior contour of the nozzle exposed to external airflow passing around the aircraft fuselage.
[0019] FIG. 1 further shows a nozzle static ring structure 60 for mounting the nozzle to the engine, aircraft fuselage, or other environmental structure. Proximate the upstream end 23 of the convergent flap 22 , a hinge structure pivotally couples the convergent flap to the static ring structure 60 for relative rotation about a fixed transverse axis 503 . A synchronization ring 62 is mounted between inboard and outboard aft portions 64 and 66 of the static ring structure and may be longitudinally reciprocated by actuators (e.g., pneumatic or hydraulic actuators-not shown). In the condition of FIG. 1 , the synchronization ring is at a forwardmost/upstreammost position. The synchronization ring is coupled to each flap pair by an associated linkage 70 . Each linkage 70 includes a central bell crank 72 pivotally coupled by a hinge mechanism to a bell crank ground point 74 at the trailing edge of the static ring structure inboard portion 64 for relative rotation about a fixed transverse axis 504 . To drive rotation of the bell crank through its range of rotation about the axis 504 , the bell crank is coupled to the synchronization ring by an associated H-link 76 . A forward end of the H-link is pivotally coupled to the synchronization ring by a hinge mechanism for relative rotation about a transverse axis 506 which shifts longitudinally with the synchronization ring. An aft end of the H-link is pivotally coupled to the bell crank by a hinge mechanism for relative rotation about a transverse axis 508 which moves along a circular path segment centered about the axis 504 in response to linear translation of the axis 506 . Thus, as viewed in FIG. 1 , a rearward shift of the synchronization ring produces a clockwise rotation of the bell crank about the axis 504 . Rotation of the bell crank is transferred to articulation of the associated flap pair by an associated pair of transfer links 78 . Forward/upstream ends of each pair of transfer links are pivotally coupled to the bell crank for relative rotation about a transverse axis 510 which also moves along a circular path segment centered about the axis 504 in response to linear translation of the axis 506 . Aft/downstream ends of the transfer links are pivotally coupled to the divergent flap 26 for relative rotation about a transverse axis 512 . As discussed below, in the exemplary embodiment movement of the axis 512 is not entirely dictated by the rotation of the bell crank and associated static ring translation. Rather, it may be influenced by other forces, namely aerodynamic forces arising from relative pressures internal and external to the nozzle. In exemplary embodiments, the axis 512 falls aft of the axis 502 and along a forward half of the span between upstream and downstream ends of the divergent flap. More narrowly, it falls along a forward third, and, in the illustrated embodiment, approximately in between about the first 5% and 15% of such span.
[0020] In the exemplary embodiment, the external flap 50 has a forward end 90 pivotally coupled by a hinge mechanism to the static structure outboard portion 66 for relative rotation about a fixed transverse axis 520 . Proximate its downstream end 92 , the external flap is pivotally coupled by a hinge mechanism to the divergent flap 26 (slightly more forward of its downstream end 28 ) for relative rotation about a transverse axis 522 . The external flap is configured so that the span between the axes 520 and 522 is extensible and contractible such as by having an upstream link 94 telescopically mounted relative to a main body portion 96 of the external flap and coupling the external flap to the static ring structure. The extensibility/contractability may have a limited range. As explained in greater detail below, a further limitation on that range may be desirable. To that end, a secondary link or mode strut 100 is provided having a forward end portion 102 pivotally coupled to the static ring structure for relative rotation about a fixed transverse axis 524 which may be close to the axis 520 . If the axes 520 and 524 are coincident, it may be advantageous to drill one hole through all pivot points for low cost. However, if the width of the external flap 50 is such that the main body portion 96 on either circumferential side of the flap are substantially circumferentially spaced from the mode strut, it may be advantageous to locate the axis 520 relatively closer to the engine centerline than the axis 524 so as to maintain a good mechanical advantage for the mode strut.
[0021] An aft end portion 104 of the mode strut is pivotally coupled to the divergent flap 26 for relative rotation about an axis 526 fixed relative to the mode strut but floating relative to the divergent flap with a restricted range of movement. The exemplary range of movement is provided by the use of a pair of mounting brackets 110 at an intermediate location on the divergent flap, each having a slot 112 accommodating an obround slider 113 on a pivot shaft 114 fixed along the axis 526 relative to the mode strut. The slider and shaft are free to move along the slot between first and second ends 116 and 118 thereof. An exemplary intermediate location is, approximately within the middle third of the divergent flap length and the middle third of the span between axes 512 and 522 .
[0022] In operation, the position of the synchronization ring 62 determines a nominal throat radius R T and associated throat area (i.e., a throttle condition). In a given synchronization ring position, the aerodynamic forces may then determine the mode which is nominally associated with the divergent flap interior surface angle θ. FIG. 1 shows the synchronization ring at the forward extremity of its range of motion, thereby establishing the maximum nominal throat area. FIG. 1 further shows a high mode condition in which the aerodynamic forces place the divergent flap in its maximum θ condition with the slider 113 bottomed against the slot end 116 . Under changed conditions, the force balance across the combination of external flap 50 and divergent flap 26 may produce an alternate θ. For example, FIG. 2 shows a maximum area, minimum θ low mode condition in which the slider 113 is substantially bottomed against the slot end 118 . In an alternate configuration, the operation of the mode strut is reversed (i.e., the slider arrangement is at the strut's connection to the static structure rather than at its connection to the divergent flap).
[0023] During the transition between high and low modes for a given nominal throat area, there will be slight movement of the axes 502 and 512 . The instantaneous center of rotation of the divergent flap occurs along the intersection 530 of a pair of planes respectively defined by axes 503 and 502 on the one hand and 510 and 512 on the other. With this intersection falling at or near the nozzle throat surface, changes in throat area with mode are limited. In an exemplary embodiment, throat area change with mode shift is well under 2% across all nominal throat areas with the maximum change at the minimum throat area condition. It may be advantageous to configure any implementation such that the minimum change in throat area with mode shift occurs at a particularly sensitive point in the flight envelope for a given application (e.g., design points for aerial refueling, landing, and the like). Relative to an alternate situation in which the axis 502 is fixed, this can provide a greater consistency in throat radius during mode transitions at a given nominal throat area. Clearly, the exact location of the instantaneous throat moves slightly along the surface portion 40 which may also entail a slight longitudinal throat position change in addition to the slight throat radius change.
[0024] FIG. 3 shows the synchronization ring 62 shifted to the rearmost extreme of its range of motion to produce a minimum throat area/radius condition. Specifically, FIG. 3 shows this in a high mode condition as discussed above. During the transition of the synchronization ring, there is associated telescoping (contraction as shown) of the external flap. The need to accommodate a sufficient range of telescoping across the throat area range may, as noted above, exceed a desired range of extensibility associated with the mode shift. Thus the mode strut may still operate to restrict a range of movement of the divergent flap and external flap combination. FIG. 4 shows the flap in a low mode minimum throat area/radius condition.
[0025] Advantageously, the actuation linkage and flap geometry is chosen to permit a range of throat area conditions effective to address the desired performance envelope. An exemplary envelope would include a maximum throat radius which is about 150% of a minimum throat radius (e.g., in excess of 140%). Similarly, the mode strut and its mounting are configured to provide a desired mode range. An exemplary mode range involves a minimum θ of between −5° and 5° and a maximum 8 of between 10° and 25°. Such range may advantageously be provided across all throat areas.
[0026] The present nozzle may be engineered as a redesign of an existing nozzle or otherwise engineered for an existing environment (e.g., as a drop-in replacement for an existing nozzle). For example, the illustrated nozzle may be formed as a replacement for a generally similar nozzle but wherein a bell crank is connected to the convergent flap (or the hinge point between the convergent and divergent flaps) rather than to the divergent flaps. The reengineering could preserve the synchronization ring and potentially portions of the linkage including the bell crank. Reengineering also could preserve basic details of the external flap and mode strut, although potentially requiring minor geometry tweaks if the exact ranges of throat area and flap angle are to be maintained.
[0027] One or more embodiments of the present invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. For example, when implemented as a reengineering of an existing nozzle, various details of the existing nozzle may be preserved either by necessity or for convenience. Additionally, the principles may be applied to non-axisymmetric nozzles in addition to axisymmetric nozzles and to vectoring nozzles in addition to non-vectoring nozzles. Accordingly, other embodiments are within the scope of the following claims. | A turbine engine nozzle assembly has an upstream flap and a downstream flap pivotally coupled thereto for relative rotation about a hinge axis. An actuator linkage is coupled to the downstream flap along a forward portion thereof for actuating the upstream flaps and downstream flaps between a number of throat area conditions while permitting mode changes. | 5 |
FIELD OF THE INVENTION
This invention relates to heat exchangers of the type having a header plate supporting the open ends of a plurality of tubes and a tank secured to the header plate; and more specifically, to an improved connection between the tank and the header plate.
BACKGROUND OF THE INVENTION
Prior art of possible relevance includes the following U.S. Letters Pat. No.: 3,894,580 issued July 15, 1975 to Chartet; U.S. Pat. No. 4,324,028 issued Apr. 13, 1982 to Severson; U.S. Pat. No. 4,324,290 issued Apr. 13, 1982 to Moranne; U.S. Pat. No. 4,331,201 issued May 25, 1982 to Hesse; and U.S. Pat. No. 4,448,321 issued May 15, 1984 to Hanlet. Of the foregoing, the Hesse and Moranne patents have the most relevance.
The effort by the automotive industry to reduce the weight of vehicles to thereby improve mileage is seen in increasing use of non-metallic materials is various parts of vehicles. Heat exchangers, more commonly termed radiators, are no exception. While metal materials are still employed in the cores of such heat exchangers because of their greater thermal conductivity over other materials, other heat exchanger components that do not require good thermal conductivity are being made of plastic. A primary example is the so-called tanks which are fitted to the heat exchanger core most typically by securement to the header plates which define the ends of such cores.
Because the joint between the header plate and the tank is one of dissimilar materials, prior techniques of brazing or soldering the joints can no longer be employed. In lieu thereof, to effect the necessary seal, a gasket is disposed between the tank and the header plate and any of a variety of means are employed to hold the components in assembled relation with the gasket under compression to assure a seal at the operating pressure for which the heat exchanger was designed.
It is, of course, necessary that the means employed to effect the connection be strong and long lived to prevent leakage. At the same time, it is desirable that the means be such that disassembly of the component parts can be effected when required for serving. It is also desirable that the means utilized lend themselves to use in mass production to minimize cost.
Attempts to achieve these objects have resulted in proposals wherein a header plate is provided with a peripheral groove in which the gasket to be compressed may be disposed. The tank is provided with a peripheral flange sized to be wholly received in the groove and adapted to compress the gasket therein. The outer wall of the groove is then deformed in part to overlie the flange and the tank and hold the same in a position compressing the gasket. This approach is exemplified by the above identified Morrane and Hesse patents.
Unfortunately, because this approach involves deformation of a metal wall which necessarily may be sufficiently thin so as to be easily deformed, the same may not always be as strong as might be desired. Pressure within the system during operation will act against the deformed material and tend to deform it back toward the original configuration. When such occurs, the compressive forces exerted on the gasket are lessened and leakage may occur.
Moreover, these constructions require a relatively wide groove or recess to receive the entirety of the width of the flange. This results in a relatively long moment arm between the point of deformation of the outer groove wall over the flange and the point whereat the inner groove wall meets the header plate which increases the force concentration at the latter location.
Furthermore, the sealing methods employed in such constructions are totally dependent upon the degree of compressive force maintained on the seal by the tank-header plate connection. Consequently, lessening of this force lowers the efficiency of the seal.
In addition, because these constructions require deformation of the flange after the tank is assembled thereto, the assembly process is undesirably expensive in view of the need for fixtures and specialized tooling to provide deformation of the flange.
The present invention is directed to overcoming one or more of the above problems.
SUMMARY OF THE INVENTION
It is a principal object of the invention to provide a new and improved header-tank connection. More specifically, it is an object of the invention to provide a connection wherein stress concentrations are minimized, wherein sealing is not totally dependent upon mechanical connections, and wherein the process of assembling the tank to the header plate can be considerably simplified.
According to the invention, there is provided a metal header plate supporting the open ends of a plurality of tubes. A groove extends around the periphery of the header plate and has a bottom wall surrounded by an upstanding wall which in turn has spaced apertures therein. A compressible gasket is located in the groove and a plastic tank having an opening surrounded by a rim is employed. The rim has a series of outwardly projecting lugs and is otherwise sized and configured to be fitted within the groove with the lugs extending through and being captured in aligned ones of the apertures with the tank compressing the gasket so that the gasket effects a seal between the tank and the header plate.
In a preferred embodiment, the sides of the lugs facing the walls have cam surfaces for camming the upstanding wall away from the header plate to allow the rim to enter the groove and the lugs to enter the apertures.
In a highly preferred embodiment, the sides of the lugs opposite the bottom wall have retaining formations for retaining parts of the upstanding walls which define boundaries of the apertures. The retaining formations are in interference fit with such sides of the lugs.
According to the invention, the retaining formations may be slightly concave surfaces.
In its best mode, the invention contemplates that the rim have a tapered surface inwardly of the tank which is at least partially within the groove. The gasket is in sealing engagement with such tapered surface and is exposed to the interior of the tank so as to be subjected to pressurized fluid therein.
In a modified embodiment of the invention, the cam surface may be located on the upper edge of the upstanding wall rather than on the side of the lug facing the bottom of the groove.
Other objects and advantages will become apparent from the following specification taken in connection with the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a somewhat fragmentary, perspective view of a tank and header plate assembly made according to the invention;
FIG. 2 is an enlarged, vertical section of one embodiment of a connection made according to the invention;
FIG. 3 is a view similar to FIG. 2 but showing another embodiment of the invention;
FIG. 4 is a somewhat schematic view of an early stage in the process of assemblying a tank to a header plate according to the invention;
FIG. 5 is a view similar to FIG. 4 but at an intermediate stage in the assembly process; and
FIG. 6 is a view similar to FIGS. 4 and 5 but showing the final stage of the process.
DESCRIPTION OF THE PREFERRED EMBODIMENT
One exemplary embodiment of the invention is illustrated in FIGS. 1 and 2 of the drawings and is seen to include a radiator tank 10, typically formed of plastic and a header plate 12 formed of metal. Conventionally, the header plate 12 receives the open ends 14 of a plurality of tubes 16 (only one of which is shown). The tubes 16 will typically be of brass, copper or aluminum or other metal of good thermal conductivity.
The tank 10 has an opening 18 which is surrounded by a rim 22. One or more coolant ports 26 are in fluid communication with the interior of the tank 10. As best seen in FIG. 2, the header plate 12 includes a peripheral groove generally designated 28. The groove is defined by an upstanding outer wall 29, a bottom wall 30 and an inner wall 31 which merges with the main body of the header plate 12 by means of a round. In other words, according to the invention, all components of the groove 28 are integral with the header plate 12 and are typically formed therein by a stamping operation.
As can be seen in FIGS. 1 and 2, the outer wall 29 is provided with a plurality of apertures 32. As can be seen from FIGS. 1 and 2, for the orientation of the assembly as shown therein, the upper boundry of each aperture 32 is generally defined by a continuous portion 34 of the outer wall 29.
Extending outwardly from the rim 22 are a plurality of lugs 36 formed integrally and immovably on the tank 10 as by a conventional molding process. The lugs 36 are spaced corresponding to the spacing between the apertures 32 and are aligned therewith. The same are such as to extend through the corresponding apertures 32 as seen in FIGS. 1 and 2 whereby the tank 10 is captured within the groove 28 and assembled to the header plate 12.
In the embodiment illustrated in FIGS. 1, 2 and 4-6, to facilitate assembly of the tank 10 to the header plate 12, the side 38 of each lug 36 is rounded so as to essentially define a cam surface. As can be seen in FIGS. 4-6, when, during the assembly process, the tank 10 is moved downwardly with the rim 22 aligned with the groove 28, the cam surface 38 on each lug will engage the corresponding continuous portion 34 of the upstanding wall 30 for the corresponding aperture 32. This relationship is illustrated in FIG. 4. Continued downward movement of the tank 10 will result in the tank walls deflecting somewhat to the left as viewed in FIG. 5 while the outer wall 29 will deflect to the right by reason of the camming action. This is illustrated in FIG. 5.
When the tank 10 has fully entered the groove 28 as illustrated in FIG. 6, the upper side 40 of each of the lugs 36 will be just even with or slightly below the upper edge of the corresponding aperture 32 and the inherent resilience of the components will allow the tank 10 to return to its original configuration as will the outer wall 29 bringing the continuous portion 34 into overlying relation with the upper sides 40 of the lugs 36. This essentially establishes an interference fit which may be enhanced by the provision of retaining formations in the form of noses 42 on the outermost part of the upper side 40 of the lugs 36. The retaining noses 42 serve to define concave surfaces 44 on each of the lugs 36 on the upper sides 40 thereof.
In some instances, where the material of which the outer wall 29 is made is of relatively low resilience or is sufficiently thin so as to easily deform, external means may be employed to return the outer wall 29 to the position illustrated in FIGS. 1, 2 and 6.
In the usual case, the header plate 12 will be generally rectangular as is apparent from FIG. 1 and as a result, corners 46 will be present in all parts of the header plate 12 including the upstanding wall 30. Where lugs 36 are located at the corners 46 of the tank 10, the outer wall 29 will be slotted as at 48 at such corners so as to allow each of the individual portions of the outer wall 29 to deflect without being resisted by hoop strength.
A modified embodiment is illustrated in FIG. 3 and in this case, the cam surface 50 on each lug 36 is less rounded than the cam surface 38. To provide the requisite camming action, the upper edge 52 of the outer wall 29 may be curved away from the tank 10 to thereby define a cam surface on the upper edge 52 of the outer wall 29. In this embodiment, the cam surfaces 50 and 52 coact to provide the necessary camming action depicted in FIGS. 4-6 respectively. In some instances, if the cam surface defined by the curved upper edge 52 is sufficiently generous, the cam surface 50 may be omitted entirely.
To provide sealing, an elastomeric gasket 54 is disposed in the groove 28 and the inner side of the rim 22 provided with a flared or tapered surface 56. The flared surface 56 not only prevents interference between the interior wall of the tank 10 with the side wall 34 or round 36 during the assembly process, but serves to effect a better seal than obtained in prior art constructions wherein the seal is compressed by the underside of a flange solely against a bottom of a groove. In particular, because of the tapered or flared surface 56, the gasket compressingly abuts the inner side of the side wall 31, the inner portion of the bottom wall 32 and the flared surface 56; and is so located as to be exposed to pressurized fluid within the tank 10. As can be appreciated from the drawings, such fluid under pressure will tend to force the gasket downwardly within the groove 28 but since the gasket 54 is in abutment with the bottom wall 30 of the groove 28, it cannot move downwardly. As a result, such pressure tends to cause the gasket 54 to bear with increased force proportional to the pressure of the fluid, against both the inner side wall 31 and the flared surface 40 as well as the bottom wall 30 to increase and enhance the sealing engagement between the components.
From the foregoing, it will be appreciated that a tank-header assembly connection made according to the invention provides improved strength over prior art connections since permanent deformation of outer wall 29 is not required to restrain the lugs 36 and maintain the assembly in assembled relation. Furthermore, enhanced sealing is obtained as mentioned immediately preceding and considerable assembly process economies are garnered as a consequence of avoiding any need for special fixtures and forming processing required to deform groove walls after the components are in assembled relation. | A tank-header connection including a groove extending about the periphery of a header plate and having a bottom wall surrounded by an upstanding wall with spaced apertures therein. A compressible gasket is located in the groove and a plastic tank having an opening surrounded by a rim is provided. The rim has a series of outwardly projecting lugs and is otherwise sized and configured to fit within the groove with the lugs extending through and being captured in aligned ones of the apertures. | 5 |
BACKGROUND
[0001] 1. Technical Field
[0002] The present disclosure relates generally to completing and producing oil and gas wells, and specifically to a novel method and system for deploying a downhole screen.
[0003] 2. Background Art
[0004] In the process of completing on oil or gas well, a tubular is run into the hole through which produced fluids will be communicated to the surface. Typically, this tubular includes a screen assembly that filters gravel, sand, and other particulate matter from entering the tubular.
[0005] When running this completion string into the well, the well may contain drilling mud, brine, or other fluid. Further, this fluid may be laden with rock, cutting chips, sand, and the like. Fluid tends to enter the empty tubular through the screen assembly, and such particulate can substantially plug the screen assembly by the time it has been lowered into the desired position.
[0006] Accordingly, it is desirable to provide a screen assembly that resists plugging during run-in-hole operations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The invention is described in detail hereinafter on the basis of the embodiments represented in the accompanying figures, in which:
[0008] FIG. 1 is a longitudinal cross section of a downhole screen assembly according to a present embodiment, showing a tubular member with apertures formed through the wall, a sleeve slideably disposed about the tubular member with openings that correspond to the apertures, and an actuator that remotely moves the sleeve with respect to the tubular member;
[0009] FIG. 2 is an enlarged longitudinal cross section of the downhole screen of FIG. 1 , showing detail of the actuator as actuation of the screen is first begun;
[0010] FIG. 3 is an enlarged longitudinal cross section of the actuator of FIG. 2 , showing the body lock ring having been displaced and further engaged the sleeve under the influence of a pressurized interior; and
[0011] FIG. 4 is a perspective view of the body lock ring of the actuator of FIG. 3 , showing an interior wall surface having ratchet teeth for unidirectional movement against ratcheting teeth of the slideable sleeve of FIG. 3 ;
[0012] FIG. 5 is an enlarged longitudinal cross section of the actuator of FIG. 3 , showing the sleeve moved to the open position after remote actuation.
DETAILED DESCRIPTION
[0013] FIG. 1 is a longitudinal cross section of a downhole screen assembly 10 for use within a well 8 according to a present embodiment. Screen assembly 10 includes a tubular member 12 , which may be cylindrical in shape. However, other tubing shapes, such as square tubing, may be used as appropriate. Tubular member 12 includes a plurality of apertures 14 for the intake of well fluids from an exterior or annular region 16 to the interior 18 during well production. Tubular member 12 may have a closed lower end 20 for terminating the bottom of the tubing string in the well. If multiple screen assemblies 10 are provided in a tubing string, only the lowest screen assembly would have a closed lower end.
[0014] According to an embodiment, screen assembly 10 includes a sleeve 30 having the same shape type as tubular member 12 , which preferably abuts but can be moved relative to tubular member 12 . Sleeve 30 is shown disposed about the exterior wall surface of tubular member 12 , but in an alternative arrangement (not illustrated), the tubular member could be disposed about the sleeve. Sleeve 30 includes a plurality of openings 32 , which correspond to apertures 14 . Sleeve 30 may have a closed lower end (not illustrated) if it is the last device in tubing string.
[0015] FIG. 1 shows sleeve 30 in a shut position where openings 32 are offset from apertures 14 to prevent fluid flow therebetween. In the embodiment illustrated, sleeve 30 can slide longitudinally along axis 24 with respect to tubular member 12 , and openings 32 are radially aligned with longitudinally offset from apertures 14 . However, in other embodiments (not illustrated), openings 32 may be radially offset instead of or in addition to longitudinally offset, and sleeve 30 is capable of rotating with respect to tubular member 12 .
[0016] Screen assembly includes a mesh, screen or filter 40 disposed so as to prevent sand, sediment, gravel, and other particulate matter of predetermined size from entering into the interior 18 of tubular member 12 . FIG. 1 shows mesh 40 to be disposed about the exterior of sleeve 30 , but meshing 40 can be disposed within tubular member 12 , within apertures 14 , between tubular member and screen 30 , within openings 32 , or any combination of the above as would be known to one of ordinary skill in the art.
[0017] A actuator 50 is operatively connected between tubular member 12 and sleeve 30 which provides for remote, interventionless actuation from the surface of screen assembly 10 to move screen 30 with respect to tubular member 12 so that openings 32 align with aperture 14 to allow fluid flow into the interior 18 . In this manner, downhole screen assembly 10 can be run into a well 8 with sleeve 30 in a shut position, thereby preventing fluid flow into the screen assembly and minimizing the tendency for particulate matter to plug mesh 40 . Once screen assembly 10 has been lowered to the desired position within well 8 , sleeve 30 may be actuated to an open position to allow well production simply by pressurizing interior 18 , as is described below with respect to FIGS. 2-5 .
[0018] Although actuator 50 is shown in FIG. 1 as being located at the top of sleeve 30 , it may also be located the bottom or somewhere in the middle of sleeve 30 .
[0019] FIG. 2 is an enlarged longitudinal cross section of the downhole screen of FIG. 1 , showing detail of actuator 50 . In a particular embodiment, actuator 50 includes a housing 52 with an inner cylindrical chamber 51 , through which tubular member 12 passes and in which a portion 31 of sleeve 30 is located. Sleeve portion 31 includes ratchet teeth 52 . A body lock ring 54 is provided within housing 52 , and it also includes ratchet teeth 56 that engage ratchet teeth 52 so as to allow axial movement of the body lock ring 54 with respect to sleeve portion 31 in one direction only as described in further detail below.
[0020] Body lock ring 54 is axially movable about tubular member 12 within chamber 51 . A first end 55 of body lock ring 54 acts as an annular piston face and is in fluid communication with the interior 18 of tubular member 12 via a conduit 60 . Body lock ring 54 includes inner and outer dynamic seals 57 , 58 , for example grooves with seated o-rings, that seal against an outer wall section of tubular member 14 and in the inner wall of chamber 51 within housing 52 , respectively, yet allow relative movement of body lock ring 54 . The second end 59 of body lock ring 54 rests against a resilient member 62 , such as a coiled spring, which resists an increase of pressure acting on piston face 55 .
[0021] Conduit 60 also includes a check valve 64 that selectively connects the interior 18 to the exterior 16 . As illustrated, check valve 64 may include a ball 65 and a seat 66 , whereby the ball 65 is forced and seals against the seat 66 when the fluid pressure within the interior 18 is pressurized with respect to the pressure of the exterior 16 . When the pressure gradient is reversed, ball 65 lifts off of seat 66 and allows flow. Accordingly, when screen assembly is being run into the well, as shown in FIG. 1 , well fluid can enter tubular member 12 through check valve 64 and conduit 60 , rather than through apertures 12 to reduce the risk of plugging the screen assembly. Although only one check valve 64 is illustrated, multiple check valves may be used as appropriate.
[0022] FIG. 2 depicts screen actuator 50 after the screen assembly has been run into the well and at the initial point in the actuation sequence where the interior fluid pressure has been raised to shut check valve 64 , thereby allowing the tubular member 14 to be pressurized at the surface, with a concomitant increase in pressure acting at piston face 55 of body lock ring 54 .
[0023] Referring now to FIG. 3 , further increasing fluid pressure within interior 18 causes a greater force to be exerted on piston face 55 of body lock ring 54 , thereby compressing resilient member 62 and moving body lock ring 54 toward sleeve 30 . As body lock ring 54 moves toward sleeve 30 , ratchet teeth 56 are forced past and engage ratchet teeth 52 , as explained in greater detail below with reference to FIG. 4 .
[0024] FIG. 4 is a perspective view of body lock ring 54 according to a particular embodiment. The first end 55 has a smaller internal diameter than the second end 59 . Near the first end 55 , a circumferential groove 68 is provided around the exterior wall surface into which dynamic seal 58 is seated for sealing against the wall of chamber 51 in housing 52 ( FIG. 3 ). Similarly, a circumferential groove 67 is provided around the inner wall surface into which dynamic seal 57 is seated for sealing against the outer wall section of tubular member 12 ( FIG. 3 ). Body lock ring 54 includes a section having ratchet tooth profile 56 . In particular, and as best seen in FIG. 3 , a typical ratchet tooth profile is similar to a buttress thread; one side of each tooth is perpendicular to the longitudinal axis 24 (as in a square tooth), while the obverse side of each tooth is sloped (as in a ‘V’ tooth).
[0025] Preferably, body lock ring 54 includes a number of slots formed therein to provide a limited resilience to allow body lock ring to elastically deform in a radial direction. As the ‘V’ sides of ratchet teeth 56 slide against the ‘V’ sides of ratchet teeth 52 ( FIG. 3 ), an outward radial force is created that temporarily deforms body lock ring 54 , thereby allowing the teeth to pass each other. However, when the square sides of ratchet teeth 56 engage the square sides of ratchet teeth 52 , no radial force is exerted on body lock ring 54 , and no axial motion is permitted. In this manner, body lock ring 54 is capable only of unidirectional motion with respect to portion 31 of sleeve 30 ( FIG. 3 ).
[0026] As illustrated, four slots are provided. Two partial slots 70 A, 70 B are formed halfway through body lock ring 54 at first end 55 , one partial slot 71 is formed halfway through body lock ring 54 at second end 59 , and one slot 72 is a full slot formed through the entire ring. However, other numbers and combinations of slots and half slots, or other materials, mechanisms, or techniques may be used as appropriate to obtain a ratcheting effect or unidirectional motion. Additionally, body lock ring 54 is described and illustrated as having a ratchet tooth profile 56 on its inner diameter to engage a ratchet tooth profile 52 on the outer diameter of sleeve portion 31 , a body lock ring with ratchet teeth on its outer diameter may be used as appropriate.
[0027] Returning back to FIG. 3 , body lock ring 54 is nearly fully engaged with sleeve 30 due to the pressurization of the interior 18 of tubular member 12 . Now referring to FIG. 5 , the interior 18 is depressurized. Resilient member 62 forces body lock ring 54 back into its original position, and because of the unidirectional ratchet threads 56 , 52 , sleeve 30 is axially moved along with body lock ring 54 into an open position. Openings 32 are now aligned with apertures 14 to allow well production.
[0028] Although screen assembly 10 is described herein predominately with respect to a single unit, multiple screen assemblies may be used within a single tubing string. Pressurizing the tubing string works to actuate every body lock ring in the string, and subsequently releasing the internal pressure opens every screen in the completion at once.
[0029] The Abstract of the disclosure is solely for providing the United States Patent and Trademark Office and the public at large with a way by which to determine quickly from a cursory reading the nature and gist of technical disclosure, and it represents solely a preferred embodiment and is not indicative of the nature of the invention as a whole. The design of screen assembly 10 as described herein also allows the screen gauge to be remotely adjusted by cycling or adjusting the internal pressure so as to clear the screen or increase production, for example.
[0030] While various embodiments have been illustrated in detail, the disclosure is not limited to the embodiments shown. It is apparent that modifications and adaptations of the above embodiments may occur to those skilled in the art. Such modifications and adaptations are in the spirit and scope of the disclosure. | An interventionless downhole screen that is resistant to plugging during run-in-hole operations and a method for remotely actuating the screen. The screen includes a perforated sleeve that is slideably disposed coaxially with a perforated tubular member. When running, the sleeve is in a closed positioned with its openings offset from the apertures in the tubular member, thereby blocking flow through the screened openings, while a check valve through the tubular member allows fluid ingress. To actuate for production, the tubular member is pressurized, which moves a piston into ratcheting engagement with the sleeve. A subsequent depressurization allows the piston to return to its original position, carrying with it the sleeve to an open position where the sleeve and tubing perforations are aligned for allowing fluid flow into the tubular member. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of U.S. patent application Ser. No. 13/850,463, filed on Mar. 26, 2013, which is a continuation of U.S. patent application Ser. No. 12/908,050, filed on Oct. 20, 2010, which claims the benefit of U.S. Provisional Patent Application No. 61/253,249, titled “Advanced Payment Options for Powered Cards and Devices,” filed Oct. 20, 2009, each of which is hereby incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
This invention relates to magnetic cards and devices and associated payment systems.
SUMMARY OF THE INVENTION
A card may include a dynamic magnetic communications device. Such a dynamic magnetic communications device may take the form of a magnetic encoder or a magnetic emulator. A magnetic encoder may change the information located on a magnetic medium such that a magnetic stripe reader may read changed magnetic information from the magnetic medium. A magnetic emulator may generate electromagnetic fields that directly communicate data to a magnetic stripe reader. Such a magnetic emulator may communicate data serially to a read-head of the magnetic stripe reader.
All, or substantially all, of the front as well as the back of a card may be a display (e.g., bi-stable, non bi-stable, LCD, LED, or electrochromic display). Electrodes of a display may be coupled to one or more capacitive touch sensors such that a display may be provided as a touch-screen display. Any type of touch-screen display may be utilized. Such touch-screen displays may be operable of determining multiple points of touch. Accordingly, a barcode may be displayed across all, or substantially all, of a surface of a card. In doing so, computer vision equipment such as barcode readers may be less susceptible to errors in reading a displayed barcode.
A card may include a number of output devices to output dynamic information. For example, a card may include one or more RFIDs or IC chips to communicate to one or more RFID readers or IC chip readers, respectively. A card may include devices to receive information. For example, an RFID and IC chip may both receive information and communicate information to an RFID and IC chip reader, respectively. A device for receiving wireless information signals may be provided. A light sensing device or sound sensing device may be utilized to receive information wirelessly. A card may include a central processor that communicates data through one or more output devices simultaneously (e.g., an RFID, IC chip, and a dynamic magnetic stripe communications device). The central processor may receive information from one or more input devices simultaneously (e.g., an RFID, IC chip, dynamic magnetic stripe devices, light sensing device, and a sound sensing device). A processor may be coupled to surface contacts such that the processor my perform the processing capabilities of, for example, an EMV chip. The processor may be laminated over and not exposed such that such a processor is not exposed on the surface of the card.
A card may be provided with a button in which the activation of the button causes a code to be communicated through a dynamic magnetic stripe communications device (e.g., the subsequent time a read-head detector on the card detects a read-head). The code may be indicative of a user's desire to pay for a purchase immediately when the user's next periodic credit card statement is available (e.g., at the next monthly credit card statement). An online service may be provided that allows a user to indicate categories of purchases and/or specific purchases upon which payment will be made as soon as the next credit card statement is available.
A card may be provided with a button associated with a code indicative of placing an associated purchase into an installment payment plan. The first installment may be due at the next due date. An online service (e.g., website) may be provided that allows a user to review previous credit card purchases and/or categories of credit card purchases and define installment payment plans for such purchases. Different buttons may be utilized to communicate different codes associated with different types of installment plans (e.g., one button may be 3 equal installments over the next 3 months while another button may be 6 equal installments over the next 6 months).
A card may be provided with a button associated with a code indicative of paying the most recent credit card bill for a user. Accordingly, at any time, a user may pay his/her credit card bill without having to use, for example, an online service (e.g., log into a webpage).
A card may be provided with a button associated with a code indicative of a request for information associated with an alert update feature. Such information may include, for example, synchronization information such that internal timing circuitry may be resynchronized. An alert may be preprogrammed into a card, for example, that is indicative of the times when bills will be due for a credit card statement (e.g., the first of every month). Accordingly, an information receiver (e.g., a light-based information receiver) may receive information after an alert update feature button is pressed (e.g., to resynchronize a clock on a card). A clock internal to the card may indicate to a user that a bill is due based on this received (or pre-set information). Such an alert may take the form of, for example, the activation of an LED (e.g., a blinking LED) or the presence of particular indicia (e.g., alert indicia) on a display of a card. A card may be preprogrammed with a particular day of a month (e.g., 6 th of every month) and a user may press a button to view this payment date on a card.
A card may be provided with a button associated with a code indicative of paying for a purchase using rewards points and/or rewards cash. Accordingly, for example, a user may select a button on the card to indicate that rewards are to be used to complete a particular transaction (e.g., point-of-sale transaction) rather than some other account type (e.g., credit or debit) that may otherwise be used to complete the transaction.
A card and/or one or more accounts associated with a card may be associated with a card holder's mobile communication device (e.g., mobile phone). Accordingly, for example, a user may opt to receive confirmations (e.g., text message updates) once a payment option is selected.
Once a text confirmation of the selected payment option is received, a user may alter the originally selected payment option. For example, a confirmation of the selected payment option may provide the user with an ability to change the originally selected payment option to yet another payment option (e.g., change from an originally selected rewards points payment option to an installment payment option).
A user's mobile device may be linked to the user's purchases after a transaction has been conducted. Targeted advertisements (e.g., discount coupon offers), for example, may be sent to the user's mobile phone in response to a single purchase or a pattern of multiple purchases.
A user's mobile communication device may execute one or more applications that may be linked with a user's card and/or one or more accounts associated with a user's card. In so doing, a user's interaction with his or her card may be tailored to the user's preferences via mobile applications that may be executing on the user's mobile device. For example, a user may request (e.g., via a mobile device application) that text confirmations be sent to the user's mobile device upon selection of a particular payment option. Further, a user may request (e.g., via a mobile device application) that choices be provided to the user upon selection of certain payment options (e.g., an installment payment plan may default to three monthly payments, but the user may be given the opportunity to change the plan to six monthly payments at the user's discretion).
BRIEF DESCRIPTION OF THE DRAWINGS
The principles and advantages of the present invention can be more clearly understood from the following detailed description considered in conjunction with the following drawings, in which the same reference numerals denote the same structural elements throughout, and in which:
FIG. 1 is an illustration of cards constructed in accordance with the principles of the present invention;
FIG. 2 is an illustration of a card constructed in accordance with the principles of the present invention;
FIG. 3 is an illustration of a card constructed in accordance with the principles of the present invention;
FIG. 4 is an illustration of a card constructed in accordance with the principles of the present invention;
FIG. 5 is an illustration of a mobile device constructed in accordance with the principles of the present invention;
FIG. 6 is an illustration of a mobile device constructed in accordance with the principles of the present invention;
FIG. 7 is an illustration of a mobile device constructed in accordance with the principles of the present invention; and
FIG. 8 is an illustration of a mobile device constructed in accordance with the principles of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows card 100 that may include, for example, a dynamic number that may be entirely, or partially, displayed via display 112 . A dynamic number may include a permanent portion such as, for example, permanent portion 111 . Permanent portion 111 may be printed as well as embossed or laser etched on card 100 . Multiple displays may be provided on a card. For example, display 113 may be utilized to display a dynamic code such as a dynamic security code. Display 125 may also be provided to display logos, barcodes, as well as multiple lines of information. A display may be a bi-stable display or non bi-stable display. Permanent information 120 may also be included and may include information such as information specific to a user (e.g., a user's name or username) or information specific to a card (e.g., a card issue date and/or a card expiration date). Card 100 may include one or more buttons such as buttons 130 - 134 . Such buttons may be mechanical buttons, capacitive buttons, or a combination or mechanical and capacitive buttons.
Card 100 may include button 199 . Button 199 may be used, for example, to communicate information through dynamic magnetic stripe communications device 101 indicative of a user's desire to pay for an item on credit, but to debit the credit account for the amount from a user's bank account when the next credit statement posts (or the subsequent credit statement posts and the associated bill is due). Persons skilled in the art will appreciate that pressing a button (e.g., button 199 ) may cause information to be communicated through device 101 when an associated read-head detector detects the presence of a read-head of a magnetic stripe reader.
Card 100 may include button 197 . Button 197 may be used, for example, to communicate information through dynamic magnetic stripe communications device 101 indicative of a user's desire to pay for an item using rewards points and/or rewards cash.
Button 198 may be utilized to communicate (e.g., after button 198 is pressed and after a read-head detects a read-head of a reader) information indicative of a user's desire to divide payment for the purchase over installments. A card may include a default number of installments (or a set dollar amount of installments such as $100). A user may change this default installment number of dollar amount online via an online website. Similarly, multiple buttons may be provided on a card and each button may be associated with a different installment option (e.g., 3 installments, 6 installments, and/or $100 installments).
Usage of buttons 197 , 198 , and/or 199 may be linked at the user's option to the user's mobile device (e.g., mobile phone, laptop, or PDA) upon issuance of card 100 to the user. Text messages, for example, may be communicated to a user's mobile phone to confirm selection of a particular payment option. In addition, a user may be provided with an opportunity to modify or cancel a previously selected payment option via a text messaging sequence that may be initiated through a payment option selected by pressing any one or more of buttons 197 - 199 .
Architecture 150 may be utilized with any card. Architecture 150 may include processor 120 . Processor 120 may have on-board memory for storing information (e.g., application code). Any number of components may communicate to processor 120 and/or receive communications from processor 120 . For example, one or more displays (e.g., display 140 ) may be coupled to processor 120 . Persons skilled in the art will appreciate that components may be placed between particular components and processor 120 . For example, a display driver circuit may be coupled between display 140 and processor 120 .
Memory 142 may be coupled to processor 120 . Memory 142 may include data that is unique to a particular card. For example, memory 142 may store discretionary data codes associated with buttons of card 150 . Such codes may be recognized by remote servers to effect particular actions. For example, a code may be stored on memory 142 that causes a user-defined installment plan to be setup for the purchase on a remote server (e.g., a remote server coupled to a card issuer's website). Memory 142 may store types of payments that a user may select. Each type of payment may be associated with a button. Or, for example, a user may scroll through a list of payment types on a display on the front of the card (e.g., using buttons to scroll through the list).
Any number of reader communication devices may be included in architecture 150 . For example, IC chip 152 may be included to communicate information to an IC chip reader. IC chip 152 may be, for example, an EMV chip. As per another example, RFID 151 may be included to communicate information to an RFID reader.
A magnetic stripe communications device may also be included to communicate information to a magnetic stripe reader. Such a magnetic stripe communications device may provide electromagnetic signals to a magnetic stripe reader. Different electromagnetic signals may be communicated to a magnetic stripe reader to provide different tracks of data. For example, electromagnetic field generators 170 , 180 , and 185 may be included to communicate separate tracks of information to a magnetic stripe reader. Such electromagnetic field generators may include a coil wrapped around one or more materials (e.g., a soft-magnetic material and a non-magnetic material). Each electromagnetic field generator may communicate information serially to a receiver of a magnetic stripe reader for a particular magnetic stripe track.
Read-head detectors 171 and 172 may be utilized to sense the presence of a magnetic stripe reader (e.g., a read-head housing of a magnetic stripe reader). This sensed information may be communicated to processor 120 to cause processor 120 to communicate information serially from electromagnetic generators 170 , 180 , and 185 to magnetic stripe track receivers in a read-head housing of a magnetic stripe reader. Accordingly, a magnetic stripe communications device may change the information communicated to a magnetic stripe reader at any time. Processor 120 may, for example, communicate user-specific and card-specific information through RFID 151 , IC chip 152 , and electromagnetic generators 170 , 180 , and 185 to card readers coupled to remote information processing servers (e.g., purchase authorization servers). Driving circuitry 141 may be utilized by processor 120 , for example, to control electromagnetic generators 170 , 180 , and 185 .
FIG. 2 shows card 200 that includes button 211 associated with display 215 , button 212 associated with display 216 , and button 213 associated with display 217 . Each button may be associated with a feature displayed in display 210 . A user may press a button in order to communicate data representative of the feature through a magnetic stripe communications device or other communications device (e.g., RFID or IC chip). A light emitting diode (or other source of light) may be associated with each button to indicate to a user what feature was selected by a user.
A user may be able to select multiple features such that multiple feature codes are communicated in tracks of magnetic stripe data communicated by a magnetic stripe communications device. Such codes may be provided in discretionary data fields. Such codes may be repeated on each track of communicated magnetic stripe data (e.g., repeated on tracks 1 and 2 or repeated on tracks 1, 2, and 3). In doing so, a user may associate multiple features to a purchase. A user may set that a purchase be automatically paid regularly by, for example, pressing button 211 for a purchase transaction. A user may press button 212 to set that a purchase for installment payment under one installment plan (e.g., 3 equal installments). Button 213 may allow a user to set that a purchase for installment payment under another installment plan (e.g., 6 equal installments).
The features associated with each card may be pre-determined by a user. For example, a user may select features to place on a card when ordering a card. Additionally, a user may go to a card issuer's website and select attributes of features. For example, a user may visit a card issuer's website and select the particular offering that is to be purchased whenever a user selects the feature associated with button 211 and displayed on display 215 .
Information associated with a button may be displayed via a display or permanently printed, embossed, or laser engraved on a card. Card 200 may include a light sensing device to receive information via light pulses from a display (e.g., a television, mobile phone, or laptop display). A user may select to change the features or attributes of features from a card issuer's website and may reconfigure a card accordingly. Alternatively, a card may be provided with buttons and no descriptive information. A user may change the features or attributes of features associated with one or more buttons via a card issuer's website and remote processing may perform the associated processing as a result of on-card button selections.
Different codes may be communicated depending on the feature or attributes of features on a card. Such codes may be changed via a wireless communications signal (e.g., a light-based communications signal). In doing so, processing may occur off-card at a remote server without the need to determine what feature a user associated with a code. Persons skilled in the art will appreciate that a card issuer may monitor the frequency and number of times that a user utilizes a particular feature. Additionally, the card may receive wireless communications signals (e.g., WiFi signals) associated with the modifications and additions).
FIG. 3 shows card 300 that may include dynamic magnetic stripe communications device 310 , buttons 311 - 315 , permanent information 320 , display 350 , data receiving device 370 , and buttons 331 - 333 . Button 331 may be associated with a first line of displayed information on display 350 . Button 332 may be associated with a second line of displayed information on display 350 . Button 333 may be associated with a third line of displayed information on display 350 . Persons skilled in the art will appreciate that buttons 331 - 333 may actually be virtual buttons on display 350 and display 350 may be a capacitive touch screen.
Data receiving device 370 may be a light or sound sensor for receiving information through received light or sound. Portion 399 may be displayed on display 350 . The first line of portion 399 may be associated with button 331 and may, for example, cause a code to be communicated (e.g., with magnetic stripe data for authorizing a purchase transaction) to a magnetic stripe reader that is associated with a user's desire to initiate an overlimit feature. Persons skilled in the art will appreciate that a user's transaction may be declined for overdrawing from the user's credit account (or other account). A user may utilize an overlimit feature to use such an overdrafted account for an additional fee. In this manner, selecting such a feature may allow a previously declined purchase transaction to be authorized and an overlimit feature fee be placed on the account.
The second line of portion 399 may be associated with, for example, button 332 of display 350 and may be a pay bill feature. A pay bill feature may cause any outstanding bill for a user's account to be paid. Accordingly, a user does not have to log into his/her online account (or mail a check) to authorize payment of an outstanding bill.
The third line of portion 399 may be utilized for a user to select an alert update feature. A card may be provided to a user with knowledge of when a bill payment is due for a user (and/or when a statement posts). An internal clock may keep track of these events and notify a user of such events. A user may select an update alert to, for example, receive information via a communications channel (e.g., via light pulses) associated with an alert. Such an update may, for example, re-synchronize the internal clock of a card (e.g., to remove any timing errors accumulated by the timing circuitry of the card). An alert may be provided, for example, if a user overdrafts from a particular account.
FIG. 4 shows card 400 that may include signature line 410 and display 420 . Persons skilled in the art will appreciate that card 300 of FIG. 3 may depict the obverse side of a card and card 400 of FIG. 4 may depict the reverse side of a card. Individual components of card 300 of FIG. 3 or card 400 of FIG. 4 may be provided on either side of a card or both sides of a card. More than one instance of a component may be provided on any side of a card (e.g., the same side as a component or a different side as a component). Persons skilled in the art will appreciate that a user may communicate feature codes representative of a user's on-card selection via codes that may be displayed visually and entered into a webpage as part of an online payment.
A display may display not only a code for an online payment, but also indicia representative of the feature. In doing so, the user can confirm that the right feature was selected. Persons skilled in the art will appreciate that different codes for the same feature may be displayed and communicated via a dynamic magnetic communications device. In doing so, the security of the card may be increased. Additionally, the same or different codes may be communicated on different tracks of data to represent the selection of a particular feature. A code may be utilized, for example, to communicate information about an installment plan a user desires to initiate for a purchase.
FIG. 5 shows mobile device 500 , which may be a mobile telephonic device. Device 500 may include one or more physical buttons (e.g., button 540 ). Device 500 may include one or more display screens 510 . Such a display screen may be touch sensitive such that virtual buttons (e.g., button 530 ) may be provided on virtual card 520 . Virtual card 520 may appear similar to a physical card described herein. A user may select different virtual cards by, for example, swiping his/her finger across a touch-sensitive display to scroll to the next virtual card. Mobile phone 502 may include a communications device operable to communicate data to a card reader. For example, mobile phone 502 may include an RFID antenna to communicate to an RFID reader, a pop-out IC chip panel operable to be fed into an IC chip reader, or a magnetic communications device having a magnetic emulator operable to communicate magnetic stripe data wirelessly to a read-head of a magnetic stripe reader. Virtual button 530 may be provided to indicate a user's desire for a regular pay option for a purchase. Virtual button 531 may be provided to indicate a user's desire for an installment pay option for a purchase. Virtual button 532 may be provided to indicate a user's desire for a rewards points pay option for a purchase.
FIG. 6 shows mobile device 600 , which may be a mobile telephonic device having executable applications that may be used by a user to conduct a financial transaction. Alternately, mobile device 600 may optionally be linked to a card issued to the user of mobile device 600 . In either instance, the user may have previously requested (e.g., at card issuance) to receive confirmation messages during the course of any financial transaction.
A user may, for example, choose at the point of sale to finance a purchase with rewards points. Confirmatory message 604 may be received (e.g., via text messaging) by mobile device 600 . In so doing, a user may have an opportunity to confirm the pending transaction using the originally selected payment option (e.g., by selecting the appropriate button 602 ). Conversely, the user may have an opportunity to override the user's original payment option selection by selecting an alternate payment option (e.g., installment pay or regular pay).
FIG. 7 shows mobile device 700 . Message 702 may be displayed as a result of the user's original request to finance a pending transaction using an installment payment plan. A confirmation message (e.g., text message 702 ) may then be displayed to allow the user to confirm that a default number of installment payments (e.g., 3) is acceptable. Alternately, the user may be given the opportunity to override the default selection by selecting a different number of installments (e.g., 6 or 9 installments).
Persons skilled in the art will appreciate that users may define how confirmatory messaging may be conducted. In particular, a user may have an opportunity to visit a card issuer's website to select the user's confirmatory messaging preferences. For example, a user may simply opt out of confirmatory messaging. Alternately, a user may wish to opt into confirmatory messaging and may further define options associated with such messaging (e.g., always confirm with a default selection and a list of available options that may be selected instead of the default selection). Accordingly, a user may be able to customize a level of interaction at the point of sale via his or her confirmatory messaging preferences.
FIG. 8 shows mobile device 800 . Message 802 may be displayed as a result of a targeted advertisement that may be sent (e.g., via text messaging) subsequent to a purchase. For example, message 802 may first confirm that a purchase of gasoline was transacted using a user's card or application-enabled mobile device. A promotion may be offered by the product supplier (e.g., gasoline supplier) and/or the product vendor (e.g., gasoline station) that results in targeted advertisement 802 . Accordingly, the user may be informed of rewards that may be earned as a result of continued patronage.
Persons skilled in the art will also appreciate that the present invention is not limited to only the embodiments described. Instead, the present invention more generally involves dynamic information. Persons skilled in the art will also appreciate that the apparatus of the present invention may be implemented in other ways than those described herein. All such modifications are within the scope of the present invention, which is limited only by the claims that follow. | Advanced payment applications are provided to improve the functionality of cards and devices. For example, a user interface may be placed on a card (e.g., a physical button) or a telephonic device (e.g., a virtual button on a capacitive touch screen). Manual input provided to this user interface may, for example, cause an item purchased on credit to be paid via one or more user accounts (e.g., bank accounts) as soon as the next credit statement posts or becomes due. A user may decide to pay for an item when the next statement becomes due at a point-of-sale magnetic stripe reader by using an interface on a card to cause information to be communicated through the infrastructure indicative of a user's desire to pay the for an item when the next statement becomes due. | 6 |
FIELD OF THE INVENTION
[0001] The present invention relates to the field of vision correction, particularly to corrections achieved by means of spectacle lenses, contact lenses or intraocular lenses which include correction of high order aberrations.
BACKGROUND OF THE INVENTION
[0002] Currently performed optometric measurements for the determination of the specification of vision correction lenses generally measure aberrations of the type defocus and astigmatism, and to a lesser extent, also tilt. Common optometric devices for measuring defocus and astigmatism problems are the trial frame and the phoropter. Both devices rely on the subjective perception of the quality of sight perceived by the patient and therefore are referred to as subjective methods. Alternatively, an optical refractometer can be used for measuring defocus and astigmatism of the eye in an objective manner.
[0003] Aberrations such as tilt, defocus and astigmatism are considered low order aberrations. However, higher order aberrations, such as spherical aberration, coma and the even higher order aberrations, collectively known as irregular aberrations, are also present due to the imperfect optical properties of the human eye. The term “high order” or “higher order” aberrations, as used throughout this specification and as claimed, is meant to include all those aberrations besides the commonly corrected tilt, defocus and astigmatism aberrations. Furthermore, throughout this specification, and as claimed, the order by which aberrations are referred to are the orders of the wavefront aberrations, as expressed by their Zernike polynomial representation, rather than the order of ray aberrations. Under this convention, tilt, for instance is a first order aberration, defocus and astigmatism are second order aberrations, coma and coma-like aberrations are of third order, spherical and spherical-like aberrations are fourth order, and the above-mentioned irregular aberrations are those of fifth order and higher.
[0004] Once the diffraction limit of the eye's imaging capability has been exceeded, this occurring when the pupil size is typically larger than approximately 2 to 3 mm, the size of the minimum detail in the image projected onto the retina, and hence the ultimate visual acuity of the subject, becomes a function of how well the sum total of the aberrations present are corrected. If, in addition to the usually corrected power and astigmatism, higher order aberrations were also corrected, it would be possible to provide super-normal vision for the subject, with performance noticeably better than the commonly accepted optimum vision acuity, known as 20/20 vision. Since, however, correction of the low order aberrations generally improves vision to an acceptable level, little effort has historically been made to attempt to correct for the higher order aberrations present in the eye. Furthermore, even though low order aberration correction may provide acceptable visual acuity during the daytime or in well-lit rooms, under which conditions the pupil aperture is small, the level of low order correction may prove to be unacceptable at lower light levels, when the pupil aperture is larger and the level of aberrations increases.
[0005] In order to be able to correct higher order aberrations, the extent of these aberrations must be measured, and corrective measures then applied, such as the prescription of correction lenses or the performance of eye surgery. Different methods for measuring high order aberrations are described, for instance in U.S. Pat. No. 6,155,684, for “Method and Apparatus for Precompensating the Refractive Properties of the Human Eye with Adaptive Optical Feedback Control” to Bille et al.
[0006] A subjective method for measuring high order aberrations is described In Israel patent application No. 137,635 for “Apparatus for Interactive Optometry”, filed by the applicants of the present application.
[0007] Recent developments in the field of high order aberration correction for the human eye have, to date, only involved either corrective action such as laser surgery, or the use of contact lenses or intraocular lenses. Effective correction of higher order aberrations using spectacles has not hitherto been considered possible, since effective correction of such higher order aberrations is sensitive to the direction of passage of the light through the lens. In the case of spectacles, the optical axis of the spectacle lens and the optical axis of the eye may deviate from each other, both because of the natural rolling action of the eyeballs and also because of the limited accuracy with which the spectacles may be fixed relative to the wearer's eyes.
[0008] In the published PCT application in Patent Document WO 00/75716 for “Super Vision” to E. I. Gordon, there is described a method of correcting for spherical aberrations in human vision by means of an aspherical lens design, but the method does not utilize full wavefront measurement. In this document, it is stated specifically that the suggested solution is inadequate for use with spectacle lenses, since “because of deviations between the corneal vision axis and the axis of the lens, eye glass (spectacle) type corrections are not however feasible unless some means are used to fix the cornea relative to the spectacle lens.”
[0009] In U.S. Pat. No. 5,220,359 to J. H. Roffman for “Lens Design Method and Resulting Aspheric Lens”, there is described a solution for aberration correction in contact, intraocular, natural or spectacle lenses. However, the suggested solution is for aspherical lenses only, which are rotationally symmetric. Furthermore, the method is a subjective method of substituting aspheric lenses until the optimum subjective correction is achieved, and does not involve a complete wavefront measurement.
[0010] Contact lenses and intraocular lenses, however, being more or less fixed relative to the eyes, are not considered to suffer from the above-mentioned disadvantage of spectacle lenses. In U.S. Pat. Nos. 5,777,719, 5,949,521 and 6,095,651, all for “Method and Apparatus for Improving Vision and the Resolution of Retinal Images” to D. R. Williams et al. (each a continuation of the previous), there are described methods of providing correction data of higher order aberrations for use in the manufacture of contact lenses and intraocular lenses, as illustrated in FIG. 1 of each of these patents. Very sparse enabling details are given, however, of how to apply the measurements obtained in the design of contact or intraocular lenses.
[0011] The majority of sight correction is still, however, currently achieved by the use of spectacles, this probably being the least expensive, most risk-free and most convenient method of sight correction. There therefore exists an important need for the provision also of spectacle lenses corrected for higher order aberrations.
[0012] The disclosures of each of the publications mentioned in this section, and in other sections of this specification, are hereby incorporated by reference, each in its entirety.
SUMMARY OF THE INVENTION
[0013] The present invention seeks to provide a new spectacle lens for the correction of human vision, including the correction of high order aberrations, and a method for constructing such a lens. The present invention thus enables the provision of super normal vision using spectacles. Different lenses are described for use at a partial or a fuller field of view (FoV). The method applies corrective measures based on data obtained from high order wave front measurements. Although the method of the present invention is described in this specification using its implementation in the prescription of spectacle lenses as a preferred embodiment to illustrate the method, it is to be understood that it may also be implemented with any other vision corrective measures such as contact lenses, intraocular lenses or even in refractive eye surgery.
[0014] As opposed to prior art methods of correcting high order aberrations in vision, using real-time wavefront measurements and corrective adaptive optics, the present invention achieves the correction by means of a suitably constructed fixed lens.
[0015] When customizing a spectacle lens to correct wave front aberrations, a natural solution would be to design a lens that would fully correct the wave front, thus creating an emetropic lens-eye system. Such a solution would indeed be practical if the eye and corrective spectacle lens were a deterministic fixed system. However, since the spectacles and eye are capable of mutual movement, both in position and angular alignment, this is not the case, and this simple solution, although optimized for one predefined relative position, is not robust to the real life situation of relative movement of eye and spectacles, resulting in degradation in vision.
[0016] Contact lenses designed to provide high order aberration correction, such as those described in the above-mentioned Williams et al. patents, have to be accurately aligned on the eye, both laterally and rotationally, in order to successfully provide high order vision correction, and maintaining such alignment is not a trivial task. If the same design criteria used for such contact lenses were to be applied for the construction of spectacle lenses with higher order aberration correction, the effect of tilt of the eye would significantly degrade the correction. The accurate alignment and positioning of spectacles, on the other hand, is a well known problem encountered with any non-rotationally symmetric lenses, such as cylindrical lenses, bifocals, multifocals or any of the modern progressive lens designs. Many different types of such lenses are widely and successfully used in spectacles, despite the alignment and position variation which can occur with spectacles.
[0017] There is thus provided, according to a preferred embodiment of the present invention, spectacle lenses which correct high order aberrations of the eye either for a full field of view or for a partial field of view. The embodiment for higher order correction for the full field of view is enabled by adopting a compromise correction, which is less than the optimum correction possible when the lens optical axis and the optical axis of the eye coincide, but which nevertheless provides an improvement over hitherto corrected low order aberrations in spectacle lenses. For the partial field of view embodiment, an optimum correction is performed over a limited paraxial region of the lens, and the well-known second order corrections are applied outside of this partial field of view.
[0018] According to both of these embodiments, super normal vision is provided to the user when the lens optical axis and the optical axis of the eye coincide. When there is deviation of the two axes, such as when the user does not look directly through the optical axis of the lens, or when the spectacles are being worn slightly misaligned in relation to the wearer's eyes, the lens designed according to these preferred embodiments of the present invention, provides vision quality reduced in comparison with optimal super vision ability, but the reduction in performance is sufficiently small that 20/20 vision or better is still maintained.
[0019] Lenses constructed according to preferred embodiments of the present invention, thus allow the user to experience super normal vision without undue difficulties when looking straight forward, and at the same time, significant tilt of the eye does not degrade the acuity of vision experienced compared to normal 20/20 vision. For large angles of tilt, it is usually more comfortable physically to tilt the head in the preferred direction. Thus, for the field of view generally used, these lenses thus provide significantly better vision correction than conventional prior art spectacle lenses can provide. Optimal use of spectacles incorporating lenses according to the present invention, is an easy-to-learn task, not dissimilar to that encountered in learning to use bifocal, multifocal or progressive lenses.
[0020] According to another preferred embodiment of the present invention, the spectacle lens is optimally corrected for higher order aberrations in the wearer's eyesight only over the central portion of the lens, typically within ±1° of its optical axis. Outside of this field of view, no correction beyond the conventional correction for power and astigmatism is attempted. The resulting lens thus provides super normal vision when the center of the lens is being used, and off axis, the performance tapers to that of conventional 20/20 correction.
[0021] Two preferred methods are suggested, according to different embodiments of the present invention, by which the corrective lens is designed in order to optimize the vision performance for acceptable values of the field of view and relative axial deviation between the eye and lens optical systems.
[0022] In a first preferred method the Modulation Transfer Function (MTF) of the overall eye and lens optical system is optimized. The MTF is commonly used to evaluate the performance of an optical imaging system, and specifically, the quality of the visual acuity achieved using the system. The MTF graph of the overall eye and lens system may thus be used to evaluate the performance of a corrective lens design, by optimizing the total summed MTF values for best overall performance over the range of use desired.
[0023] The major factors that influence the MTF value of this eye/lens system are spatial frequency, the angle of transit of the light, within the field of view, through an axially aligned eye and the tilt angle of the eye with respect to the lens. For the sake of simplicity, the latter two angles are termed and claimed as “vision angles” in this application. According to a preferred embodiment of this method, the effect of these three factors is taken into account, by implementing a weight function in the MTF optimization process. Each value of the MTF calculated is given a different weight, that is dependent on the spatial frequency, the angle in the field of view and the tilt angle of the eye used for that particular MTF calculation, according to predefined criteria dependent on subjective conditions and on the extent of correction sought. Thus, for example, the central field of view (the fovea) is given a significantly bigger weight than the outer field of view, since the visual acuity of the natural eye degrades so strongly in the outer field, that in general, only paraxial vision is used for high-definition sight. Furthermore, the MTF is calculated within a set of limited boundaries that are considered to be relevant for normal human vision, meaning a maximum defined resolvable spatial frequency, a maximum defined field of view and a maximum eye tilt angle.
[0024] After determining the weighting function and boundaries for performing the calculations, the lens surfaces are optimized to give an overall best MTF performance within the predefined boundaries and limitations applied to the correction required, taking into account the total MTF values and the related weights for the spatial frequencies, the FoV angles and the tilt angles.
[0025] According to the second preferred method, optimization is performed on the wavefront of the overall eye and lens optical system. After determining the weight functions and boundaries to be used for the angle in the field of view and for the tilt angle of the eye, the correction lens surfaces are optimized to give the overall minimum wave front aberrations, preferably defined by minimum RMS deviation from a plane wave of the wavefront, taking into account the related weights for the various FoV and tilt angles. If measurements of the wavefront at different field of view angles are not available, than the optimization is done only for the various tilt angles. The wavefront RMS for a specific tilt angle is the RMS of the resulting wavefront, when the measured wavefront is transmitted through the corrective lens at the specific tilt angle. The optimized lens is then calculated such as to minimize the total value of all RMS values at various tilt angles, including the effects of their relevant weights.
[0026] According to both of the above preferred methods, the inputs used for the lens design include wavefront measurement of the patient's eye and measurement of the correction lens position relative to the patient's eye.
[0027] The design of the lens, according to various preferred embodiments of the present invention, consists of at least some of the following steps:
[0028] i. A wavefront measurement of the eye is performed. Such a measurement can be attained by a wave front analyzer, such as those described in the above-mentioned U.S. Pat. No. 6,155,684 or 6,095,651. The output of such a wavefront measurement can be either an X-Y-Z co-ordinate plot of the wavefront surface or a polynomial (Zernike, Taylor or another) describing the aberrations measured.
[0029] ii. The wavefront measured is automatically transformed by software into a corrective lens design, which consists of a back surface and a front surface. One surface may preferably be spherical and/or cylindrical and is operative to correct lower order defocus and astigmatism aberrations. The second surface may preferably be any X-Y-Z defined surface, and is operative to correct the higher order aberrations.
[0030] iii. Alternatively and preferably, any combination of two surfaces may be used which results in correction of the wave front.
[0031] iv. The design described in sections ii or iii above can be calculated such that for a specific predetermined position of a lens relative to the inspected eye, the wavefront is distorted by the lens in such a manner that the aberrations in the eye's optical system corrects the distortion to produce an exact image on the retina, undistorted by the aberrations of the eye. Thus, the total lens-eye system will behave as a perfectly corrected optical system.
[0032] v. A solution according to a preferred embodiment of the present invention is a design that gives an optimized, but not perfectly corrected solution over a wide field of view. This optimized solution is defined as a lens design, which, together with the eye, has a total residual aberration such that when calculated across a defined field of view around the eye/lens optical axis, it gives the minimal standard deviation of distortion from zero.
[0033] vi. Alternatively and preferably, the optimized solution is defined as a lens design, which, together with the eye, has a total residual aberration such that when calculated across a defined range of angles of tilt of the optical axis of the eye with respect to the lens optical axis, it gives the minimal standard deviation of distortion from zero.
[0034] vii. Even more preferably, the optimized solution is defined as a lens design, which, together with the eye, has a total residual aberration such that when calculated across a defined field of view around the eye/lens optical axis, and across a defined range of angles of tilt of the optical axis of the eye with respect to the lens optical axis, it gives the minimal standard deviation of distortion from zero.
[0035] viii.Another preferred solution consists of the above high order corrections performed only for a limited area around the optical axis. Over the remainder of the lens area, correction is preferably made only for lower order aberrations (defocus and cylinder). A smooth transition is applied between the two sections.
[0036] ix. Any of the above-mentioned preferred designs, after calculation by a suitable program, may be transformed into a formatted data file for outputting directly to a lens manufacturing machine. The lens is then manufactured according to the prescribed data file. The manufacturing process needs to be such that the unique non-symmetric correction surface may be easily manufactured (CNC or similar).
[0037] x. Software is provided for conversion of the wave front measurement data into a data file for manufacturing of a corrective lens. The conversion is performed according to any of the methods mentioned above.
[0038] It is to be understood that the methods, according to the above-mentioned preferred embodiments of the present invention, which involve optimization of the correction lens for angular ranges of both tilt and field of view are relevant specifically for the optimization of spectacle correction lenses. If one of the above-mentioned preferred methods is used for optimization of either contact or intraocular lenses, or for optimizing the parameters of a refractive surgical procedure on the eye, the optimization is only meaningfully performed over a range of angles of the field of view, since the lens is fixed relative to the eye, and there cannot therefore be any meaningful tilt.
[0039] Furthermore, when performing refractive surgery of the eye to correct the aberrations present therein, a common method used is to ablate the surface of the cornea to the desired shape using an excimer laser. The cornea is only one component of the ocular imaging system, which effectively consists of a number of optically operative elements, starting with the outermost refractive surface of the cornea, through the aqueous humor, the lens and the vitreous humor. The cornea supplies approximately two thirds of the eye's refractive power, and the lens most of the remainder. According to a preferred method of the present invention, in which optimization of optical parameters of the ocular imaging system is performed in preparation for refractive surgery, the only parameter in fact available for optimization is the accessible front surface of the cornea. The profile of the cornea can be accurately measured by means of corneal topography, to provide a starting value for the optimization procedure. The optimization procedure is preferably performed by adjusting the corneal front profile to reduce the aberrations present in the subject's vision over a predetermined range of angles of off-axis vision within a defined field of view of the subject's eye, and also optionally over a predetermined range of spatial frequencies.
[0040] There is also provided in accordance with another preferred embodiment of the present invention, a method of correcting aberrations in the vision of a subject, consisting of the steps of measuring the aberrations at an eye of the subject, providing a correction lens, and optimizing over a range of vision angles, parameters of the correction lens, such that the aberrations are minimized over the range.
[0041] The parameters of the lens may preferably consist of at least one of a first surface, a second surface, and a thickness, while the aberrations may preferably consist of high order aberrations.
[0042] Furthermore, the correction lens may be either a spectacle lens, a contact lens or an intraocular lens. For the case of a spectacle lens, the vision angles may be angles of tilt of the axis of the eye relative to the lens and/or angles of off-axis vision of the eye. For a contact lens or an intraocular lens, the vision angles may preferably be angles of off-axis vision of the eye.
[0043] In accordance with yet another preferred embodiment of the present invention, the method of optimization of the parameters of the lens as described above, may consist of the steps of calculating a first modulation transfer function of a combination of the lens and the eye for a given vision angle of the eye, varying the vision angle over a predefined range of angles, calculating new modulation transfer functions for each of a plurality of vision angles within the range of angles, performing a summation of the calculated modulation transfer functions, and varying the parameters of the lens to optimize the summation of the modulation transfer functions.
[0044] Furthermore, when the correction lens is a spectacle lens, the optimization of the parameters of the lens as described above, may preferably consist of the steps of calculating a first modulation transfer function of a combination of the lens and the eye for a given angle of tilt and a given angle of off-axis vision of the eye, varying at least one of the angle of tilt and the angle of off-axis vision over a predetermined range of angles, calculating new modulation transfer functions for the range of angles, performing a summation of the calculated modulation transfer functions, and varying the parameters of the lens to optimize the summation of the modulation transfer functions.
[0045] In the above described methods, the step of optimizing the parameters of the correction lens over a range of vision angles may preferably be performed over a predetermined range of spatial frequencies.
[0046] In addition, the above mentioned step of measuring the aberrations at an eye of the subject preferably consists of measuring a wavefront emitted from the subject's eye. The calculation of a modulation transfer function of the combination of the lens and the eye may preferably be performed by calculating the effect of the passage of the wavefront through the lens.
[0047] In accordance with yet more preferred embodiments of the present invention, the calculation of the modulation transfer function mentioned above, may also consist of the step of applying a predefined weighting to each of the new modulation transfer functions for each of the vision angles before the summation of the calculated modulation transfer functions is performed. This predefined weighting may preferably be a function of the angle of tilt of the axis of the eye relative to the lens, and/or of the angle of off-axis vision within a predefined field of view of the eye, depending on the case.
[0048] In accordance with still more preferred embodiments of the present invention, in the methods described above where the method of measuring aberrations at an eye of a subject consists of measuring a wavefront emitted from the subject's eye, the optimization of the parameters of the lens may preferably consist of the steps of calculating the deviation of the wavefront from a plane wavefront after passage through the combination of the lens and the eye, for a given vision angle of the eye, varying the vision angle over a predefined range of angles, calculating a new deviation of the wavefront for each of a plurality of vision angles within the range of angles, summing the calculated deviations of the wavefront, and varying the parameters of the lens to minimize the sum of the deviations of the wavefront from a plane wavefront.
[0049] Alternatively and preferably, the optimization of the parameters of the lens may consist of the steps of calculating the deviation of the wavefront from a plane wavefront after passage through the combination of the lens and the eye, for a given angle of tilt and a given angle of off-axis vision of the eye, varying at least one of the angle of tilt and the angle of off-axis vision over a predetermined range of angles, calculating a new deviation of the wavefront for each of a plurality of vision angles within the range of angles, summing the calculated deviations of the wavefront, and varying the parameters of the lens to minimize the sum of the deviations of the wavefront from a plane wavefront.
[0050] In accordance with yet more preferred embodiments of the present invention, the calculation of the deviation of the wavefront from a plane wavefront after passage through the combination of the lens and the eye, as mentioned above, may also consist of the step of applying a predefined weighting to each of the deviations of the wavefront calculated for each of the vision angles before the summation of the calculated deviations is performed. This predefined weighting may preferably be a function of the angle of tilt of the axis of the eye relative to the lens, and/or of the angle of off-axis vision within a predefined field of view of the eye, depending on the case.
[0051] There is further provided in accordance with still another preferred embodiment of the present invention, a method of correcting aberrations in the vision of a subject, consisting of the steps of measuring the aberrations at an eye of the subject, measuring the profile of the front surface of the cornea of the eye, optimizing over a range of angles of off-axis vision within a predetermined field of view of the eye, the front surface of the cornea, such that the aberrations are minimized over the range, and performing refractive surgery on the eye such that the cornea acquires the optimized front surface.
[0052] In the above mentioned method, the optimization of the front surface of the cornea may preferably consist of the steps of calculating a first modulation transfer function of the eye with the front surface for a given angle of off-axis vision of the eye, varying the angle of off-axis vision over a predefined range of angles, calculating new modulation transfer functions for each of a plurality of angles of off-axis vision within the range of angles, performing a summation of the calculated modulation transfer functions, and varying the front surface of the cornea to optimize the summation of the modulation transfer functions.
[0053] Furthermore, the optimization of the front surface of the cornea over a range of angles of off-axis vision may be performed over a predetermined range of spatial frequencies.
[0054] Additionally and preferably, the method may also consist of the step of applying a predefined weighting to each of the new modulation transfer functions for each of the angles of off-axis vision before the summation of the calculated modulation transfer functions is performed. The predefined weighting may also be a function of the angle of off-axis vision within a predefined field of view of the eye.
[0055] In accordance with a further preferred embodiment of the present invention, the measuring of the aberrations at an eye of a subject mentioned above in connection with optimization for refractive surgery, may preferably consist of measuring a wavefront emitted from the subject's eye. In such a case, the optimization of the front surface of the cornea may consist of the steps of calculating the deviation of the wavefront from a plane wavefront after passage through the eye with the cornea front surface, for a given angle of off-axis vision of the eye, varying the angle of off-axis vision over a predetermined range of angles, calculating a new deviation of the wavefront for each of a plurality of vision angles within the range of angles, summing the calculated deviations of the wavefront, and varying the front surface of the cornea to minimize the sum of the deviations of the wavefront from a plane wavefront.
[0056] Furthermore, in any of the above-mentioned methods of correcting aberrations in the vision of a subject by refractive surgery, the aberrations may consist of high order aberrations.
[0057] Finally, there is provided in accordance with yet further preferred embodiments of the present invention, a lens for correction of aberrations in the vision of a subject, constructed by any of the methods mentioned above.
BRIEF DESCRIPTION OF THE DRAWINGS
[0058] The present invention will be understood and appreciated more fully from the following detailed description, taken in conjunction with the drawings in which:
[0059] [0059]FIGS. 1A and 1B are schematic views of the method whereby a spectacle lens, constructing and operative according to a preferred method of the present invention, corrects for higher order aberrations occurring in the user's eye. FIG. 1A schematically shows measurement of the aberrated wavefront from the eye, and FIG. 1B schematically shows how the lens corrects these aberrations;
[0060] [0060]FIG. 2 is a flowchart schematically describing the steps taken in constructing lenses according to a preferred embodiment of the present invention;
[0061] [0061]FIGS. 3A and 3B are schematic diagrams for illustrating respectively the use of the terms tilt and field of view, as used in preferred embodiments of the present invention;
[0062] [0062]FIGS. 4A and 4B show typical graphs of weighting factors W used respectively for the field of view and tilt angles in weighting the MTF for the optimization procedure according to preferred embodiments of the present invention;
[0063] [0063]FIGS. 5A and 5B schematically illustrate the results of optimization processes according to preferred embodiments of the present invention, respectively for an on-axis imaging case, and for a case of the eye imaging at a tilt angle;
[0064] [0064]FIG. 6 shows plots of the modulation transfer function (MTF) for imaging produced by a standard healthy eye, having what is commonly termed 20/20 vision;
[0065] [0065]FIG. 7 shows plots of the MTF for imaging produced by a myopic eye;
[0066] [0066]FIG. 8 shows plots of the MTF for imaging produced by an eye whose vision is corrected by means of a prior art spectacle lens, correcting for low order aberrations only;
[0067] [0067]FIG. 9 shows plots of the MTF for imaging produced by an eye corrected by means of spectacle lenses constructed according to a preferred embodiment of the present invention, when the user looks through the lens axially;
[0068] [0068]FIG. 10 shows MTF plots of an eye, whose vision has been corrected by means of the same spectacle lens as is used to provide the results shown in FIG. 9, but wherein the lens is tilted by an angle of 10° from the on-axis case; and
[0069] [0069]FIG. 11 is a schematic view of a spectacle lens, constructed and operative according to another preferred embodiment of the present invention, in which the lens is divided into two areas, a central area and an outer area.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0070] Reference is now made to FIGS. 1A and 1B, which schematically illustrate the method whereby a spectacle lens, constructing and operative according to a preferred embodiment of a method of the present invention, corrects for aberrations occurring in the user's eye, including corrections of higher order aberrations.
[0071] In FIG. 1A is shown a measured wavefront 10 exiting the eye 12 of a subject. The wavefront is distorted because of the aberrations present in the eye, including higher order aberrations, and the object of the measurement step is to characterize these distortions. FIG. 1B is a schematic illustration of a lens 14 , constructed according to a preferred embodiment of the present invention, located in front of the subject's eye 12 . The lens 14 has a predetermined shape, such that a predetermined distortion is applied to a parallel undistorted wavefront 16 on traversing the lens. This predetermined distortion is such that when this wavefront 18 is imaged by the eye 12 , the known measured aberrations of the eye, including higher order aberrations, exactly compensate for the applied predetermined distortion of the wavefront 18 , and an undistorted image is focused onto the retina 20 .
[0072] The lens 14 preferably has two surfaces, 22 , 24 , at least one of which is free-form, in order to enable the lens to compensate for the higher order aberrations of the eye.
[0073] Reference is now made to FIG. 2, which is a flowchart schematically describing the steps taken in constructing a lens according a preferred embodiment of the present invention. In step 30 , the aberrations in the eye to be corrected are measured by means of wavefront analysis, as is known in the art. The output of this measurement is preferably in the form of a Zernike polynomial, describing the wavefront distortion measured in step 30 . In step 32 , the lens position and inclination relative to the patient's eye is measured. These measurements are necessary since the correcting lens and the eye to be corrected together form one optical imaging system to be optimized, and the inter-lens distance of such a system, for instance, is one of the parameters which determines performance. Preferably, the back vertex distance and the pantoscopic angle are the most important parameters required in step 32 . In step 34 , the measurements of the wavefront and lens position made in steps 30 and 32 respectively, are entered into a model including the distorted wavefront and an initial estimate for the precompensating correction lens, typically corrected for power, or power and astigmatism only. The weighted parameters used to define the boundaries and extent of the correction required are stored in step 35 . Using these weighting parameters and correction boundary limits, in step 36 , a lens design is optimized which corrects for the aberrations defined in the model used in step 34 . This optimization can be preferably performed by an optical design software package as is known in the art, such as the Zemax program, manufactured by Focus Software Inc. of Tucson, Ariz., U.S.A., or by any other suitable optimization method. For a given lens material entered into the optimization program, the output of this lens design step is the shape and thickness of the lens, including the shapes of the first surface profile 40 and the second surface profile 38 of the lens. As is known in the art, one of these surfaces may preferably be spherical to correct defocus aberrations, with or without a cylindrical component to correct astigmatism. Use of such a toroidal shape for one surface provides convenience and compatibility with conventionally supplied lens shapes. The second surface may preferably be a free-form surface, computed to optimally compensate the aberrations, including higher order aberrations, measured in step 30 . Alternatively and preferably, both surfaces may be free-form, and their combined refractive effect used to correct both the lower order and higher order aberrations.
[0074] Reference is now made to FIGS. 3A and 3B, which are schematic diagrams for illustrating the use of the terms tilt and field of view. In FIG. 3A, there is shown a schematic eye 40 , whose vision is corrected by means of a spectacle lens 42 . The optical axis of the eye 40 is tilted with respect to the lens 42 , such that the light from the object being viewed traverses the lens 42 at an angle from its optical axis. This angle is known as the tilt angle 44 . Since the eye is tilted towards the direction of the object, the light is focused onto the fovea 46 of the retina, which is the center of sharpest vision.
[0075] In FIG. 3B, there is shown the same schematic eye 40 as in FIG. 3A, with its vision corrected by means of a spectacle lens 42 . However, in this case, in order to illustrate the effect of differing fields of view on the subject's vision, the eye 40 is shown untilted with respect to the spectacle lens 42 . The solid lines show the optical axis of the eye 48 and an incoming axial beam of light 50 being focused by the eye onto the fovea 46 of the retina. In contrast to this, the dotted lines show an incoming off-axis beam of light 52 , whose central ray 54 makes an angle 56 with the optical axis of the eye which delineates the limit of the field of view. Because of the angle of the FoV, the off-axis beam is not focused onto the retina at the fovea 46 , but at a spot 58 some distance from it.
[0076] The field of view in a typical normal subject extends to approximately a half solid angle, being slightly more than 180° in the horizontal direction, and slightly less in the vertical direction. However, it is well-known from the physiology of the eye, for instance in FIG. 5. 2 on page 129 of the book entitled “Modern Optical Engineering” by W. J. Smith, published by SPIE Press, McGraw Hill, New York, 3 rd . edition, 2000, herewith incorporated by reference, that the visual acuity of the eye decays very rapidly as the retinal position of the image moves away from the fovea. Thus, for example, when the incoming light is at an angle of ±2° from the eye's optical axis, the visual acuity is only approximately 50% of its maximum foveal value, while for an angle of ±20°, the visual acuity is one order of magnitude less than its maximum foveal value. The subjective result of this phenomenon is that the field of view practically used by a typical healthy subject is generally limited to a very small angle, of the order of a degree or two in normal visual usage. For this reason, correction for aberrations over a wide field of view is not regarded as necessary, since only a narrow field of view is generally used.
[0077] Tilt, on the other hand, is a widely used movement in normal visual activity, and angles of tilt of 20°, and even more, are typically used before the muscular discomfort of holding the eyeball tilted makes it preferable for the subject to turn his head into the direction he is looking. For this reason, the angle of tilt should preferably be taken into account when optimizing the MTF of the lens/eye system for aberrational correction.
[0078] Weighting factors are applied to the possible ranges of angles of view and angles of tilt and the MTF for the tangential and sagittal fan of rays defined by the boundaries of vision to be corrected are calculated using the relevant weighting factor for each point calculated. Reference is now made to FIGS. 4A and 4B, which show typical graphs of weighting factors W used respectively for the field of view and tilt angles in weighting the MTF for the optimization procedure. Each graph shows the weighting used as a function of the specific parameter only. In FIG. 4A, since the field of view over which correction is required is limited, the preferred weighting curve used is sharp around the optical axis of the eye, and outside of this region, falls rapidly to zero. In FIG. 4B, on the other hand, is shown a preferred weighting curve used for tilt correction, having a wide top and a broad half-width, such that tilt over a wide range of angles is taken into account in optimizing the MTF of the eye/lens optical system. The exact shape of the weighting curves is selected according to a combination of the physiological effects of the parameter being weighted, and the subjective requirements of the correction desired. The angular extent of the weighting curves defines the boundaries of correction to be applied.
[0079] The MTF of the eye/lens system, for use according to a preferred method of optimization of the present invention, is given by the expression:
MTF=MTF [V,(α FoV ), (α t )],
[0080] where: V is the spatial frequency in cycles per mm;
[0081] α FoV is the vectorial angle in the field of view; and
[0082] α t is the tilt angle.
[0083] It is understood that the angles are taken over the complete range in both azimuthal and vertical directions.
[0084] According to this first preferred method of the present invention, the lens parameters, such as the surface shapes, and the lens thickness, are optimized using a commercial optical design program, in order to maximize the total sum of the MTF of the eye/lens system, within the constraints of the boundaries and weightings given to the visual parameters, as described above. Alternatively and preferably, any other optimization method can be used besides commercial optical design software. This summation of MTF's can be expressed as:
ΣMTF[V, α FoV , α t ]·W[V, α FoV , α t ]
[0085] where W is the predetermined weighting function as a function of the spatial frequency resolution; the field of view angle; and the tilt angle.
[0086] The spatial frequency may or may not be weighted depending on the method of subjectively specifying the value of the MTF in determining required system performance. Spectacle lenses for different subjective use may preferably be constructed emphasizing better low spatial frequency performance, or high spatial frequency performance, or neither, and a weighting factor applied or not applied accordingly.
[0087] The result of this optimization process is a spectacle lens which provides optimum correction of aberrations, including higher order aberrations, for the subject's eye over a predefined range of tilt angles and over a predefined field of view, and optionally over a predefined range of spatial frequencies. The lens according to this preferred embodiment of the present invention provides super vision over the range of tilts and field of view preselected. Though the level of visual acuity attained falls short of the maximum level possible with an optimized, purely axial correction, it is generally still significantly better than the level of visual acuity achievable with prior art lenses corrected for low order aberrations only, and also better than the level of visual acuity achievable overall with prior art lenses corrected for higher order aberrations but only for paraxial vision.
[0088] According to a second preferred embodiment of the present invention, the correction lens design is optimized, by means of an optical design program, such that the wavefront which exits the eye, after passing through the correction lens, has a minimum level of aberrational distortion departure from a plane wavefront. One preferred method of defining this minimum is by taking the RMS departure from a plane wavefront of the calculated wavefront at each point, and summing all of these RMS values for each optimization iteration, to achieve the minimum RMS deviation level. This ensures that the lens provides optimal correction of the aberrations of the eye, including high order aberrations. Like the first preferred embodiment, the optimization is performed taking into account the relative weighting factors and boundaries of the field of view and tilt angles, and the spatial frequency range over which optimum correction is to be achieved. Like the first embodiment, the major weighting is preferably applied to the tilt angle, such that the resulting lens design is that which shows optimal aberration correction, including high order aberrations, over the defined tilt angle range, and with minimal sensitivity to change of the tilt angle.
[0089] Reference is now made to FIGS. 5A and 5B, which schematically illustrate the result of the above optimization process for an on-axis imaging case, and for a case of the eye imaging at a tilt angle. In FIG. 5A, the measured wavefront 60 at the exit of the eye 62 , distorted because of the inherent aberrations of the eye, is corrected by paraxial passage through a lens 64 , constructed according to one of the preferred methods of the present invention, and the resulting wavefront measured in front of the lens is a corrected wavefront 66 , as optimally close to an undistorted plane wave as the optimization procedure of the present invention has allowed.
[0090] In FIG. 5B, the eye 62 is tilted at an angle 68 to its natural straight-ahead position. The wavefront 60 measured on the eye's optical axis at its exit is identical to that measured for the case of FIG. 5A since the aberrations are, to a first order, independent of roll of the eye. The wavefront in this case passes through the correction lens non-axially, but the lens, constructed according to one of the preferred methods of the present invention, is such that the resulting wavefront measured in front of the lens is a corrected wavefront 70 , as optimally close to an undistorted plane wave as the optimization procedure of the present invention has allowed. In general, the correction achieved at such a tilt angle is less than that achieved for the wavefront 66 in the straight-ahead case shown in FIG. 5A, but the correction is still sufficiently good that the level of visual acuity achieved is generally better than that achieved by prior art methods of correction only of low order aberrations. By alternative selection of the weighting factors used in the optimization procedure, optimum correction can be preferably achieved at angles other than for the straight-ahead orientation, if this is the desired performance required.
[0091] Reference is now made to FIGS. 6 to 10 , which are plots of the modulation transfer function for images produced by a standard healthy eye, a myopic eye, an eye whose vision is corrected by means of a prior art spectacle lens, correcting for low order aberrations only, and an eye corrected by means of spectacle lenses constructed according to preferred embodiments of the present invention. It should be emphasized that the MTF curves plotted represent the performance of the optical imaging system only, and that retinal limitations will generally not enable achievement of the full acuity indicated by the MTF curves. The MTF curves are plotted for an eye having an entrance pupil of 3 mm, and for fields of view of up to 10°. The diffraction limit for these conditions is also plotted on each graph, as curve 71 .
[0092] [0092]FIG. 6 is a set of MTF curves for a standard healthy eye, having what is commonly termed 20/20 vision. Curve 72 shows the MTF for on-axis vision down the center of the field of view. The MTF curves labeled 73 and 74 are those obtained at the limits of the field of view used in this optimization, namely ±10°.
[0093] In FIG. 7, there is shown a typical set of MTF curves 75 of a myopic eye. As is observed, the MTF is severely degraded from that of the standard eye shown in FIG. 6, even at very low spatial frequencies. Little difference is observed over different angles of field of view.
[0094] The use of prior art spectacle lenses to correct for defocus and astigmatism only, is able to provide an MTF, as shown in FIG. 8, similar to that of the standard eye. Curve 76 shows the MTF at the center of the field of view, and curves 77 and 78 at the limits of the field of view used in this optimization, namely ±10°. As is observed, the correction at the center of the field of view is good, but it decays significantly off axis, especially at the higher spatial frequencies.
[0095] Reference is now made to FIG. 9, which is an MTF plot of an eye, whose vision has been corrected by means of a spectacle lens constructed and operative according to a preferred embodiment of the present invention, to provide the optimum possible higher order aberration correction over a field of view of ±10°. The MTF for the central field of view is marked 80 , and those at the extremities, 77 and 78 .
[0096] As is observed, the MTF curves are significantly improved with respect to those obtained with the prior art lens, shown in FIG. 8, and even with respect to a healthy eye, such that an excellent level of super vision is achieved. It is found that an improvement of up to 300% is obtained in the MTF of the corrected visual image, and as is observed, the MTF curve is very close to that of the diffraction limit for that pupil size. In effect, such a level of improvement in visual acuity is not practically achievable, since due to the size of the photo-receptor spacing on the retina the retinal resolution limits optimum visual acuity to about 20/8. An important feature of the results shown in FIG. 9 is apparent in that the visual acuity at the edges of the allowed field of view shows only a slight fall off in performance from that on axis. The visual acuity achieved is seen to be still significantly better than that achieved with the prior art correction lens, or even with a standard healthy eye.
[0097] However, the optimum correction shown in FIG. 9 is only achieved for on-axis vision, when the eye is centralized with respect to the optical axis of the corrected lens, both laterally and angularly, and the MTF is optimized for the full field of view chosen, ±10°. If the eye and lens are mutually tilted such that there is an angular deviation between these two optical axes, then the image quality decays in comparison with the on-axis con.
[0098] Reference is now made to FIG. 10, which illustrates this effect of tilt. FIG. 10 is an MTF plot of an eye, whose vision has been corrected by means of the same spectacle lens as is used to provide the on-axis visual image quality shown in FIG. 9, but wherein the lens is tilted relative to the eye by an angle of 10° from the on-axis case. The curves 82 and 83 show the MTF obtained at the limits of the tilt used, ±10°. As is observed, the MTF decays from the on-axis case, but is still similar to that provided by the prior art, low order aberration correction lens, as shown in FIG. 8, or that provided by a standard healthy eye. This lens can thus be summarized as giving close to optimum super vision for on-axis vision, without an unreasonable decay of correction when the eye is rolled.
[0099] If however, the optimization procedure were to be performed over the selected range of angles of tilt, using a higher tilt weighting factor, and a lower field of view weighting factor, the lens performance could be modified to provide better acuity at higher tilt conditions than those shown in FIG. 10
[0100] Reference is now made to FIG. 11, which is a schematic view of a spectacle lens 90 , constructed and operative according to another preferred embodiment of the present invention, in which the lens is divided into two areas, a central area 92 , covering a field of view of ±1° when the spectacles are worn correctly, and an outer area 94 . In the central area, the lens is designed to provide optimum paraxial high order aberration correction, such as that shown in FIG. 9. In the outer area 94 of the lens, correction is applied only for low order aberrations, such as defocus and astigmatism, such prior art corrections being more tolerant of angular tilt than the high order aberration correction of the central area 92 . As a result, when the user's eye is directed paraxially through the central area of the lens, the optimum level of super vision is obtained, whereas when the user rolls his eye to look at an angle to the optical axis of the lens, he observes a conventionally corrected image, such as is obtained using currently available spectacle lenses. A smooth transition is preferably arranged between the two areas of the lens, to provide a natural image. Such an embodiment can be effectively described in terms of the weighting factors, wherein the FoV weighting factor is made very sharp, almost resembling a step function.
[0101] It is appreciated by persons skilled in the art that the present invention is not limited by what has been particularly shown and described hereinabove. Rather the scope of the present invention includes both combinations and subcombinations of various features described hereinabove as well as variations and modifications thereto which would occur to a person of skill in the art upon reading the above description and which are not in the prior art. | A novel method for the design and construction of a spectacle lens for the correction of human vision, including the correction of high order aberrations. The lens enables the provision of super-normal vision using spectacles. Different lenses are described for use at a partial or a fuller field of view. The method applies corrective measures based on data obtained from high order wave front measurements of the subject's eye. According to one method, the Modulation Transfer Function (MTF) of the overall eye and lens optical system is optimized. According to another method, the optimization is performed on the wavefront of the overall eye and lens optical system. Both methods use weighted functions in the optimization procedure. This method of high order aberration correction is also applicable for the design of contact lenses and intra-ocular lenses, and for the execution of refractive eye surgery. | 0 |
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