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BACKGROUND OF THE INVENTION
This invention relates to an ignition system having capacitive intermediate storage of the energy required for the ignition pulse. The present invention relates, more particularly, to an ignition system having a plurality of storage capacitors which are charged from a battery via a charging device, the capacitors being temporarily discharged sequentially by means of switches via an ignition transformer so as to provide an input to a spark plug. The ignition system is particularly suitable for use in conjunction with Otto and Wankel engines.
Capacitor ignition systems are known per se and are described in detail, particularly in comparison to previously generally employed coil ignition systems; see, for comparison, Motortechnische Zeitschrift, Vol. 24, pages 291-295 and pages 439-443 (1963) as well as Elektronik, Vol. 8, pages 235-238 (1966).
A comparison of the high voltage capacitor ignition systems (HVCI) and the coil ignition systems shows that the capacitor ignition systems are substantially insensitive to soiling of the spark electrodes of the spark plug and its adjacent portions which results during operation from lead, soot and combustion residues. The spark duration during discharging at the spark electrodes of the spark plug for capacitor ignition is ordinarily very short compared to the spark duration conditions for coil ignition. Whenever coil ignition is used, a series of subsequent sparks and glow periods follow the actual initial spark ignition at the spark plug, occuring at the end of the voltage rise time, when voltage across the plug is in its maximum. In such a case, even if the spark ignition occuring at the voltage peak itself were not able to cause a fuel ignition, the prepared fuel-air mixture can nevertheless be ignited by the subsequent sparks (required spark duration up to about 1400 μsec.) The known ignition with HVCI involves substantially only the initial spark and a relatively very short follow-up discharge time (about 50 μsec.). Depending on the type of engine and its operating state, individual fuel mixture ignitions may be missing because the single occurring spark between the electrodes of a spark plug will not always initiate the fuel ignition with certainty; for example, whenever the composition of the fuel-air mixture is unfavorable and/or the constituents are inhomogeneously mixed.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a high voltage capacitor ignition system in which the above-mentioned drawbacks resulting from a single triggering spark having a short firing duration are avoided.
Another object of the present invention is to provide a high voltage capacitor ignition system having increased dependability for the ignition of the fuel mixture.
These and other objects are achieved by an improved ignition system, having a capacitive storage arrangement which includes a plurality of capacitors for storing energy required for developing ignition pulses. A charging circuit is connected between each of the capacitors and a direct current supply for charging the capacitors. An ignition transformer is coupled respectively to each of the capacitors via respective thyristors. A firing circuit is coupled to the thyristors for selectively, individually firing the thyristors during successive time intervals so as to discharge sequentially the capacitors via the ignition transformer.
A plurality of parallel connected storage capacitors and respectively associated thyristors are provided which are consecutively fired to discharge sequentially the storage capacitors.
The ignition system according to the present invention provides that a plurality of sparkovers are produced at the spark plug in rapid succession so that dependable ignition of the fuel-air mixture is assured. Depending on the time of the initiation of the discharge of the next following storage capacitor, the arc discharge across the electrodes of the plug will either already have been terminated or it will be still continuing. In the former case, a further spark ignition is produced with a subsequent arc discharge; in the latter case, the still present arc discharge remains in effect for a correspondingly extended period of time.
In practice, the effective spark duration is thus increased by the ignition system of the present invention in proportion to the number of storage capacitors, assuming that all capacitances are identical, it being a question of circuit design or advisability -- as regards the engine -- whether further spark ignitions are produced in the meantime. This assures that even with unfavorable fuel-air mixture conditions or operating states combustion interruptions will no longer occur. Whereas such high dependability could previously be achieved only with the dual arrangements of complete ignition systems, as for example in some Wankel and aircraft engines, the ignition system of the present invention produces satisfactory operation using an arrangement which includes a plurality of storage capacitors and switching devices, such as thyristors. Such components can today be manufactured inexpensively with relatively few structural parts.
In a preferred embodiment of the present invention an ignition pulse generator is provided which feeds pulses for the timed sequence of ignitions to the control inputs of a plurality of thyristors. This ignition pulse generator may be constituted, for example, by shift register controlled by a clock pulse generator or by a plurality of monostable flipflops which can be constructed as an integrated circuit. When monostable circuits are employed, the ignition pulse is derived via a differentiation circuit from the trailing edge of the output signal which has been, in effect, delayed by a desired time period. Alternatively, known pulse delay circuits or networks can be employed which produce second and subsequent pulses that are delayed with respect to an initial pulse, the first delay and subsequent delays being arbitrarily predetermined, as for example in a delay line.
In order to assure complete discharging of the storage capacitors and to prevent oscillation of the discharge voltage during the discharging of the storage capacitors, the present invention provides for the connection of a bypass diode in parallel with the primary winding of an ignition transformer.
It has been found, however, that during discharging of the individual storage capacitors the oscillation occurring at the primary side of the ignition transformer is strongly attenuated but that it does temporarily produce negative polarity values of the discharging voltage, in spite of the parallel connected, bypass diode.
A negative voltage pulse produced during discharging of the first storage capacitor could cause the thyristors disposed in the parallel branches and associated with the other storage capacitors to be fired at an undesired point in time. In order to assure definitely that the second and possibly subsequent storage capacitors will discharge only at the desired points in time as determined by the ignition pulse generator, the present invention provides means for preventing the firing of the thyristors during passage of the discharge voltage through the zero value. In particular, Zener diodes are provided in the control inputs of the thyristors, the diodes having a Zener voltage higher than the highest occurring negative discharging voltage. According to another preferred embodiment of the invention, thyristor firing transformers may also be provided in the control inputs of the thyristors.
The use of these measures, i.e. the placing of Zener diodes or thyristor firing transformers in the control input paths to the thyristors, it is assured that the discharges following the discharge of the first capacitor will not occur at the moment when the voltage passes through the zero point.
The passage of the discharging voltage through the zero point can be utilized, in particular preferred embodiments of the present invention, to produce a simple and inexpensive circuit arrangement for producing an ignition pulse for the thyristor of the second discharging circuit. In an ignition system having two discharging circuits, the pulse for firing the second thyristor is derived from the discharging pulse of the first discharging circuit, the control input of the thyristor of the second discharging circuit being connected to zero voltage, or reference point, of the system. In this manner a special firing pulse generator can be eliminated, the discharge of the second discharging circuit directly following the discharge of the first discharging circuit.
If a discharge of the second discharging circuit directly after the discharging of the first discharging circuit is not desired, the present invention provides another solution according to which, without any special additional means, such as Zener diodes and/or thyristor firing transformers, a firing of the thyristors by the negative values of the charging voltage at undesirable times is prevented. In this case, the cathodes of the thyristors, together with one side of the primary winding of the ignition transformer are connected to the zero reference potential of the system and the other side of the primary winding is connected to the negative polarity side of the charging device. It is assumed that the charging device, in this case, includes a transformer whose secondary and primary windings are conductively, or ohmically, isolated from one another. In this manner it is assured that the cathodes of the thyristors are always at a clear potential, i.e. zero volts, so that undesired firing of the thyristors cannot be produced at this point.
In order to reduce the power input requirement of the ignition system according to the present invention and to reduce the capacitive load on the direct voltage converter, a further preferred embodiment of the present invention provides that the storage capacitors have different dimensions so that the capacitances become smaller in the sequence of their discharge. The first discharged capacitor has the highest capacitance and the last discharged capacitor has the lowest capacitance. This is based on the consideration that the first sparkover at the spark plug will lead, if not to ignition of the fuel-air mixture, to a substantial ionization of the mixture so that the subsequent discharges at the spark plug require only little energy to ignite the fuel-air mixture.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic and block diagram of a high voltage capacitor ignition system having a multiple discharge circuit in accordance with the present invention.
FIG. 2 is a schematic and block diagram of a control circuit including a shift register particularly useful in practicing the present invention.
FIG. 3 shows waveforms including a clock pulse waveform used in explaining the operation of the circuit of FIG. 2.
FIG. 4 is a schematic and block diagram of a control circuit having an arrangement of monostable multivibrators particularly useful in a preferred embodiment of the present invention.
FIG. 5 shows waveforms including a clock pulse waveform helpful in understanding the operation of the circuit of FIG. 4.
FIG. 6 is a schematic and block diagram illustrating a preferred embodiment of the present invention including a pulse delay ciruit for a firing pulse generator.
FIG. 7 is a schematic diagram of a circuit arrangement having a thyristor firing transformer in the control electrode input line of a thyristor.
FIG. 8 is a schematic diagram of a circuit arrangement for firing a second thyristor by the discharge pulse of a first discharge circuit in accordance with a preferred embodiment of the present invention.
FIG. 9 shows the voltage waveform on the primary side of the ignition coil illustrated in the circuit of FIG. 8.
FIG. 10 is a schematic and block diagram illustrating a preferred embodiment of the present invention including an ignition circuit having thyristor cathodes connected to ground.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 1, a multiple discharge circuit for an ignition system includes a battery 1, for example an automobile battery and a charging circuit 2, for example a direct voltage to direct voltage converter. The battery 1 furnishes energy for charging storage capacitors 3, 4 and 5 from the charging circuit 2. The storage capacitors 3 to 5, which are arranged in parallel branches, have respective thyristors, 6, 7 and 8 associated with them, the thyristors 6 to 8 being controlled to fire by respective outputs of an ignition pulse generator 9. This pulse generator 9 is triggered by a conventional device for example breaker points 10 or a magnetic generator.
Whenever any one of the thyristors 6 to 8 is fired the respective one of the capacitors 3 to 5 disposed in series therewith is discharged, an ignition transformer 11 being coupled between each of the storage capacitors 3 to 5 and a spark plug (not shown) as usual to convert the stored voltage on the respective storage capacitors 3 to 5 into the required firing voltage of from about 10 kv to about 30 kv. An ungrounded output terminal 12 from the secondary winding of the ignition transformer 11 leads to a so-called ignition distributor (not shown) in which conventional interrupter contacts, high voltage terminals and usually firing angle adjustment arrangements are accommodated. The other terminal of the secondary winding of the transformer 11, as well as one terminal of its primary winding, is connected to a fixed reference voltage (ground).
At the given firing time, the breaker points 10 are operated to activate the pulse timer 9, which produces a first pulse, thereby discharging the capacitor 3 by firing the thyristor 6 so that a first arc or glow discharge occurs at the spark plug which is coupled to the terminal 12 via the conventional ignition distributor. This first arc or glow discharge has a duration of substantially 50 μs.
When the spark path is extinguished, a slight amount of residual energy will produce an oscillation, however no additional sparkover occurs between the points of the spark plug. After a time interval of, for example, about 50 μs, the thyristor 7 associated with the second storage capacitor 4 is fired by a pulse from the firing pulse generator 9 so that this storage capacitor is also discharged. Consequently, a second discharge will occur between the points of the spark plug. the triggering voltage of the spark path for the discharge following the first discharge, due to the strong ionization of the fuel-air mixture by the first spark, will generally be substantially reduced. The capacitor 4 and the capacitor 5, which is subsequently discharged via the thyristor 8, may have lower capacitance, under certain circumstances, than the first capacitor 3. Since the fuel-air mixture is already ionized, the required energy for ignition of the fuel-air mixture by action of the second or third discharges can be less.
In order to prevent the first capacitor 3 from becoming charged from the other two capacitors 4 and 5 after the capacitor 3 has been discharged, the individual parallel branches associated with the capacitors 5 and 6 are coupled together and to the capacitor 3 via respective blocking diodes 13. To assure complete discharging of all the capacitors 3 to 5, and to prevent an undesired change in polarity of the voltage across the primary winding of the transformer 11, a bypass diode 14 is connected in parallel with the primary winding of the transformer 11. The transformer 11 is effective to step up the voltage applied to its primary winding to the firing voltage of from about 10 kv to about 30 kv, the high voltage appearing at the terminal 12 which is coupled to an electrode of the spark plug via the conventional ignition distributor.
In the illustrated embodiment of FIG. 1, the ignition system has three parallel-connected storage capacitors. It is to be understood, however, that the invention is not limited to systems having three storage capacitors; rather, the invention may be practiced with circuits which include only two storage capacitors or more than three storage capacitors. A control circuit specifically usable in conjunction with four storage capacitors is illustrated in FIG. 2, waveforms helpful in understanding the operation of this control circuit being shown in FIG. 3.
In FIG. 2, a control circuit, which includes a pair of breaker points 15, corresponding to the breaker points 10 of FIG. 1, and a pulse generator, corresponding to the pulse generator 9 of FIG. 1, is illustrated in detail. The control circuit includes a firing time generator, shown as the pair of contacts 15, connected to a pulse forming circuit 16 whose DATA output signal appears as a pulse only when the pair of contacts 15 are opened and whose CLEAR output signal appears as a ONE only when the pair of contacts 15 are closed.
The CLEAR and DATA output signal terminals are connected respectively to the CLEAR and DATA input terminals of a shift register 17. The data output terminal of the pulse forming circuit 16 is also connected to the SET input terminal of a bistable multivibrator (flip-flop) 18 so that the output of the latter is set to ONE whenever the pulse forming circuit 16 supplies a ONE signal from its DATA output terminal to the SET input terminal of the bistable multivibrator 18.
The output terminal of the bistable multivibrator 18 is connected to a first input terminal of a two-input NAND circuit 19 whose other input terminal is connected to the connecting point between the free terminal of a grounded capacitor 20 and one terminal of a resistor 21. The other terminal of the resistor 21 is connected to the output terminal of the NAND circuit 19.
The circuit elements 19-21 operate as a clock pulse generator which feeds its clock pulses to the CLOCK pulse input terminal of the shift register 17, the clock pulses being produced so long as the bistable multivibrator 18 remains in the state in which it is set by the pulse signal from the DATA output terminal of the pulse forming circuit 16.
The output terminal of the NAND circuit 19 is also coupled to the input terminal of an inverter circuit 22 which has its output terminal connected to a first input terminal of a two-input NAND circuit 23. The output terminal of the NAND circuit 23 is connected to the RESET input terminal of the bistable multivibrator 18. The second input terminal of the NAND circuit 23 is connected to the fourth (D) output terminal of the shift register 17, the shift register 17 being provided with five output terminals A, B, C, D and E, the fifth terminal E being connected to the RESET input terminal of the shift register 17.
The output terminals A to D of the shift register 17 are respectively connected, via respective transistor stages 24 to 27 and respective diodes 28 to 31 (only transistors 24, 27 and diodes 28, 31 being shown) to the firing electrodes of four respective thyristors (not shown) which are operatively arranged, for example as shown in FIG. 1, to discharge sequentially four storage capacitors which, in turn, supply input signals to an ignition transformer corresponding to the ignition transformer 11 of FIG. 1.
The respective transistors 24-27 are provided with respective, emitter-to-ground resistors 32 to 35, and with respective series connected resistors 36 to 39 between their respective base electrodes and the respective output terminals A to D of the shift register 17.
It can be assumed firstly that all of the output terminals A to E of the shift register 17 have a ZERO signal appearing thereon because of the appearance initially of a ONE signal on the CLEAR input terminal of the shift register 17. Upon the opening of the pair of contacts 15, the pulse forming circuit 16 supplies a pulse signal to the DATA input terminal of the shift register 17 causing the shift register 17 to provide a ONE signal on its output terminal A. This ONE signal causes the transistor 24 to conduct and a firing pulse is supplied to the first thyristor (not shown) via the diode 28.
The pulse signal from the pulse forming circuit 16 also is fed to the bistable multivibrator 18 and sets it into a first state thereby energizing the clock pulse generator 19-21. The clock pulse generator 19-21 supplies clock pulses to the CLOCK input signal of the shift register 17 shifting the ONE signal from stage to stage of the shift register 17 so as to cause the transistors 25-27 to become conductive in sequence as a result of the sequential appearance of the ONE signal on the terminals B to D. Thus firing pulses are supplied to the second to fourth thyristors (not shown) via respective diodes (diode 31 being shown) subsequent to the firing of the first thyristor.
Upon the appearance of a ONE signal on the output terminal D, the bistable multivibrator 18 is reset by action of the NAND circuit 23 which has its second input connected to the output terminal D of the shift register 17. Thus the clock pulse generator 19-21 is turned off, its final CLOCK pulse shifting the ONE signal stored in the shift register 17 to the last stage of the shift register 17, a ONE appearing on the terminal E. Since the terminal E is connected to the RESET terminal of the shift register 17, the shift register 17 is reset and awaits another pulse from the pulse forming circuit 16.
FIG. 3 shows that, for example, every 5 msec. a firing pulse is produced by the pulse forming circuit 16 upon the opening of the pair of contacts 15 of the firing time generator. This pulse actuates the bistable multivibrator 18 to enable the clock pulse generator 19-21.
The pulse signal supplied to the DATA input of the shift register 17 sets the first stage of the shift register and a ONE signal is produced at the output terminal A. All other output terminals B to E have been set and remain for the present at ZERO. With each subsequent clock pulse from the clock pulse generator 19-21 the ONE information is shifted stage-by-stage and appears sequentially as ONE's on the terminals B to D, as can be seen in FIG. 3, only one ONE signal appearing at any time. Thus, the first to fourth thyristors (not shown) are fired in succession. If the ONE signal has reached the output terminal D of shift register 17, the clock pulse generator 19-21 is blocked via the bistable multivibrator 18 until the next firing pulse is produced by the pulse forming circuit 16.
A further possibility for controlling a plurality of, for example four, thyristors is provided by the circuit arrangement shown in FIG. 4 using a plurality of monostable multivibrators 40-43. A firing time generator, shown as a pair of contacts 44, is connected to the input of a pulse forming circuit 45. Each of the multivibrators 40-43 has its CLEAR input terminal connected to an output terminal of the pulse forming circuit 45. The respective Q outputs of the multivibrators 40-43 are connected, respectively, to respective control electrodes of transistors 46 to 49 via respective resistors 50 to 53. The emitters of the transistors 46 to 49 are connected to ground via respective resistors 54 to 57 and to respective firing electrodes of four thyristors (not shown) via respective diodes 58 to 61. When the pair of contacts 44 is opened, all the monostable multivibrators 40 and 43 are set to ZERO by the initial pulse fed to their respective CLEAR inputs, i.e. their Q outputs display ZERO signals, as shown in FIG. 5. With only a slight delay the B (data) input of the multivibrator 40 receives a trigger pulse (FIG. 5) from the pulse forming circuit 45 which pulse makes the transistor 46 conductive via the Q 1 output (FIG. 5) from the multivibrator 40 and thus controls the first thyristor (not shown) via the diode 58. After expiration of a given delay time, determined by an external RC circuit, the multivibrator 40 returns to its stable state and triggers the multivibrator 41 via its Q 1 output. This multivibrator 41 fires the second thyristor (not shown) via the transistor 47 and diode 59. After further predetermined delay times, the third thyristor (not shown) is triggered by the Q 2 and Q 3 outputs and the fourth thyristor (not shown) is triggered via the Q 3 and Q 4 outputs. After this signal passage, all Q outputs of the multivibrators 40 to 43 show ZERO signals. A further clearing signal would not be required before the next firing time. However, in order to prevent faulty operating states, such as for example as a result of an absence of the operating voltage, a clearing signal pulse is preferably always again provided from the pulse forming circuit 45. As can be seen from FIG. 5, the Q 1 , Q 2 , Q 3 and Q 4 outputs from the multivibrators 40 to 43 appear sequentially as ONE's.
The waveforms of FIG. 5 show the above-described operating states. The signal pulse first reaches all CLEAR inputs of the multivibrators 40 to 43 from the pulse forming circuit 45 and sets all of the Q outputs to ZERO. After a short delay time, which is less than 1 μsec., the multivibrator 40 receives a trigger pulse from the pulse forming circuit 45 and an output pulse of, for example, 30 μsec. appears at its Q 1 output as a ONE level signal. This first rectangular pulse is then followed directly by sequential Q 2 , Q 3 and Q 4 output pulses of the ONE level from the subsequently connected multivibrators 41 to 43, which response respectively to the disappearance of the ONE level signals on the Q 1 , Q 2 , Q 3 outputs of the multivibrators 40 to 42.
A further embodiment of an ignition system according to the present invention is shown in FIG. 6. Opening of a pair of contacts 62 of the firing time generator causes a firing pulse control signal to reach the firing electrode of a thyristor 63 from the pulse forming circuit 64 via a diode 65. The thyristor 63 conducts therby discharging a capacitor 66 via a primary winding 67 of an ignition transformer 68. A positive voltage pulse appears across the primary winding 67 of the ignition transformer 68. Oscillation is prevented by a bypass diode 69 connected across the primary winding 67. The positive pulse is fed to a series resonant circuit including a coil 70 and a capacitor 71, having a resonant frequency of, for example, 10 KHz and connected between the high side of the primary winding 67 and ground. An attenuated periodic oscillation as a result appears across the capacitor 71. The first negative half wave of this oscillation is fed via a rectifier 72 and resistor, and appears across a resistor 73 as a pulse. The pulse which appears across the resistor 73 is fed via a coupling capacitor 74 to a conventional phase-inverter amplifier 75 and thence to a conventional emitter follower 76 via a coupling capacitor 77. Positive half waves do not reach the amplifier 75 because of the action of the rectifier 72 and a diode 78 which in effect shorts positive half waves to ground.
The resulting positive pulse, which constitutes the output from the emitter follower 76, is delayed in time by about 50 μsec. by virtue of inherent delay of the circuit and is fed to the firing electrode of a thyristor 81 via a series connected zener diode 79 and diode 80. Thus a further positive voltage pulse is produced across the primary winding 67 of the ignition transformer 68 as a result of the thyristor 81 discharging a capacitor 82. In order to prevent the charge on either of the capacitors 66 and 82 from charging the other, isolating diodes 83 and 84 are connected in series with respective capacitors 82 and 66 and a 350 volt source. The circuit of FIG. 6 is relatively insensitive to interfering noise pulses, an important desirable characteristic for ignition systems. It is to be understood that if required additional time delay could be provided by appropriate delay circuit members incorporated into the circuit of FIG. 6 if needed in any particular case for firing the thyristor 81.
FIG. 7 shows another possibility for firing a thyristor, for example a thyristor 85 corresponding to the thyristor 7 in the second discharge circuit of the ignition system of FIG. 1, definitely only at the moment predetermined by the firing pulse generator. In addition to a resistor 86 and a diode 87 connected in series, both serving to protect the thyristor 85, a special thyristor firing transformer 88 is provided, its secondary being connected across the series connected resistor 86 and the diode 87. The resistor 86 is connected between the firing electrode and the cathode electrode of the thyristor 85. The transformer 88 thus conductively isolates the firing pulse generator, which is to be connected to the input terminal 89 of the primary winding of the transformer 88, from the firing electrode of the thyristor 85. This conductive isolation assures that the negative voltage pulses occurring during discharging of the first capacitor (not shown) will not lead to firing of thyristor 85.
The firing pulse generators may here be, as already mentioned, a shift register controlled by a clock pulse generator or a plurality of monostable flip-flops. When moonostable circuits are employed, the firing pulses are derived, using a differentiating circuit, from the trailing edge of output signals which has been delayed for the desired period of time. However, known pulse delay circuits and networks could also be used which produce second and subsequent firing pulses having appropriate time delays with respect to the first firing pulse which can be arbitrarily predetermined, such as in delay lines, for example.
As shown in FIG. 8 a circuit arrangement in accordance with a preferred embodiment of the present invention includes a battery 90 for charging the storage capacitors 91 and 92 by means of a conventional charging circuit 93. The storage capacitors 91 and 92 have thyristors 94 and 95 respectively associated with them and, when triggered, effect respectively the discharging of the storage capacitors 91 and 92. A blocking diode 96 is connected ahead of the capacitor 92 to prevent its charge from partially being transferred to the capacitor 91 subsequent to its discharge.
To fire the first thyristor 94 its firing electrode is connected, via a diode 97, to the output of a firing pulse generator 98 which is triggered by the firing time generator, shown generally as a pair of contacts 99. The firing electrode of the second thyristor 95 is connected, via a diode 100 and a resistor 101, to ground, the zero reference point of the circuit. The diodes 97 and 100, which are positioned, respectively, in the control inputs to the thyristors 94 and 95 serve to protect these thyristors against the high positive peak value of the discharge voltage. The cathodes of each of the thyristors 94 and 95 are connected to ground via the primary winding of an ignition transformer 102, the high voltage output of which is developed across its secondary winding and appears at its terminal 103, which in turn is connected to a high voltage distributor (not shown). A bypass diode 104 is connected across the primary winding of the transformer 102.
The operation of a preferred circuit for the ignition system according to the present invention will be explained with the aid of FIG. 9. When the first thyristor 94 is fired by the firing pulse generator 98, which may be provided by any one of a number of known trigger circuits, preferrably operatively arranged to have negative pulse suppression, a voltage results across the primary winding of the ignition transformer 102 as it is shown by the curve 105 and the interrupted curve 106 enlarged in scale for the sake of clarity. The voltage pulse rise and the pulse duration substantially depend on the type of ignition transformer employed, stray inductance, winding capacitances and ohmic resistances being the characteristic parameters. A strongly attenuated oscillation thus results across the primary winding at which, in spite of the bypass diode, a negative voltage peak value of several volts occurs, dependent on the surge current behavior of the diode 104. In practice, the diode 104 will generally be accommodated in a switching device, separated from the ignition transformer 102 so that the resistance of the input line may also influence the oscillation amplitude.
In spite of the provision of the diode 104, there will thus temporarily result a negative value of a few volts for the discharging voltage which, however, can be utilized in a particularly advantageous manner in the circuit of FIG. 8 for firing the second thyristor 95 and thus discharging the capacitor 92 as required. If the firing electrode of the thyristor 95 is connected, as shown, via the diode 100 and the resistor 101 to ground, the electrical reference point of the circuit, the thyristor 95 is fired substantially immediately after the zero passage of the voltage oscillation produced during discharging of the first capacitor 91 so that the capacitor 92 can be discharged at the appropriate time. Thus the discharging of the second discharging circuit is effected directly after the discharging of the first discharging circuit and the voltage across the primary winding of the ignition transformer 102 will approximately correspond to the solid curves 105 and 107 shown in FIG. 9.
As can be seen from the foregoing discussion relative to FIGS. 8 and 9, with a minimum of effort an ignition system according to the present invention can be used to approximately double the effective voltage application period as compared to the conventional capacitor ignition systems.
FIG. 10 illustrates a preferred embodiment of the present invention having the grounded negative pole of a battery 108 as its reference point. Energy is taken from the battery 108 for charging three storage capacitors 109, 110 and 111. The charging is effected by means of a conventional charging circuit 112. The charging circuit 112 includes a transformer for producing the required voltage of several hundred volts, using conductively isolated primary and secondary windings.
The storage capacitors 109, 110 and 111 have associated respectively with them thyristors 113, 114 and 115 whose firing causes these storage capacitors 109, 110 and 111 to be respectively discharged.
The storage capacitors 109 to 111 are each connected between the negative output terminal and the positive terminal of the charging circuit 112, and blocking diodes 116 and 117 are disposed respectively in the input leads to the capacitors 110 and 111. A bypass diode 119 is further connected in parallel with the primary winding of an ignition transformer 118, which primary winding is connected in series with the cathode-anode paths of each of the thyristors 113 to 115.
The cathodes of thyristors 113, 114 and 115 are each connected to ground, the reference point of the system, as well as to a first terminal 120 of the primary winding of the ignition transformer 118, i.e. are at zero potential. The other terminal 121 of the primary winding is connected to the negative output terminal of the charging circuit 112. The negative terminal of the charging circuit 112 is substantially isolated with respect to the reference potential of the system because of the transformer (not shown) employed therein. The cathodes of thyristors 113 and 115 thus lie at an unchanging zero potential (ground) and undesired firing of these thyristors by a negative voltage pulse on the cathode side cannot occur.
The ignition transformer 118, as in the previously-described embodiments, is substantially charged with positive voltage pulses during the discharging of the capacitors 109 to 111. Only the first terminal 120 of the primary winding of the ignition transformer 118 is connected with the reference point which is of no significance for the operation of the ignition transformer 118. Thus a discharging process produces the desired negative high voltage pulses at terminal 122 with respect to the reference point.
The respective firing electrodes 123, 124 and 125 of the respective thyristors 113 to 115 receive a succession of pulses for firing, the firing pulses being furnished by the firing pulse generator (not shown) as shown, for example, in FIG. 1.
It is, however, also within the scope of the present invention to connect instead only two storage capacitors in parallel. The idea of the invention is to produce a plurality (at least two) of consecutive spark heads in order to increase the firing dependability particularly under otherwise unfavorable operating conditions, such as a partial load and/or at higher revolution rates.
It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims.
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An ignition system having capacitive storage of energy required for developing ignition pulses, particularly in Otto and Wankel engines, includes a capacitive storage arrangement, a charging circuit connected between the capacitive storage arrangement and a direct current supply for charging the capacitive storage arrangement, and an ignition transformer coupled to the capacitive storage arrangement via a thyristor switching arrangement for temporarily discharging the capacitive storage arrangement through the ignition transformer to develop pulses therein for application to spark plugs or the like.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present invention is related to co-pending applications entitled “TRACK BUFFER IN A PARALLEL DECODER,” filed Dec. 30, 2004, Ser. No. 11/024,805 and “DECISION VOTING IN A PARALLEL DECODER,” filed Dec. 30, 2004, Ser. No. 11/024,803, the contents of both of which are hereby incorporated by reference in their entirety.
FIELD OF THE INVENTION
The present invention relates in general to wireless communication systems, such as ultrawide bandwidth (UWB) systems, including UWB receivers, mobile receivers and transceivers, centralized receivers and transceivers, and related equipment. More specifically, the present invention relates to a parallel decoder used in such devices to decode received UWB signals encoded according to a code such as a convolutional code.
BACKGROUND OF THE INVENTION
As ultrawide bandwidth (UWB) communication becomes increasingly desirable for wireless devices due to its speed and capacity combined with its resilience to interference within high-frequency bands, it is increasingly necessary to adopt effective error correction and related coding methods for maintaining step with the high accuracy demands associated with UWB communication. It should be noted that a UWB signal may be defined, in accordance with, for example, The Federal Communications Commission “First Report and Order, Revision of Part 15 of the Commission's Rules Regarding Ultra-Wideband Transmission Systems,” ET Docket 98-153, Feb. 14, 2002 as any signal occupying more than 500 MHz in the unlicensed 3.1-10.6 GHz band and meeting a specified energy spectrum or energy spectral density mask. As with many engineering challenges, two predominant constraints guide design activities associated with a UWB system: application speed and power consumption. To address these concerns, various coding schemes can be used to optimize speed and error resiliency while maintaining power consumption at acceptable levels. Thus coding performance and complexity are of great concern in UWB systems.
Convolutional codes are a common choice for coding a continuous sequence of message symbols and provide useful coding performance for UWB systems. For many reasons, convolutional codes can provide power savings due to inherent characteristics of the code and because the error correcting capabilities of the code reduce the requirement for retransmission which can also contribute greatly to saving power on both the transmitter and receiver sides. As will be appreciated by one of ordinary skill, in a convolutional encoder, one message symbol of k bits can be encoded into one code symbol of n code bits, with k and n typically being small integers and with k<n, resulting in a code with a rate of k/n. A typical encoder can be constructed as a shift register plus a series of n connection groups to n summing nodes which produce an n-bit codeword output based on a message symbol input bit and the contents of the shift register. The constraint length K of the encoder is generally taken to be the length of the encoder shift register plus one. Another common parameter used in describing encoders is M which is taken to mean the number of shift register or memory elements. Thus, in the case of a code with a rate of ½, and a constraint length of M=3 (K=4), a typical convolutional encoder for such a code can be described as, for example, a finite state machine (FSM) with 2 M , or 8 states.
In a conventional trellis decoder used for decoding convolutionally encoded signals, the speed at which at which a codeword can be processed is proportional to the trellis depth, or the number of possible state transitions required to converge on the correct message word. Thus for code symbols received at a code rate r n , a decoding operation must perform fast enough to generate the recovered message symbol at the message symbol rate r k . Since, in a conventional decoder such as, for example, a trellis decoder, decisions are made only after the trellis is traversed and the surviving path calculated, the trellis depth can have a large impact on the processing speed required to meet the requirement of generating recovered symbols at the symbol rate. A trellis depths even as short as 2 or 3, double and triple the processing speed required to decode the message symbol at the original message symbol rate leading to unsuitable decoding speeds for high speed transmissions such as transmissions within the UWB symbol rate ranges. Since the trellis depth is a function of the constraint length of the code, and can affect the Forward Error Correction (FEC) capability of the code, along with other desirable features of the code, it would be desirable in the art for a method and apparatus for rapidly decoding a received sequence encoded according to a convolutional code without sacrificing the power savings and other benefits associated with code constraint selection.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying figures, where like reference numerals refer to identical or functionally similar elements throughout the separate views and which together with the detailed description below are incorporated in and form part of the specification, serve to further illustrate various embodiments and to explain various principles and advantages in accordance with the present invention.
FIG. 1 is a block diagram illustrating blocks associated with an exemplary Ultra Wide Band (UWB) receiver in accordance with various exemplary embodiments of the present invention;
FIG. 2 is a diagram illustrating an exemplary timing relationship between a received symbol rate and iteration rates required for decoding in conventional decoders using Add Compare Select (ACS) elements;
FIG. 3 is a diagram illustrating path and branch metrics associated with an exemplary trellis node in accordance with various exemplary embodiments of the present invention;
FIG. 4 is a block diagram illustrating inputs to an exemplary Add Compare Select (ACS) element associated with an exemplary trellis node in accordance with various exemplary embodiments of the present invention;
FIG. 5 is a block diagram illustrating an iterative ACS processing configuration associated with conventional decoding;
FIG. 6 is a block diagram illustrating exemplary parallel ACS elements associated with parallel trellis decoding in accordance with various exemplary embodiments of the present invention;
FIG. 7 is a block diagram illustrating exemplary parallel ACS elements associated with parallel trellis decoding of FIG. 6 , connected in accordance with various exemplary parameters; and
FIG. 8 is a flow chart illustrating exemplary procedures in accordance with various exemplary embodiments of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention provides comparatively low complexity, low power consumption and high speed forward error correction (FEC) in UWB receivers through the use of decoding such as, trellis decoding, Viterbi decoding, maximum likelihood decoding, and the like, of a convolutionally encoded message sequence. The parallel trellis decoder reduces decoding time and decoding power consumption by eliminating the need to iteratively compute decoder trellis traversals and by maintaining a surviving path metric for a series of parallel computation units. Thus, decoded message symbols can be generated at approximately the symbol rate, taking into account certain latency, at reasonable power levels, an achievement which is not generally possible using alternate designs such as conventional iterative, that is, non-parallel, decoder designs including some designs which purport to be at least partially parallel. The present invention accomplishes fast decoding while maintaining acceptable power levels and error correction performance levels associated with convolutional coding.
A series of stages in an exemplary receiver 100 is shown in FIG. 1 . As will be appreciated by those of ordinary skill in the art, convolutional codes as noted above are generated by subjecting a sequence of message symbols to coding operations in a convolutional encoder (not shown). The convolutional encoder applies n generator polynomials to the message sequence to generate a code word having n symbols for every message symbol. A typical convolutional encoder is configured either in hardware, in software, or in a combination of hardware and software, as a linear shift register with M storage locations and n different sets of connections between n respective summation nodes and various combinations of registers within the shift register corresponding to n respective generator polynomials. Each connection set corresponds to a generator polynomial and is associated with one of the n code symbol outputs associated with code words of the convolutional code. In a ½ rate code, for example, 2 code symbols are generated for every 1 received message symbol and thus 2 sets of connections to the encoder shift register corresponding to the generator polynomials for the code are used to generate the 2 code symbols for each code word.
Each of the unique sets of connections to the input shift register associated with the n th generator are exclusive ORed to form the code symbol for the n th generator and the n code symbols from the n code generators are multiplexed such that n code symbols are generated for every k input symbols at the input symbol rate. Code symbols are transmitted at baseband frequency and received as a UWB signal 101 at an exemplary receiver 100 .
As noted above and as shown in Table 1, in accordance with various exemplary embodiments, a message sequence can be encoded with a convolutional code with a rate of ½, and having a constraint length K=6 to achieve a good range performance for various modes. Given a code rate of ½, or a punctured rate of, for example, ¾ for optional modes, the choice of constraint K=6 offers an excellent performance vs. complexity trade-off, requiring, for example, only half the complexity of a code with a constraint K=7. It should incidentally be noted that a convolutional code used in connection with a convolutional interleaver can de-correlate initial demodulator errors, thereby maximizing the FEC benefits associated with the code.
TABLE 1
Data Rate
FEC Rate
Code Length
Range (AWGN)
9.2
Mbps
½
24
29.3
m
28
Mbps
½
24
29.4
m
55
Mbps
½
12
22.1
m
110
Mbps
½
6
18.3
m
220
Mbps
½
3
12.9
m
500
Mbps
¾
2
7.3
m
660
Mbps
1
2
3
m
1000
Mbps
¾
1
5
m
1320
Mbps
1
1
2
m
Table 1 shows supported data rates for low band operation in accordance with various exemplary embodiment of the present invention. The information in Table 1 is based on assumptions for range estimates that include transmit power adjustments for code word spectrum (transmit back-off of 1.2-1.9 dB), 6.6 dB CMOS noise figure for receiver, 2.5 dB implementation loss for data rates up to 220 Mbps (3 dB implementation loss for rates >=500 Mbps) and the like.
The UWB signal 101 can be received at an antenna 102 and input to an RF baseband UWB receiver 103 where soft decision decoding as will be understood to those of skill in the art can be performed on baseband signals associated with the UWB signal 101 to generate soft decision data 104 for input to, for example, a correlator/branch metrics block 105 . It will be appreciated that during correlation, branch metrics can be generated identifying the Euclidian distance for the possible combination of the 2 prospective received code bits. Thus, four branch metric values associated with the four possible combinations of the two soft decision bits are shown as b(11) 106 , b(10) 107 , b(01) 108 and b(00) 109 are generated in the correlator/branch metrics block 105 and input with their respective distances or metric values to Add Compare Select (ACS) path metric block 110 . It will be appreciated that the branch metric values will be used in the ACS path metric block 110 based on a butterfly connection associated with the particular code parameters. Surviving path metrics are calculated in the individual parallel ACS elements as will be described in greater detail herein after.
When surviving states or path metrics are selected in a series of parallel or butterfly connected ACS elements, the states or metrics accumulated in a corresponding series of registers in an exemplary track buffer 112 which is described in greater detail in the related, co-pending application entitled “TRACK BUFFER IN A PARALLEL DECODER” Ser. No. 11/024,805 noted herein above. As more information is received by cycling or spinning the ACS units on the present received symbol, the accumulated surviving path metrics can be rearranged in the track buffer using register exchange techniques within the track buffer. The contents of the track buffer will contain decisions regarding the best estimate of the output symbol for each track corresponding to the outputs of the ACS units. The decisions represent the symbol regarded by operation of branch metric calculation for each ACS unit as the maximum likelihood received symbol. In addition, a voting block 114 which is the subject of the related, co-pending application entitled DECISION VOTING IN A PARALLEL DECODER” Ser. No. 11/024,803 as noted above, can be configured to analyze the contents of the track buffer 112 after a number of cycles and determine an output decision symbol. It should be noted that while the present invention is directed primarily to parallel ACS decoding, some aspects of the track buffering and voting will be discussed but only, for example, as they relate to parallel decoding.
It is important to note that in a conventional trellis decoder, as shown for example in FIG. 2 , inputs 202 are applied to a decoder or processor 200 having an iterative ACS calculator 201 . A review of the operation of the iterative ACS path metric calculator 201 in comparison to, for example, the output of symbols at output 203 , reveals that for symbols output at a symbol rate 204 , an n-cycle iteration rate 205 is necessary such that an n-stage trellis can be traversed within the processor 200 in order to generate a decision or output symbol at the symbol rate 204 . It can be easily appreciated that for data or symbol rates requiring support under UWB specifications, the n-cycle iteration rate 205 would have to be inordinately fast in order to generate a decision or output symbol at UWB data rates. Also even if the iteration rate was sufficiently fast, the computational complexity of the iterative ACS calculations is unacceptably power consuming. While some documents have described so-called parallel processing cores in relation to ACS decoders, such as in connection with the Institute of Electrical and Electronic Engineering P802.15 working group document P802.15-03/213r0r0, entitled “Implementation of High Speed Signal Processing Cores for 15-3a UWB” dated May 10, 2003, these documents fail to describe a complete parallel connected (butterfly connected) series of ACS elements. In contrast the present invention can be configured for, a UWB system where constraint 2 M-1 parallel connected ACS elements can be present such as in accordance with various exemplary embodiments of the present invention.
Trellis Decoding
As will also be appreciated by one of ordinary skill in the art, a trellis diagram is a useful tool for understanding trellis or Viterbi decoding in accordance with various exemplary embodiments. In a code trellis, rows and columns signify states and stages of operation in accordance with the underlying convolutional code and related FSM. When code words or branch metrics are received, several paths through the trellis can be traversed based on hypothetical state transitions from the present state to the next state for each of a series of possible received sequences. The state transitions will further generate a the most likely corresponding message symbol or sequence associated with the received code sequence. As noted, the rows of an exemplary trellis represent the individual ones of the 2 M code states and the columns represent the stages associated with each subsequent received code word during code word intervals. Just as the convolutional encoder, for an exemplary ½ rate code, encoded 2 code symbols (a code word) for each message symbol input to the encoder shift register, the convolutional decoder will attempt to determine the most likely message symbol corresponding to a received code word of by calculating metrics associated with each node in the trellis. As the stages are traversed, distance metrics are accumulated and paths with large metrics are abandoned so that by the “end” of the trellis, that is at the last stage, a path traced back through the trellis will reveal the surviving path and the original message sequence. As noted earlier, in a UWB receiver, waiting until all code words are received is impractical due to the limitations posed by processing speed and symbol rate.
An exemplary trellis node 300 is illustrated in FIG. 3 . It should be understood that the diagram of exemplary node 300 is a conceptual representation including the inputs and calculations and can be applied generally with each state/stage node in the exemplary decoding trellis. At 310 , a path metric P 2j (t−1) represents the path metric value carried from the previous stage, that is (t−1) from state 2 j . At 312 , a path metric P 2j+1 (t−1) represents the path metric value carried forward from the previous stage (t−1) from state 2 j+ 1. At 311 , a branch metric b 2j,j (r(t)) represents the branch metric associated with a possible traversal of the branch from state 2 j to state j given a value r(t) of the received code word. At 315 , a branch metric b 2j+1,j (r(t)) represents the branch metric associated with a possible traversal of the branch from state 2 j+ 1 to state j given a value r(t) of the received code word. Thus at 314 , a path metric P j (t) represents the updated path metric for the current stage (t). If the branch 2 j,j is traversed, the value at 314 will be the value of the accumulated path metric P 2j (t−1) at 310 and the value of the branch metric b 2j,j (r(t)) at 311 which is generally the Euclidean distance between the actually received code word and the code state value at j. If the branch 2 j+ 1,j is traversed, the value at 314 will be the value of the accumulated path metric P 2j+1 (t−1) at 312 and the value of the branch metric b 2j+1,j (r(t)) at 315 which, as noted, is the Euclidean distance between the actually received code word and the code state value at j. It will be appreciated that the branch metrics can be obtained from the output of correlator/branch metric block 105 described in connection with FIG. 1 . Although the exemplary correlator/branch metric block 105 is shown outputting four branch metrics, more can be output depending on the constraint length chosen and the resulting number of code states. In accordance, for example with various exemplary and alternative exemplary embodiments, it has been determined that the decoder of the present invention can use a constraint length of K=6 as noted herein, for achieving superior performance characteristics.
From states 2 j and 2 j+ 1, transitions can also be made to state j+2 M through respective branches, the branch from state 2 j having a branch metric b 2j,j+2 M (r(t)) at 313 and the branch from state 2 j+ 1 having a branch metric b 2j+1,j+2 M (r(t)) at 317 . Thus the value of a path metric P j+2 M (t) at 316 , if the branch from 2 j,j+ 2 M is traversed, is the value of the accumulated path metric P 2j (t−1) at 310 and the value of the branch metric b 2j,j+2 M-1 (r(t)) at 313 which is generally the Euclidean distance between the actually received code word and the code state value at j+2 M-1 . If the branch from 2 j+ 1, j+2 M-1 is traversed, the value of the path metric P j+2 M-1 (t) at 316 is the value of the accumulated path metric P 2j+1 (t−1) at 312 and the value of the branch metric b 2j+1,j+2 M-1 (r(t)) at 317 which is generally the Euclidean distance between the actually received code word and the code state value at j+2 M-1 .
Add Compare Select (ACS)
In traversing an exemplary trellis associated with FIG. 3 , various constructs can be used to accomplish the required calculations. One construct is an exemplary Add Compare Select (ACS) circuit 400 shown in FIG. 4 . It will be appreciated that ACS circuit 400 can be used to implement the trellis node of FIG. 3 . A path metric value P 2j (t−1) at 421 and a path metric value P 2j+1 (t−1) at 422 can be input to an ADD element 401 and an ADD element 402 respectively. Branch metric values, such as a branch metric value b 2j,j (r(t)) 423 and a branch metric value b 2j,j+2 M-1 (r(t)) 425 can be input to the ADD element 401 and a branch metric value b 2j+1,j+2 M-1 (r(t)) 424 and a branch metric value b 2j+1,j (r(t)) 426 can be input to the ADD element 402 the results of various combinations of calculations for traversed branches can be compared in COMPARE element 403 which can be configured to select using a SELECT line 429 one of a path metric P j (t) 427 and a path metric P j+2 M-1 (t) 428 as a surviving path.
As previously noted, conventional decoders suffer limitations in that in order to achieve decoding at the symbol rate, the decoder must iterate in order to traverse a trellis, at a rate proportional to K times the symbol rate. FIG. 5 shows a conventional ACS circuit 500 having an input multiplexer 501 , an ACS unit 502 , and a demultiplexer 503 . Input paths representing path metrics from P 0 (t−1) 504 to P 2 M (t−1) 505 can be selected for each iteration corresponding for example to each stage for comparison in the ACS unit 502 and a selection made in demulitiplexer 503 of surviving path metrics P 0 (t) 506 to P 2 M (t) 507 . The limitation of such a circuit, as previously noted, is that at symbol rates typically associated with UWB transmissions, the ACS unit 502 would need to iterate at least several time faster than the symbol rate. At best, the conventional ACS unit 502 as noted above, could be configured to process two paths, however this can easily be distinguished from the present invention in that prior art decoders such as decoder 500 of FIG. 5 .
Parallel ACS
Although as noted, some discussion exists related to the possible feasibility of processing 2 samples, e.g. branch metrics, in parallel (see, IEEE P802.15 Working Group for Wireless Personal Area Networks, (WPANs) document P802.15-03/213r0r0, entitled “Implementation of High Speed Signal Processing Cores for 15-3a UWB, May 10, 2003), none shows specifically how parallel decoding is accomplished, and all fail to describe individual ACS units connected in parallel to reduce the iteration rate to a value at or near the symbol rate. The document further admits the existence of limitations, for example at above 240 Mbps if such a decoder could be constructed. Also, given the constraints described in various documents in the art, such as K=7, the complexity levels become undesirable as noted, for example, in the discussion herein above. In stark contrast, using the principals discussed and described herein, a parallel trellis decoder can be constructed for providing full symbol rate decoding at 480 Mbps and potentially beyond.
FIG. 6 illustrates an exemplary parallel ACS circuit 600 constructed for implementation in, for example, an integrated circuit in a UWB receiver or receiver section such as the ACS branch metrics unit 110 described herein above. In the parallel ACS circuit 600 , a series of parallel ACS elements from a first ACS 0 element 601 through a (M−1) th ACS 2 M-1 −1 element 602 can receive respective parallel path metric inputs P 0 (t−1) 611 , P 1 (t−1) 612 and P 2 M −2 (t−1) 621 , P 2 M −1 (t−1) 622 . Each of the parallel ACS elements such as the ACS 0 element 601 and the ACS 2 M-1 −1 element 602 , after computing branch metrics in the manner described above in connection with FIG. 4 , generate parallel path outputs P 0 (t) 613 , P 2 M-1 (t) 614 and P 2 M-1 −1 (t) 623 , P 2 M (t) 624 which are shown schematically in open form as, for example, a butterfly connection as is illustrated in greater detail in FIG. 7 .
An exemplary decoder, for illustrative purposes, is shown in FIG. 7 for a value of M=3. Accordingly, 2 M-1 or 4 ACS units, such as ACS unit (11) 710 , ACS unit (10) 720 , ACS unit (01) 730 , ACS unit (00) 740 , can be parallel, or butterfly connected according to, for example, the configuration as illustrated in FIG. 6 and the particular generator polynomial used for encoding, and can be used to provide decoding for an exemplary convolutional code with 2 M or 8 states. It will be appreciated that for various systems and codes, different values of M will result in a different number of ACS units. Further, different generator polynomials, for the same values of M, will result in different butterfly connections between parallel elements, such as ACS unit (11) 710 , ACS unit (10) 720 , ACS unit (01) 730 , ACS unit (00) 740 .
In order to calculate surviving path metrics, branch metric values b (01) 701 , b (11) 702 , b (10) 703 , and b (00) 704 , representing for example, the distance metric associated with the present received sequence r(t) and the respective possible sequences of the sequences in the soft decision constellation as will be appreciated by those of ordinary skill, are made available to the ACS units according to for example the relationships illustrated in accordance with FIG. 4 and as shown in FIG. 7 . It will be appreciated that inputs to parallel ACS unit (11) 710 , ACS unit (10) 720 , ACS unit (01) 730 , ACS unit (00) 740 can consist of feedback inputs 711 , 712 , 721 , 722 , 731 , 732 , 741 , and 742 , such as from the previous path metric values, branch metric values b (01) 701 , b (11) 702 , b (10) 703 , and b (00) 704 , and state inputs which may be loaded during decoder initialization and the like.
Each ACS unit 710 - 740 also produces two decision signals 713 & 714 , 723 & 724 , 733 & 734 , or 743 & 744 that are used to control the operation of the track buffer 750 . These decision signals are Boolean signals that are indicative of which path metric was selected by the ACS unit 710 - 740 . The track buffer 750 uses these decision signals 713 , 714 , 723 , 724 , 733 , 734 , 743 , and 744 to determine how it will manipulate stored values.
It should be noted that the clock rate for an exemplary processor in accordance with various embodiments, is 8.8 nanoseconds and further track buffer 750 may be provided with a spin signal 751 such as a clock signal, cycle signal, or the like at around the processor clock speed to allow the contents of the track buffer to be updated through register exchange or the like as is described in greater detail in copending application “TRACK BUFFER IN A PARALLEL DECODER” Ser. No. 11/024,805.
It will be appreciated that in accordance with various exemplary embodiments, the present invention can be practiced as an exemplary procedure, such as procedure 800 as illustrated in FIG. 8 . At start 801 , it can be determined whether a new code symbol, sequence or the like, has been received at 802 . For illustrative purposes, in determining whether a code symbol, sequence, or the like, has been received, it will suffice that new branch metric values, for example as described above, associated with possible received code states will be available at the output of an exemplary correlator/branch metric block such as the correlator/branch metric block 105 as described herein above in accordance with a clock rate, cycle rate, or the like for the decoder. At 803 , the branch metric values can be used as needed by the parallel ACS elements in accordance with, for example, the descriptions provided herein above such as the particular code generator used. Using the new branch metric values which, as will be appreciated and as is described herein above, represent the probabilities associated with the four possible received code symbol pairs, the present state information, the path metrics associated with the previous state, new path metrics can be calculated in each of 2 M-1 parallel connected ACS elements and a surviving path selected, for example, as described in connection with the operation of the ACS elements at 804 . Although at 805 the procedure is indicated as ending, it will be appreciated that a single “iteration” is shown for illustrative purposes. It is understood that the procedure in accordance with various exemplary embodiments, can continue to repeat, for example, as new branch metric values are received.
Track Buffer and Decision Decoding
The track buffer 112 , shown in FIG. 1 , can be used to receive the results of the 2 M-1 parallel connected ACS units associated with parallel ACS elements in the ACS path metric block 110 /ACS circuit 600 , 700 shown in FIGS. 1 , 6 , and 7 . When results are generated from, for example, add elements, in the form of, for example, 2 M path metric values, the path metric values can be stored in the track buffer 112 in corresponding 2 M registers. As path metric values are generated through the operation of the ACS path metric block 110 /ACS circuit 600 , 700 , the values can be accumulated in a memory element, such as a buffer 510 . The accumulated path metric values can be pushed into the buffer through register exchange depending on the value associated with the surviving path selection and, for example, the branch metric value with a first path representing one of two possible values for the selection and a second path representing the other of two possible values for the selection. The current selections for the corresponding registers are reflected in a current register depending on where the previous results were pushed.
It will be appreciated that the track buffer will have a depth of τ which can be around 100 to around 150 representing the number of spin cycles for the track buffer to perform register exchange and the like. It should be noted that the clock rate for an exemplary processor in accordance with various embodiments, is 8.8 nanoseconds and further the track buffer may be provided with a spin signal such as a clock signal, cycle signal, or the like at around the processor clock speed to allow the contents of the track buffer to be updated through register exchange or the like. While the track buffer depth τ represents a latency in the decision processing for the decoder, it is power efficient in that the buffer contents are exchanged as opposed to iterative and computationally intensive ACS calculations. In an additional step, the accumulated decisions may be voted on to arrive at the most likely decision symbol.
Additional Modifications
As noted above, the present disclosure illustrates and describes an exemplary parallel trellis decoder with 2 M-1 parallel ACS elements for use in a high-speed UWB environment. It will be appreciated that while various values for K and M have been described such as K=6 (M=5), and K=4 (M=3) for illustrative purposes for example, in FIG. 7 , different values of K can be used without departing from the invention. It will also be appreciated that the particular implementation of the decoder will be specific to the underlying convolutional code used, for example, to encode symbol sequences and, for a particular value of K, there may be many possible generator polynomials which can be used in an encoder to yield slightly different codes. However, use of 2 M-1 parallel ACS units is consistent with the present invention and any of the slight differences noted above resulting in, for example, slightly different connections can be considered to are intended to fall within the scope of the present invention.
CONCLUSIONS
The disclosed DS-UWB design provides scalable performance across a wide range of application requirements. This design leads to significant reductions in implementation complexity as compared to other proposed UWB PHY designs, while allowing increased scalability to high data-rate and low-power applications. This means that performance for applications such as high-rate data transfers for power-constrained handheld devices can significantly improved relative to current UWB PHY proposals. At the same time, the DS-UWB approach benefits from the significant benefits of true UWB operation, i.e., low fading in multipath, optimal interference characteristics, inherent frequency diversity and precision ranging capabilities.
Although this disclosure discusses a UWB device using the IEEE 802.15.3a standard by way of example, the general design is also applicable to other wireless networks, and should not be considered to be limited to application with respect to IEEE 802.15.3a networks. It should further be noted that while the present invention is applicable to trellis decoding in a UWB device which operates at different speeds and in different modes, the present invention should not be limited to any particular type of decoding operation, but can be used in any decoding situation where a convolutionally encoded symbol is present and for which its features would be advantageous.
This disclosure is intended to explain how to fashion and use various embodiments in accordance with the invention rather than to limit the true, intended, and fair scope and spirit thereof. The foregoing description is not intended to be exhaustive or to limit the invention to the precise form disclosed. Modifications or variations are possible in light of the above teachings. The embodiment(s) was chosen and described to provide the best illustration of the principles of the invention and its practical application, and to enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims, as may be amended during the pendency of this application for patent, and all equivalents thereof, when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled.
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A method ( 700 ) and apparatus ( 600 ) are described for performing parallel decoding in connection with 2 M-1 parallel ACS unit in ACS unit ( 110 ), track buffer ( 112 ) and voting unit ( 114 ) in an Ultrawide Bandwidth (UWB) receiver having a parallel trellis decoder for decoding a message sequence encoded according to a convolutional code. Outputs from the track buffer can be input to a voting unit ( 114 ) where a voting scheme can be applied and a decision rendered as to the originally transmitted message sequence.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Application Ser. No. 61/830,482 filed Jun. 3, 2013, the disclosure of which is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to a process for preparing a paper pulp composition wherein the pulp is readily moldable and, upon curing, is structurally rigid. More particularly, the invention relates to a process for pulping paper into a composition suitable for use as recycled paper, craft items, picture frames, crown molding, furniture and other products.
BACKGROUND OF THE INVENTION
The general concept of recycling paper is well known and a variety of methods exist for recycling paper and generating products from that paper. Generally, recycled paper lacks the structural integrity, rigidity and stability of the original paper incorporated into the recycled products. Moreover, the processes for recycling, or reclaiming, paper can be expensive and can require the use of a variety of chemicals.
It is also generally known to use wet or pulped process papers combined with an adhesive such as polyvinyl acetate based glue or a starch for a variety of purposes, for example, as arts and crafts material. These processes are generally known as “papier-mâché” processes. The resulting products are generally fragile, are unstable and will degrade over time, limited in stability by the integrity of the original paper and the effectiveness of the recycling process. Untreated, the products will develop mold and commonly will rot from the inside out. The processes heretofore known generally result in a finished product which is structurally weak, quickly degrades and is not suitable for any load bearing applications. It is common to lay the papier-mâché over a frame to lend strength to the end product or to otherwise provide supplementary supporting members to the product.
The current invention overcomes the limitations of the known processes and results in a pulped paper product that is rigid, highly stable, and has structural rigidity substantial enough to bear moderate loads. Moreover, the process is easy and inexpensive in comparison to many previously known methods for creating recycled paper products.
SUMMARY OF THE INVENTION
The present invention provides a paper pulping process which results in a recycled paper product that is stable, long-lasting and rigid enough to provide moderate load bearing capabilities. The process results in a wet slurry that is readily moldable and can be used in a variety of applications. For example, the resultant paper product can be molded into picture frames, crown molding, Christmas ornaments, candle holders, art paper, or dimensional products. The dimensional products can then be used to manufacture articles including furniture such as bookshelves, chairs, tables and the like. Moreover, the process is generally easy to perform and results in consistent and predictable end products. In one embodiment, a bleach is added to the composition primarily as a sanitizing agent to prevent molding and to decrease foul smells that can accompany the paper pulp during and after curing. Bleach can also be added so that the resultant paper pulp product is substantially neutral in color, preferably white, so that the product can be colored, painted, stained or tinted.
The inventive process and product disclosed herein was originally designed for use by organizations providing services to individuals with physical and mental limitations. The process is easy to achieve and safe to perform with highly predictable results. Recycled paper, preferably office waste, is gathered for use in the process and product. After processing, the resultant paper product can then be used for a variety of purposes. For example, in rehabilitation services or organizations providing services to those with disabilities, the resultant product can be used to make arts and crafts that can then be offered for sale. Unexpectedly, as the process described herein was derived, it became apparent that the process and product could be used in a variety of other applications as further disclosed herein.
The process generally includes combining a raw paper product, preferably recyclable paper such as newspapers, office paper and office waste materials along with marble dust, a starch, polyvinyl alcohol and water to form a slurry. As indicated, a bleach product can be added to the process to result in a neutral or white color end product. The addition of marble dust, starch and polyvinyl alcohol to the recycled paper result in a pulp product that can be molded and cured in a relatively short time. For example, the product can be troweled in to picture frame molds and then dried at approximately 90 degrees Fahrenheit over a two-day period. The resulting picture frame is rigid, can be painted, tinted or varnished.
To increase rigidity and stability of the final product a stabilizer may be added to the slurry. While several stabilizing products can be used, such as sulfonated melamine formate, the preferred stabilizer is calcium lignosulfonate.
These particular objects and advantages may apply not only to the embodiments disclosed herein, but may apply for other uses and processes as well and thus are not limited by the scope of the claims herein.
DETAILED DESCRIPTION OF THE INVENTION
The inventive process generally uses waste paper products, such as newspaper and office paper waste to create a stable pulped paper or slurry that is moldable and colorable for use in a variety of applications after it cures. Applications may include manufacturing picture frames, crown molding or other three dimensional objects by molding the slurry in prepared molds. The product can also be used to generate recycled paper for card stock and the like. Additionally, the product can be molded in to dimensional structures, such as 2×4 inch “boards” which can then be manufactured in to load bearing furniture, for example bookshelves, tables and the like.
Creating the pulp composition includes mixing raw paper product with marble dust, starch, polyvinyl alcohol and water. Bleach can be added to the composition as a sanitizing agent to diminish the potential for the development of mold and to neutralize odor causing bacteria. Foul smells may develop during and after curing of the paper pulp without the addition of bleach. Moreover, bleach can be added so that the resultant paper slurry is neutral in color or white, if preferred. And a stabilizing agent, such as calcium lignosulfonate can be added to enhance the overall stability and strength of the finished products. The resulting end product is mold resistant and will not rot or degrade as quickly as traditional papier-mâché compositions.
The raw paper materials are collected preferably from waste newspaper and office paper waste. The paper, marble dust and dry starch are mixed together in a commercially available mixer. When combined, the polyvinyl alcohol, water and, if desired, bleach products and stabilizer are added to the dry ingredients. The mixer is covered to reduce the loss of liquid ingredients and to increase water retention throughout the mixing process. It is preferred that the composition is continuously mixed for at least two hours to achieve a complete pulp of the paper and to result in a uniform and consistent slurry of all of the ingredients. The marble dust combines with and embeds into the naturally occurring pores in the waste paper and adds to the overall strength of the end product. The starch stiffens the resulting paper pulp while the soluble polyvinyl alcohol acts as an emulsifier and binding agent to combine all of the fiber materials and adheres the calcium carbonate (marble dust) to the paper fibers.
It may be beneficial to add a stabilizing ingredient to the slurry to further strengthen the finished product. The addition of a small amount of calcium lignosulfonate decreases water in the slurry and acts as a static charge neutralizing compound to statically charged materials with loose ionic bonding, such as the calcium carbonate. Adding this product allows less water to be used but enhances workability of the slurry. Generally, the calcium lignosulfonate will comprise less than 1% by volume of the slurry. The preferred amount will be between 0.4% and 0.6% by volume.
The preferred materials include marble dust that includes approximately 99% calcium carbonate (CaCO3) sifted at approximately 35 mesh (500 micrometer) sieve. One such product is generally available from Mississippi Lime Company and marketed as their Calcarb AFM Athletic Field Marker Ground Calcium Carbonate. In addition to the calcium carbonate, a small amount of crystalline silica is included. The preferred pH of the product is between 8 and 9. The preferred polyvinyl alcohol is provided by Sekisui and is the PVOH 205S which is a water soluble polyvinyl alcohol. The preferred starch or amylum is the well-known polysaccharide presenting as food grade starch. The preferred bleach is a perchlorate at between 5% and 9% in solution. The preferred bleach is sodium hypochlorite provided at 8.25% reduced to the preferred 5% in solution.
It is also possible to tint or color the paper pulp prior to curing. During the step of mixing the ingredients, tinting materials such as paint, solid colors, varnishes and the like can be added so that the finished product is uniformly colored. Additional materials such as gold leaf, silver beads or other highlighting materials can be added during mixing so that the product is “decorated”. This is particularly useful when the pulp is used to create picture frames, crown molding and the like.
The general formulation of the composition of the paper pulp product described herein is shown in Table 1. The preferred composition is approximately 13%-14% raw paper, approximately 26%-27% marble dust, approximately 9%-10% food grade starch, approximately 3%-4% polyvinyl alcohol and approximately 45%-47% water. If bleach is added it is added at less than 1% total solution, preferably 0.25% or less total slurry volume. If calcium lignosulfate is added as a stabilizer it will comprise between 0.4% and 0.6% of the slurry composition.
EFFECTIVE
RANGE OF
COMPOSITION BY
PREFERRED
COMPONENT
VOLUME
COMPOSITION
Raw paper or paper
10%-20% by volume
14% by volume
fibers
Calcium carbonate
20%-30% by volume
26% by volume
(marble dust)
Starch
5%-15% by volume
10% by volume
Polyvinyl alcohol
1%-10% by volume
3% by volume
Water
30%-60% by volume
46.30% by volume
Bleach
0.1%-2% by volume
0.25% by volume
Calcium lignosulfate
0.1%-1% by volume
.045% by volume
The preferred composition for manufacturing the pulped paper product is as follows: 4,400 grams of raw paper, 8,400 grams calcium carbonate (marble dust), 3,200 grams food grade starch, 1,200 grams polyvinyl alcohol 205S, 70 grams of bleach at 5% perchlorate solution and 14,800 grams of water for a total composition of 32,070 grams. If the calcium lignosulfonate is added as the stabilizer, approximately 141 grams will be added to the total composition. The composition is sized to be mixed in a 4.25 cubic foot cement mixer or comparable mixer. The composition is mixed for at least two hours to achieve complete pulp of the paper with uniform blending of all of the ingredients. The resultant product is formed in to desired shapes, molds, dimensional products with the like and cured over approximately two days at approximately 90 degrees F. Of course, the amount of each component can be increased or decreased to accommodate differences in mixer size. It is also likely that the amount of water, paper, starch and calcium carbonate will need to be adjusted in differing climates and at different altitudes because the mixing process will be affected by those variables.
During the mixing process, the slurry can be further modified by adding in a variety of coloring agents, textures, paint, varnish, bleach, natural coloring agents, and highlighting materials such as glitter, gold leaf or similar products. The potential materials that can be added to the slurry to change the appearance and aesthetics of the finished product are almost endless. Moreover, the products can also be enhanced using known techniques, such as placing decorative items in a mold before adding the slurry to the mold, thereby creating decoration on incorporated only on the finished surface of the product after it is removed from the mold.
After mixing but before curing the slurry, it can be formed into a desired product by several methods. For example, picture frames can be made by placing the slurry into pre-formed molds prior to curing. Dimensional products can be made by molding or forming to slurry prior to or during curing. The structural integrity of the product is suitable to form one inch, two inch or larger dimensional products that can be cut and connected for use in applications similar to light weight wood. The finished product can further be painted, colored, varnished or otherwise treated or decorated.
It will be understood that the present process is not limited strictly to use with recycled papers or paper fibers but may also be used to provide for extremely uniform pulp for paper making processes or for manufacturing articles from the pulp. This process can be modified to use virgin paper fibers and is not limited to recycled or raw paper. It will also be understood that the disclosed composition can be modified without departing from the spirit and scope of the invention. For example, modifications may have to be made to the process to accommodate differences in altitude and climate.
It is specifically intended that the present invention not be limited to the embodiments and illustrations contained herein, but include modified forms of those embodiments including portions of the embodiments in combinations of the elements and compositions so as to come within the scope of the following claims.
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This is a method and composition for a paper pulp product used to create formable or moldable products from the paper pulp that cures with significant rigidity, stability and strength. The composition includes a mixture of raw paper, calcium carbonate (marble dust), starch, polyvinyl alcohol and water. Bleach may be added to create a substantially white or neutral product. The pulp composition is particularly suitable to molding and can be used to manufacture picture frames, small items of furniture and the like. The resulting product is highly suitable to art paper, arts and crafts. The process is extremely easy and results in a product that is highly adaptable for numerous uses.
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FIELD OF THE INVENTION
[0001] The present invention generally relates to skid steer vehicles. More particularly, it relates to rear doors for skid steer vehicles.
BACKGROUND OF THE INVENTION
[0002] Skid steer vehicles such as skid steer loaders are a mainstay of construction work. In their most common configuration, they have two drive wheels on each side of a chassis that are driven in rotation by one or more hydraulic motors coupled to the wheels on one side and another one or more hydraulic motors coupled to the wheels on the other side.
[0003] The wheels on one side of the vehicle can be driven independently of the wheels on the other side of the vehicle This permits the wheels on opposing sides of the vehicle to be rotated at different speeds and in opposite directions. By rotating in opposite directions, the skid steer can rotate in place about a vertical axis that extends through the vehicle itself.
[0004] The vehicles have an overall size of about 10 by 12 feet, which, when combined with their ability to rotate in place, gives them considerable mobility at a worksite. It is this mobility that makes them a favorite.
[0005] Skid steer vehicles commonly have at least one loader (or lift) arm that is pivotally coupled to the chassis of the vehicle to raise and lower at the operator's command. This arm typically has a bucket, blade or other implement attached to the end of the arm that is lifted and lowered thereby. Most commonly, a bucket is attached, and the skid steer vehicle is used to carry supplies or particulate matter such as gravel, sand, or dirt around the worksite.
[0006] As a counterbalance to the loads provided at the front of the vehicle, skid steer vehicles typically have an engine that is located behind the operator. The radiator is also commonly disposed behind the operator, usually at the center rear of the vehicle.
[0007] A door or other access hatch is located at the very back of the vehicle to give the operator access to the engine and radiator from the very rear of the vehicle. Other doors and hatches may be disposed down the side of the vehicle or engine compartment instead of the rear to provide additional access.
[0008] One difficulty with rear engine access doors is their susceptibility to impact. Skid steer vehicles typically have a restricted view to the rear, preventing the operator from seeing behind the vehicle. Skid steer vehicles also spend a substantial amount of time traveling in reverse is close quarters. Skid steer vehicles are often operated in a rapid back-and-forth movement, making what are called “Y turns” as they move material from one pile to another perhaps several hundred times a day.
[0009] As a result, operators often misjudge the distance between the rear of the vehicles and obstacles and occasionally back skid steer vehicles into these obstacles, albeit at very slow speeds. Whenever a skid steer with a rear engine compartment door impacts an obstacle it is the door that suffers.
[0010] Even when the door is not damaged, however, the door hinges an the door latch may be damaged. The forces involved may not be great enough the actually damage the door itself, but it is often significant enough to tear or bend the hinges and latch, thereby either removing the door entirely, or jamming the door shut in its closed position
[0011] What is needed, therefore, is an improved skid steer vehicle having a door that is resistant to being damaged. What is also needed is a skid steer vehicle with a means for protecting the door hinges from upward rear impacts. What is also needed is a skid steer door that automatically protects the hinges without requiring additional operator input. What is also needed is a means for transmitting potentially damaging forces acting against the rear door directly to the frame or chassis. It is an object of this invention to provide these advantages. While not every claimed aspect of the invention provides all these advantages, each of these advantages is provided by at least one claimed aspect.
SUMMARY OF THE INVENTION
[0012] In accordance with a first aspect of the invention, a rear door and chassis interlock for a skid steer vehicle is provided, including a first elongated and laterally-extending beam fixed to a door frame of the rear door of a skid steer vehicle, the first beam having a generally horizontal and upwardly-facing surface; and a second elongated and laterally-extending beam fixed to a rear chassis of the skid steer vehicle, the second beam having a generally horizontal and downwardly facing surface; wherein the upwardly-facing surface and the downwardly-facing surface interlock over substantially their entire lateral extent to reduce upward movement of the rear door with respect to the chassis.
[0013] The second beam may be fixed to and extend between two elongated chassis members disposed on either side of the engine. The first and second beams may extend substantially the entire width of a rear-facing opening of an engine compartment and may be interlocked over substantially the entire width of the opening, The first beam may have a box structure and may include an “L”-shaped angle bracket fixed to a forward surface thereof, and the angle bracket may extend laterally across the vehicle and may have the generally horizontal and upwardly-facing surface that is configured to interlock with generally horizontal and downwardly facing surface of the second beam The upper surface of the angle bracket may extend across substantially the entire width of the engine compartment. The first beam may include a generally vertical, forward-facing and laterally extending surface to which the angle bracket is fixed, the forward-facing surface may have a first surface portion that extends above the angle bracket that may be spaced closely enough to a rearward edge of the second beam to transmit the force of forward impacts to the second beam. The first and second beams may be spaced a distance apart sufficient that they engage one another when the door is lifted before hinges supporting the door on the vehicle and a latch holding the door closed are damaged.
[0014] In accordance with a second aspect of the invention, a rear engine compartment for a skid steer vehicle is provided, including a left sidewall, a right sidewall, and a top wall that are fixed to a chassis of the skid steer vehicle and are disposed to enclose the engine an define a rear opening to the engine compartment; a first elongated and laterally-extending beam fixed to the chassis, the first beam having a generally horizontal and downwardly facing surface extending from the rear opening; and a rear door pivotally coupled to a chassis of the vehicle, the door including a door frame and a second elongated and laterally-extending beam fixed to the door frame, the second beam having a generally horizontal and upwardly-facing surface, wherein the rear door is disposed to cover the rear opening and is supported by two hinges and a latch; wherein the upwardly-facing surface and the downwardly-facing surface interlock over substantially their entire lateral extent to reduce upward movement of the rear door with respect to the chassis.
[0015] The first beam may be fixed to and extend between two elongated chassis members disposed on either side of the engine. The first and second beams may extend substantially the entire width of the rear opening, and may be interlocked over substantially the entire width of the opening. The second beam may have a box structure and includes an “L”-shaped angle bracket fixed to a forward surface thereof, and the angle bracket may extend laterally across the vehicle and may have the generally horizontal and upwardly-facing surface that is configured to interlock with generally horizontal and downwardly facing surface of the first beam. The upper surface of the angle bracket may extend across substantially the entire width of the engine compartment. The second beam may include a generally vertical, forward-facing and laterally extending surface to which the angle bracket is fixed, and the forward-facing surface may have a first surface portion that extends above the angle bracket that is spaced closely enough to a rearward edge of the first beam to transmit the force of forward impacts to the first beam. The first and second beams may be spaced a distance apart sufficient that they engage one another when the door is lifted before hinges supporting the door on the vehicle and a latch holding the door closed are damaged.
[0016] In accordance with a third aspect of the invention, a rear chassis for a skid steer vehicle is provided, including a rear door including a door frame and a first elongated and laterally-extending energy-transmitting beam transversely fixed to the bottom of the door frame, the first beam having a generally horizontal and upwardly-facing surface; and a rear chassis including left and right longitudinally extending frame members, and a left side panel, right side panel and top panel fixed to the frame members to enclose the engine, the rear chassis also including a second elongated and laterally-extending beam, the second beam having a generally horizontal and downwardly facing surface; wherein the rear door is pivotally coupled to one side of the engine compartment with hinges, and further wherein the door is secured in a closed position by a latch; and wherein the upwardly-facing surface and the downwardly-facing surface interlock over substantially their entire lateral extent to reduce upward movement of the rear door with respect to the chassis.
[0017] The second beam may extend across a rear engine compartment opening that is defined between the left and right side panels and the top panel. The first and second beams may extend substantially the entire width of rear engine compartment opening and may be interlocked over substantially the entire width of the opening. The first beam may have a box structure and may include an angle bracket fixed to a forward surface thereof, and the angle bracket may extend laterally across the door frame and may define the generally horizontal and upwardly-facing surface. The upper surface of the angle bracket may extend across substantially the entire width of the opening. A portion of the first beam may be disposed slightly forward of a portion of the second beam to reduce door damage by transmitting the force of forward impacts from the door to the second beam. The first and second beams may be spaced a distance apart sufficient that they engage one another when the door is lifted before hinges supporting the door on the vehicle are damaged.
[0018] Numerous other features and advantages of the present invention will become readily apparent from the following detailed description, the accompanying drawings, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a left side view of a skid steer vehicle in accordance with the present invention.
[0020] FIG. 2 is a fragmentary left side perspective rear view of the vehicle of FIG. 1 with the rear door closed.
[0021] FIG. 3 is a fragmentary left side perspective rear view of the vehicle of FIGS. 1 and 2 with the rear door open showing the chassis interlock and the inner door construction including the hinges, louvers and latches.
[0022] FIG. 4 is a fragmentary detailed perspective view of the upper hinge area of the vehicle shown in FIG. 3 .
[0023] FIG. 5 is a fragmentary cross-sectional view of the rear door and chassis of the vehicle of the foregoing FIGURES when the door is in the closed position as shown in FIGS. 1 and 2 taken along section line 5 in FIG. 2 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] While the present invention is susceptible of being made in any of several different forms, the drawings show a particularly preferred form of the invention. One should understand, however, that this is just one of many ways the invention can be made. Nor should any particular feature of the illustrated embodiment be considered a part of the invention, unless that feature is explicitly mentioned in the claims. In the drawings, like reference numerals refer to like parts throughout the several views.
[0025] Referring now to the FIGURES, there is illustrated a skid steer vehicle 100 . The vehicle includes a chassis 102 on which are mounted four wheels (two shown) 104 . These wheels are disposed two on each side in a fore-and-aft relationship. All the wheels are drive wheels, driven by engine 106 that is disposed in a rear engine compartment 108 of vehicle 100 .
[0026] Engine compartment 108 encloses engine 106 , surrounding it on all four sides as well as its top. A rear engine compartment door 110 encloses the rear of the engine compartment and protects a transversely-mounted rear radiator 112 that is fixed to the chassis behind the engine.
[0027] The engine compartment 108 includes a top panel 114 , a left side panel 116 , and a right side panel 118 . These panels enclose not only the engine 106 , but the radiator 112 as well. The left panel is fixed to and supported by an elongated and longitudinally-extending left side chassis member 160 which can be seen best in FIG. 1 . The right panel is fixed to and supported by an elongated and longitudinally extending right side chassis member 136 that is configured identically to left side chassis member 160 , but is disposed along the right side of the chassis and is configured as a mirror image of member 160 . Chassis members 160 and 136 extend backward along both sides of engine 106 , which is fixed to both members.
[0028] Door 110 seals against top panel 114 as well as side panels 116 , and 118 to provide protection both from the elements and from rigid objects that might damage the engine and radiator if the operator backs vehicle 100 backs up into them.
[0029] Door 110 is in the form of a rectangular frame 120 having a central rectangular opening 122 . Opening 122 is covered with louvers 124 that are disposed vertically across the aperture formed by the opening. These louvers can be pivoted about their longitudinal axes to abut one another and close opening 122 , or alternatively to open and permit air to pass therethrough. In this manner, the operator can regulate the amount of cooling provided by the radiator, which is disposed right behind door 110 .
[0030] Door 110 is supported by two hinges, an upper hinge 126 and a lower hinge 128 . The upper hinge includes two hinge plates 130 , 132 ( FIG. 4 ), and a pin (not shown) pivotally coupling the two plates together. Hinge plate 130 is bolted to a vertical member 134 that in turn is bolted to right side chassis member 136 . Plate 132 is fixed to door frame 120 and pivots together with the frame of the door when the door is opened.
[0031] Referring now to FIGS. 3 and 4 , latch 138 is pivotally coupled to door frame 120 . It holds the door open in a first position, and permits the door to be closed in a second position. Latch 138 is pivotally mounted to door 110 by a bolt 140 . As the door is opened, hinge plate 132 , which is fixed to the door frame, pivots about hinge plate 130 , which is fixed with respect to the chassis. Latch 138 pivots together with plate 132 and the door as the door is opened, with its tang 141 sliding along the top outer edge 142 of plate 130 .
[0032] Latch 138 offers no resistance to this door opening, until the door is almost completely open (as shown in FIGS. 3 and 4 ), at which point a slot 144 in plate 130 moves underneath latch 138 . Slot 144 is just wide enough to receive the outwardly extending tang 141 . The weight of tang 141 unbalances latch 138 , causing it to fall of its own weight into slot 144 .
[0033] Latch 138 is shown in two positions in FIG. 4 : a first unlatched position “A” shown in phantom lines, and a second latched position “B” shown in solid lines. Position “B” illustrates how the latch would appear when it has rotated about 90 degrees clockwise under the force of gravity. The latch is configured such that it is not perfectly balanced when in position “A”, but is top heavy. The top heavy position is determined by the location of the hole in latch 138 through which bolt 140 passes. This hole is located such that latch 138 is not only top heavy, but tends to rotate in a clockwise direction (in FIG. 3 ), supported by top edge 142 of plate 130 .
[0034] Lower hinge 128 similarly includes two plates 146 , 148 and a pin 149 pivotally coupling the two plates together. These plates and pin are identically arranged to those of the upper hinge. Hinge plate 146 is bolted to vertical member 134 . Plate 148 is fixed to door frame 120 and pivots together with the door frame when the door is opened.
[0035] The door hinges are preferably arranged so that the entire door may be removed from the vehicle by lifting the door upward until the hinge pins of the upper and lower hinges are removed from their corresponding hinge plates. The operator can stop the vehicle, open the door, lift the door upward from the bottom, and remove the door from vehicle 100 .
[0036] A spring loaded door latch 150 is fixed to the opposite side of the door as hinges 126 , 128 . It has a catch 152 that grasps a rod 154 extending from striker plate 156 . Striker plate 156 is bolted to vertical member 158 that, in turn, is bolted to chassis member 160 . The engagement of catch 152 and rod 154 prevents the door both from being opened and from being lifted off its hinges. When an upward force is applied to the closed door the catch and rod interengage to prevent the door from moving upward.
[0037] While the catch and rod are sufficiently strong to resist the force of one or two people trying to lift the closed door upward off its hinges, they may not be sufficient to prevent a substantial upward blow to the bottom of the door from lifting the door upward and either damaging the catch and rod, or damaging both the catch and rod, and the hinges, too.
[0038] To resist these more forceful blows or impacts from lifting the door and damaging the various door components, additional support structures are provided. These support structures include mechanically interengaging (or interlocking) members that resist the relative upward movement of the door with respect to the rest of the vehicle. These members are located at the bottom of the engine compartment opening and extend across the entire width of the opening.
[0039] These additional support structures are provided on both door and the chassis. They are configured to interlock automatically whenever the door is closed and disengage automatically whenever the door is opened. No additional operator activity is required to interlock these structures.
[0040] FIGS. 3 and 5 show these structures in particular detail. In FIG. 3 , they are shown as they would appear when the door is open and the structures are not mutually interengaged. In the positions shown in FIG. 3 , the door can be lifted off the vehicle without damaging the door or the vehicle itself.
[0041] FIG. 5 shows the additional support structures as they are positioned when the door is closed. In FIG. 5 they are shown interlocked to resist the upward movement of the door.
[0042] Referring now to FIGS. 3 and 5 , the structures include a first beam member 162 that is fixed to an inner surface of door frame 120 just below door opening 122 . Member 162 may be permanently or removably fixed to door frame 120 , such as by welding or bolting the member thereto.
[0043] Member 162 extends laterally, side-to-side, across the entire width of the engine compartment opening. It has the form of an L-shaped beam comprised to two major planar portions: a first planar portion 164 extending horizontally that is fixed along its laterally extending leading edge 166 to a vertically and laterally extending planar beam portion 168 having a top edge portion 169 that is fixed to edge 166 .
[0044] Member 162 is fixed to a second beam member 170 that also extends laterally, side-to-side and is in turn fixed to the inner surface 172 of the lower portion of door frame 120 just below opening 122 . Beam member 170 includes a first planar portion 174 that extends generally horizontally and laterally within door frame 120 . It also includes a second planar beam portion 176 that extends generally laterally and vertically within door frame 120 . Planar beam portions 174 and 176 are fixed together along a rearward and laterally extending edge 178 of beam portion 174 and along a bottom and laterally extending edge 180 of beam portion 176 .
[0045] Beam portion 176 generally follows the contours of the inside rear surface 172 of door frame 120 just below door opening 122 . Beam portion 176 preferably abuts and is fixed to the inside surface of door frame 120 over substantially its entire width to provide a relatively large area of support for the lower portion of the door. Since the lower portion of the door typically impacts such things as piles of dirt, sand, or rock first, it is the most prone to damage. Locating the beam members along (and fixing the beam members to) this lower portion of the door, provides particularly good protection against door damage.
[0046] While we describe edges 178 and 180 above as being fixed together, they need not be formed separately and then fixed together, but may be formed integrally from a single sheet of metal that is bent to form a laterally extending bend 182 that defines the junction between beam portions 174 and 176 .
[0047] Similarly, beam member 162 may be formed from a single sheet of metal that is bent, thereby forming a laterally extending bend 184 at the junction of beam portion 164 and beam portion 168 .
[0048] Beam member 162 and beam member 170 together form a generally rectangular box beam, having an internal, laterally extending, and generally rectangular hollow 186 . This arrangement enhances the individual strength of beam members 162 and 170 .
[0049] Beam member 162 and beam member 170 are fixed together to provide additional strength for the lower portion of door frame 120 and additional resistance to deformation when the door is impacted. As shown in FIG. 5 , the two are fixed together by a weldment 187 that extends laterally, from side-to-side, inside door frame 120 . While a weldment is preferred, the two components may be removably fixed together with bolts, for example. This arrangement can be employed to permit each beam to be more easily mounted to the door or to permit each beam to be adjusted with respect to the other.
[0050] A third component of the additional support structures is an elongated and laterally extending edge member 188 that is fixed to a forward facing vertical surface 190 of beam member 162 . Edge member 188 includes a horizontally and laterally extending portion 192 , shown here as a planar and linearly extending flange, that is coupled to a vertically and laterally extending portion 193 , also shown as a planar and laterally extending flange.
[0051] Member 188 has a generally “L”-shaped form, commonly known as “angle iron” or “angle bracket” that is comprised of flanges 192 and 193 , the two flanges being joined at right angles to one another along an upper edge of flange 193 . Vertically extending flange 193 is fixed to vertical and forward facing surface 190 of member 162 , preferably by welding.
[0052] Portion 192 has an upper surface 194 that is surmounted by an elongated interlocking member 196 . Interlocking member 196 is shown in the FIGURES as a horizontally disposed planar sheet of steel that extends outward from the rear opening 198 ( FIG. 5 ) of the engine compartment. Member 196 extends laterally across the engine compartment from one side to the other. Member 196 is fixed to and between the two elongate chassis members
[0053] When door frame 120 is closed, member 196 is disposed immediately adjacent to and slightly above upper surface 194 of horizontally and laterally extending portion 192 of edge member 188 . In this position, member 196 cooperates with surface 194 to prevent the door from moving upward when an upward force is applied to the door and he door is closed.
[0054] Member 196 and portion 192 extend substantially the entire distance across the engine compartment opening 198 . This arrangement distributes the upward force of any door impact over substantially the entire width of the door, and over substantially the entire length of members 162 and 170 .
[0055] Just as the additional support structures reduce damage to the door from being forced upward, they also reduce damage to the door by being forced forward and inward toward the engine compartment opening 198 . When the door receives an impact that drives the door forward and generally into the engine compartment, vertically and laterally extending beam portion 168 of beam member 162 is forced forward against the rear edge 200 of member 196 . This transfers the load on the door to the member 196 which is fixed to the vehicle chassis. When this impact occurs, edge 200 engages surface 190 of beam member 162 over substantially the entire width of the engine compartment opening.
[0056] The door is positioned by adjusting the positions of the hinges and the latch. For this reason, a narrow gap 202 is provided between rear-facing edge 200 and the forward-facing surface 190 of beam member 162 . A similar narrow gap 204 is provided between upper surface 194 and the bottom surface of member 196 . These two gaps extend laterally across the width of the engine compartment opening. The width of each gap 202 , 204 is preferably the same across the entire width of the engine compartment.
[0057] From the foregoing, it will be observed that numerous modifications and variations can be effected without departing from the true spirit and scope of the novel concept of the present invention. It will be appreciated that the present disclosure is intended as an exemplification of the invention, and is not intended to limit the invention to the specific embodiment illustrated. The disclosure is intended to cover by the appended claims all such modifications as fall within the scope of the claims.
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An interlock for a skid steer vehicle with a rear engine compartment and a rear door to that compartment includes a beam that is mounted transversely to the bottom of the door and has an upward facing surface that, like the beam, extends across the entire rear engine compartment opening. An interlocking second member is fixed to the chassis and extends across the rear engine compartment opening. When the door is impacted and forced upward, the first beam engages the second interlocking member over its width and transfers the force from the door (and beam) to the chassis When the door is impacted with a forward-directed force, the first beam also contacts the second member and transfers the forward forces through the second member to the chassis. Injury to the door is reduced or eliminated by transferring door impact forces to the chassis since the first beam extends substantially the entire distance across the door and is fixed to an inner surface of the door's frame.
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BACKGROUND OF THE INVENTION
The invention relates in general to the reception and processing of bioelectrical signals from an organism. Furthermore, the invention relates to an improved method and apparatus for receiving bioelectrical signals, processing the signals and signaling back to the organism so as to allow the organism to either inhibit or facilitate a selected frequency.
A number of different feedback-type methods and apparatus are known dating back to as early as 1960. Early studies by several researchers focused on bioelectrical feedback on persons suffering from hemiplegia, i.e., paralysis of one lateral half of the body resulting from injury to the motor centers of the brain.
In 1960, A. A. Marinacci and M. Horande investigated neurofeed back with respect to left-sided hemiplegia. As reported in "Electromyogram in Nueromuscular Re-education", Bulletin of the Los Angeles Neurologic Society, 25: 57-71, 1960, they inserted needle electrodes into the involved left arm muscles, and could find no voluntary nerve impulses. Electrodes were inserted into the normal right deltoid to show the patient how muscle activity could produce auditory feedback. The electrodes were then inserted into the paralyzed left deltoid muscle. The patient was able to generate from 10 to 15 percent motor action potential in a location from which there had been no previous detectable activity. The same procedure was utilized successfully at other muscle sites.
In 1964, J. M. Andrews reported on study utilizing a patient group of hemiplegics who had electromyogram EMG electrodes inserted in the involved tricep muscles as reported in "Neuromuscular Re-education of the Hemiplegic with the Aid of the Electromyograph," Archives of Physical Medicine and Rehabilitation, 45: 530-532, 1964. Auditory feedback was provided as the subjects tried to generate sound and movement. A five-minute trial period was allowed, and seventeen out of the twenty patients showed an increase in motor action potentials.
In 1973, H. E. Johnson and W. E. Garton reported on ten hemiplegic patients, who utilized EMG practices as an aid in total rehabilitation rather than just the return of voluntary movement as in the Andrews study as discussed in "Muscle Re-education in Hemiplegia by use of Electromyograph Device", Archives of Physical Medicine and Rehabilitation, 54: 320-325, 1973. Five out of ten subjects had enough improvement to eliminate leg bracing on the involved side.
In 1974, J. Brudny and others used EMG feedback to treat a group of thirty-six patients, thirteen of whom had hemiparesis. Brudny, J. Korein, J., Levidow, L. Grynbaum, B. B., Lieberman, A., and Friedman, L. W., "Sensory Feedback Therapy as a Modality of Treatment in Central Nervous Disorders of Voluntary Movement," Neurology, 24: 925-932, 1974. In this study surface electrodes were used instead of inserted needle electrodes. In two individuals there was no change. In one patient there was relief from muscle spasticity. In six patients function of the extremity was re-established, and in four cases prehension became possible.
Also, in 1974, D. Swaan, P. C. W. Van Wieringer and S. D. Fokkema explored EMG feedback of seven patients, four of whom were hemiplegic. "Auditory Electromyographic Feedback Therapy to Inhibit Undesired Motor Activity," Archives of Physical Medicine and Rehabilitation, 57:9-11, 1974. The subjects taught to inhibit the peroneus longus muscle while contracting their quadricep muscle. Conventional rehabilitation methods were used to suppress the undesirable hyperactivity of the peroneus longus muscles along with the feedback. No justification was given for reinforcement of the quadriceps and inhibition of the peroneus longus.
In 1975, J. V. Basmajian, C. G. Kukulka, M. G. Narayan and K. Takebe compared EMG biofeedback plus physical therapy with the results of standard rehabilitation procedures in cases of ankle dorsiflexion paralysis after stroke repeated in "Biofeedback Treatment of a Foot-Drop After Stroke Compared With Standard Rehabilitation Techniques: Effects on Voluntary Control and Strength," Archives of Physical Medicine and Rehabilitation, 56: 231-236, 1975. The authors claimed that an increase in both strength and range of motion in the biofeedback group was twice as great as the achievements of the exercise control group. The two groups of patients were not variably matched. When biofeedback was added to physical therapy, the mixed variables were not controlled.
In 1976, L. P. Taylor and B. Bongar described the use of electromyometry feedback for the treatment of cerebrovascular lesion patients in Clinical Applications in Biofeedback Therapy, Psychology Press, Los Angeles, Calif., 1976. Patients were taught to inhibit one set of muscles while simultaneously facilitating others. For example, inhibition of thumb flexion was attempted while thumb extension was facilitated.
In 1979, F. Keefe and K. Trombly utilized EMG feedback to aid a hemiplegic patient judge limb position without being able to see the limb in "Impaired Kinesthetic Sensation: Can EMG Feedback Help?" Presented at the Proceedings of Biofeedback Society of America, Tenth Annual Meeting, February, 1979 in San Diego, Calif. The patient participated in an A-B-A-B withdrawal design to evaluate the effects of EMG biofeedback on accurate limb positioning. EMG feedback with audio feedback produced improvement in performance relative to baseline. Withdrawal of feedback produced a decrement in performance, and when EMG feedback was re-instituted, performance once again improved. The patient was able to generalize the EMG feedback training to improved functional use of the arm.
In 1979, R. Koheil, et al, at the Ontario Crippled Children Centre, developed a Joint Position Trainer to provide precise feedback of limb position to three hemiplegics. Koheil, R., Mandel, A., Herman, A. and Iles, G., "Joint Position Training for Hyperextension of the Knee in Stroke Patients: Preliminary Results", presented at the Proceedings of the Biofeedback Society of America, Tenth Annual Meeting, February, 1979 in San Diego, Calif. The Joint Position Trainer provided feedback of position rather than of muscle activity, and incorporated a goniometer attached to a leg cuff with auditory feedback of knee joint angle. Two of the three patients developed improved gait with increased control of knee hyperextension.
The results of the techniques involved had limited results because the difficulty of recognizing particular frequencies generated which could not be readily determined, nor could the subject have the ability to control these frequencies.
Other research efforts were conducted specifically upon those bioelectrical signals emanating from the brain. One of the earlier works was written in 1966 by T. Mullholland and C. R. Evans who described the use of alpha waves (approximately 7.5-11.5 Hertz) emanating from the brain to drive a feedback signal that could be perceived by the test subject and induce relaxation. Mulholland, T., and Evans, C. R., Nature, 211: 1278, 1966. The alpha waves could be controlled to some degree by the test subject's recognition of a tone or light when alpha waves were produced. Similarly, differentiation of particular frequencies of bioelectrical signal prevented the test subject from readily acknowledging and either inhibiting or facilitating particular frequencies.
Other electroencephalograph (EEG) feedback devices are described in publications by Spunda, J. and Radil-Weiss, T., "A Simple Device for Measuring the Instaneous Frequency of the Dominant EEG Activity", Electroencephalographic Clinical Neurophysiology, 32: 434, 1972. This device converted EEG frequencies into voltage levels for analysis using bandpass analysis. A series of wave form generators were activated by the flip-flop at each positively directed zero point of the filtered signal resulting in a voltage level corresponding to the frequency.
Another EEG feedback device was described in Hicks, R. G., and Angner, E., "Instrumental evaluation of EEG Time Relationships", Psychophysiology, 6:44, 1970. This device analyzed minute time displacements of EEG waves from cortical waves using peak detection and a type of logic as a feedback device.
Also, in Boudrot, R., "An Alpha Detection and Feedback Control System", Psychophysiology, 9:467, 1972, a feedback device picked up alpha waves and provided auditory and visual stimulus feedback to the patient. Then, in Pfeifer, E. A., and Usselmann, C., "A Versatile Amplitude Analyzer for EEG Signals to Provide Feedback Stimuli to the Subject", Med. Biol. Eng. 8: 309, 1970, a feedback device analyzed the amplitude and provided feedback cues to subjects in studies of EEG modification. It allowed for usage with bandpass analysis incorporating logic components and a display.
Additionally, U.S. Pat. No. 3,837,331 to Sidney A. Ross, issued Sept. 24, 1974, entitled "System and Method for Controlling the Nervous System of a Living Organism" describes an apparatus and method for determining particular frequencies of a bioelectric signal which is analog by nature. The Ross device like the other devices require the use of band pass analysis or other techniques to filter out particular frequencies to study a particular frequency of interest.
In band pass analysis, analog filters analyze how much frequency is produced in a given period of time, or a frequency in relationship to time and voltage. The apparatus required includes a precision attenuator, an active band pass filter, a rectifying means and an integrating means in addition to those components normally utilized in bioelectrical feedback devices. Furthermore, band pass analysis or power spectral analysis is necessary to isolate the particular frequency of interest. Such analysis is typically performed on a large computer requiring special analytical skills and extensive computing time. Power spectral analysis looks at the variance of a bioelectrical signal or the covariance between one or more signal channels. The signal is broken into different frequency bands in relationship to the power density which is then analyzed using a fourier series program.
Not only is the above approach burdensome and time consuming, but also inaccurate. The frequency results are often distorted because the analytical approach used is based on exponential and logrithic analysis. Determining the actual frequency desired to inhibit or facilitate is at best haphazard due to the margins for error in the above approach.
Also, the above referenced devices lack suitable means for displaying and recording the changing frequencies under study for subsequent review and manipulation for purposes of analysis. But, most importantly, these EEG feedback devices lacked the ability to establish selected limits or thresholds in which to gauge the progress of a test subject or reward the test subject once the test subject learned to inhibit or facilitate a particular frequency of interest.
The above-mentioned deficiencies are overcome by the present invention. There is a great interest in the neuropsychology and neurophysiology community for such a device which overcomes these deficiencies. Researchers and practitioners should recognize the value immediately of the present invention. Furthermore, persons suffering from nervous disorders, induced by trauma, drug use or cogenital aberration can greatly benefit from the present invention. The present invention operates as a diagnostic tool, as well as, a means for curing nervous disorders or abnormalities in the body, particularly the brain.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a functional block diagram of a first preferred embodiment of the improved method of the present invention;
FIG. 2 is a functional block diagram of a second preferred embodiment of the improved method of the present invention;
FIG. 3 is a top right perspective view of a first preferred embodiment of the improved apparatus of the present invention shown associated with a test subject; and
FIG. 4 is a top right perspective view of a second preferred embodiment of the improved apparatus of the present invention shown associated with a test subject.
SUMMARY OF THE INVENTION
The invention includes two embodiments of a method and two embodiments of an apparatus for practicing the methods, respectively.
The first method is an improved method of detecting and displaying analog bioelectrical frequencies in an organism's or person's body comprising the steps of detecting an analog bioelectrical signal at a selected location in the person's body, amplifying the analog bioelectrical signal, converting the analog bioelectrical signal to digital signals representing particular frequencies, and selecting a particular digital signal of interest and displaying and/or recording the particular signal of interest in the form of a continuous waveform over time.
The apparatus used to perform the above method comprises a receptor means for attachment to the selected location of the person or organism for receiving an analog bioelectrical signal, an amplifier for amplifying the analog bioelectrical signal received by the receptor means and associated therewith, and an analog to digital converter for converting the analog bioelectrical signal to digital signals representing corresponding electrical frequencies. The converter receives the amplified analog bioelectrical signal from the amplifier.
A computer is used for integrating amplitude of one of the digital signals over a predetermined duration and dividing a resulting value by voltage to determine a change in voltage with respect to time duration, and thereby determine electrical frequencies emitted by the person or organism. The computer then converts the resulting value divided by voltage to a format which can be plotted over time. A display monitor for displaying the prescribed format of the corresponding electrical frequencies can be incorporated.
Furthermore, a magnetic disk recorder for recording the resulting value divided by voltage over time is used to record the information for subsequent review or analysis.
The second embodiment of the method of the invention involves the first embodiment of the method described above. Additional steps include sending a signal to the person when the particular digital signal of interest falls within a selected amplitude threshold for a predetermined duration, and causing the person to mentally concentrate so as affect the amplitude of the particular digital signal of interest. This allows the person to affect a certain corresponding analog bioelectrical frequency emitted at the selected location of the person's body.
Subsequent to the step of establishing an amplitude for the particular digital signal, an additional step may include integrating the amplitude of the selected digital signal with respect to duration and dividing by the amplitude threshold voltage. This yields a determination of whether voltage of the selected digital signal is changing, and thereby whether the corresponding analog bioelectrical frequency is being inhibited or accentuated.
Also, another step may be added by displaying the selected digital signal as a continuous waveform and displaying the voltage thresholds as horizontal lines associated with the continuous waveform to facilitate the determination of whether the corresponding analog bioelectrical frequency is being inhibited or facilitated.
Similarly, a step of recording may be added where the digital signals are recorded to a magnetic medium for review and data manipulation.
The step of continuously displaying the particular digital signal of interest as a waveform changing with respect to time can be incorporated wherein the amplitude threshold voltage is displayed as a straight line.
A step of suppressing exteraneous signals unrelated to the analog bioelectrical signal of interest ma be used to suppress unwanted noise.
The apparatus used in the second embodiment is similar to that apparatus described above. The step of detecting an analog bioelectrical signal is achieved by using two electrodes positioned at the selected location of the person's body to be affected. The step of amplifying is achieved by using a signal amplifier associated with the electrodes and which recognizes voltage potential between the electrodes. The step of converting is achieved by receiving signals representing voltage variations over time and using an analog to digital converter to convert voltage variations into digital pulses.
The step of selecting is achieved using a numerical analyzer to select digital pulses corresponding to particular analog bioelectrical frequencies. The step of sending is achieved by use of a light or sound to the person when the analog bioelectrical frequency recognized between the electrodes falls within a predetermined range for a predetermined duration. The step of displaying is achieved using a waveform scroller for displaying particular digital signals as a continuous wave over time and using a monitor for displaying the continuous wave over time as plotted by the waveform scroller. The step of integrating is achieved using a computer which can compute integrals.
Other aspects and advantages of the present invention will become apparent from the following description of the preferred embodiments, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in the drawings, wherein like numerals represent like elements, an organism 5 can be monitored using a receptor means 7 as shown by the schematics of FIGS. 1-4. The receptor means 7 comprises at least two electrodes 9 of a ferrous materials shown attached to a rabbit 11 in FIG. 3 and a man 13 in FIG. 4. The electrodes 9 can be placed on any portion of the body where bioelectric signals may be of interest. As shown in FIGS. 3 and 4 the bioelectrical signals of the head 15 of the rabbit 11 and the head 17 of the man 13. Voltage potentials between the two electrodes 9 can be sensed over time and transmitted by wires 19 to an amplifying means or amplifier 21. One amplifier used is the mendocino microcomputer EEG amplifier or equivalent. The amplifier 21 is of a kind that can amplify analog signals such as bioelectrical signals produced by living organisms. Amplification is necessary because bioelectrical signals are typically very faint and cannot be readily analyzed by electrical means. Such amplifiers are commonly known in the art of electroencephalographic applications.
Once the analog bioelectrical signal is sufficiently amplified, the signal can be digitized or demodulated by an analog to digital converter means 23 so as to produce discrete digital signals which correspond to the frequencies inherent in the analog bioelectric signal. Some signal filtering may be necessary to properly process the analog bioelectric signal prior to demodulation. Demodulation of the analog bioelectric signal can be achieved by using a DASH 16 analog/digital input card 25. The input card 25 is manufactured by Metrabyte Corp., and is a high speed multifunction analog/digital I/O expansion board for a personal computer.
The DASH-16 uses an industry standard (HI-674A) 12 bit successive approximation converter with a 12 microsecond conversion time giving a maximum throughput rate of 60 KHz in D.M.A. mode. The channel input configuration is switch selectable on the board, providing a choice between 16 single ended channels or 8 differential channels with 90 dB common mode rejection and ±/-10 v common mode range.
Analog to digital conversions may be initiated in any one of 3 ways, by software command, by internal programmable interval timer or by direct external trigger to the analog to digital. At the end of the analog to digital (A/D) conversion, it is possible to transfer the data by any of 3 ways, by program transfer, by interrupt or by D.M.A. All operating modes are selected by a control register on the DASH-16 and are also supported by its accompanying utility software.
High input impedance ranges of +1 v, +2 v, +5 v & +10 v unipolar and ±/0.5 v, ±/1 v, ±/2.5 v, ±/5 v & ±/10 v bipolar are switch selectable. These ranges are common to all channels and are controlled by the gain of the input instrumentation amplifier. Other ranges may be realized with a single user installed resistor. All inputs are multiplexed through a low drift, fast settling instrumentation amplifier/sample-hold combination and the channel input configuration is switch selectable to operate as either 16 single ended or 8 differential channels.
A 3 channel programmable interval timer (Intel 8254) provides trigger pulses for the A/D at any rate from 250 KHz to 1 pulse/hr. 2 channels are operated in fixed divider configuration from an internal 1 MHz xtal clock (optional 10 MHz jumper selectable on DASH-16F). The third channel is uncommitted and provides a gated 16 bit binary counter that can be used for event or pulse counting, delayed triggering, and in conjunction with the other channels for frequency and period measurement.
2 channels of multiplying 12 bit D/A output. The D/A converters may be operated with a fixed -5 v reference available from the DASH-16 board to give a 0-+5 v output. Alternatively an external D.C. or A.C. reference may be used to give different output ranges or programmable attenuator action on an A.C. signal. D/A's are double-buffered to provide instantaneous single step update.
A -5 v (±/0.05 v) precision reference voltage output is derived from the A/D converter reference. Typical uses are providing a D.C. reference input for the D/A converters and offsets and bridge excitation to user supplied input circuits.
Digital I/O consists a 4 bits of TTL/DTL compatible digital output and 4 bits of digital input. Apart from being addressed as individual I/O ports, some of the digital inputs do double duty in some modes as A/O trigger and counter gate control inputs.
The analog/digital input card 25 is incorporated within a modified personal computer 27 which can be of an IBM PC or XT type sufficient to interface with the analog/digital input card 25.
The digital signals resulting can be further analyzed with respect to certain analog bioelectric frequencies sensed. A selector means 29 allows sufficient manipulation of the digital signals so as to separate particular digital signals which correspond to the particular bioelectric analog frequencies to be monitored. This function can also be achieved by using the DASH-16 card.
The computer 27 comprises a 8087 numerical processor card 29 with an expanded memory card 30 which among other things allows the selection of particular digital signals of interest corresponding to the bioelectric frequency to be studied. Such a selection can be performed by digital separation using certain digital filters commonly known in the art of digital filtering. Many of these techniques can be implemented by use of the DASH-16 card.
Furthermore, a computing means 31 is used to integrate the amplitude of the particular digital signal over a predetermined duration. The resulting value is divided by microvoltage to determine a change in voltage with respect to time duration, and thereby determine the bioelectric frequencies emitted by the person or animal. This calculation is achieved by the computer 27 driven by particular algorithms which are herein disclosed and addressed in Appendix A attached hereto. Appendix A is a list of software variables and their interrelationships. The computer 27 with a keyboard 28 then converts the resulting values divided by micro voltage to a format which can be plotted over time. Threshold values can be entered by the keyboard 28 and established such that when the amplitude of the resulting signal is within a certain amplitude range (the bioelectric signal is within a particular frequency) a signaling means signals to the person an auditory, visual, or sensible signal indicating that bioelectric frequencies are within the pre-determined ranges. An amplitude sensing means 35 is used which may be a simple algorithm preset or varied by a technician or the subject coordinating the monitoring.
The signaling means 33 is simply a light box or sound box 37 that emits a sound or light or series of sounds or lights which indicate to the subject that the bioelectric frequencies received by the monitoring electrodes 9 are within a preset frequency range. Of course, the signaling means can also be any other type of stimuli that can be sensed by the subject. One approach considered is the use of a video type game displaying animations which can be controlled by way of controlling the brainwave frequencies.
Once the subject is aware that bioelectric frequencies within a certain range can be sensed, a feedback phenomenon is possible. The subject can be trained to focus mentally upon obtaining the stimuli from the signaling means 33 and thereby, alter the bioelectric frequencies produced at the location of the electrodes 9. Bioelectric frequencies of a predetermined kind can either be facilitated and produced more readily or inhibited once the subject can be alerted to whether those frequencies produced are within the preset range.
Furthermore, a suppression means 39 or artifact suppression device can be used to suppress unwanted signals that would normally trigger the signaling means 33. Unwanted signals include "noise" attributable to bioelectric activity in the subject's muscles. A bipolar hookup with an ear reference may be used incorporating baseline wire 41 connected to the subject's ear or other part of the body which provides a signal to the suppressing means 33 which indicates that a comparable signal received from the electrodes 9 should be suppressed. The structure and function of the suppressed means 39 are commonly known in the art and are not further herein discussed. Suffice it to say that extraneous bioelectric frequencies not of interest emanating from a location not around the electrodes 9 can be suppressed. As shown in FIG. 4, the requisite suppression circuitry can be found within the amplifier 21 or within the computer 27.
A display means 43 or monitor 45 can be used in conjunction with a waveform scroller display card 45 and a graphics display card 46 to display the demodulated and processed data resulting from the processed bioelectric signal. The graphics display card is a Hercules monochrome card, but a number of IBM compatible cards can be used. The waveform scroller card 45 is commonly known in the art of computer graphics for displaying data points over time on a monitor.
The particular frequency of interest is displayed as a sinosoidal wave 48 which changes amplitude depending upon whether the particular frequency of interest is being inhibited or facilitated. More particularly, the waveform scroller card 47 processes the data received by the computing means 31 and displays it on the monitor 45. The actual data displayed are the values of the integration of the digital signals of interest over time divided by microvoltage representing the particular frequencies of interest making up the bioelectric signal. Upper and lower threshold levels can be established and displayed on the display monitor 45 as horizontal lines 49. The horizontal lines 49 represent particular microvolt scales correlated to particular bioelectric frequencies. When the amplitude of the sinusoidal wave exceeds the limits imposed by the horizontal lines 49, the signaling means 33 or light or sound box 37 send a particular signal to the subject to indicate that a particular frequency is not being suppressed or inhibited. When the sinosoidal wave 48 is within the horizontal lines 49 the subject is sent a different signal indicating that the particular bioelectric frequency of interest is being inhibited at least within the microvolt levels defined by the horizontal lines 49. Upon practice by the subject, the horizontal lines 49 can be brought closer together representing a requirement that even less of a particular bioelectric frequency must be produced to achieve a reward response by the signaling means. Of course. the use or nonuse of lights or reward systems can be modified.
A timing means 51 comprising timing circuitry commonly known in the art can be used to time the required duration that the level of bioelectric frequency production must stay within proscribed limits before a reward signal is given. The duration can be lessened once the subject has improved his ability to inhibit the production of certain bioelectric frequencies. Variability of the duration is a feature which allows greater clinical and therapeutic customization of the invention depending on the particular subject encountered and the level of skill developed by the subject.
A recording means 53 can be used to record to a magnetic medium or hard disk 55, or floppy disk drive 57 to record on a floppy disk (not shown). If a hard disk 55 is used, a hard disk controller card 58 is necessary and commonly known in the art of magnetic recording medium. The therapy session results displayed on the display monitor 45 can be stored in a format to be displayed and compared with past sessions or to be compared with future sessions. A large variety of software tools commonly known in the art of statistical evaluation to compare the subject's progress in inhibiting or facilitating particular bioelectric frequencies can be used. Most helpful is compressing the waveform produced over the entire session to a format which can be viewed in its entirety on a screen or page of paper. Such analysis is helpful to see the subject's ability to inhibited or facilitate a particular frequency over the period of the entire therapy session. This information is not only helpful to the clinician, but also to the subject since the cognitive effect on the subject may enhance his or her ability to further facilitate or inhibit certain bioelectric frequencies.
Although feedback is primarily provided to the subject by the signaling means 33, the display means can be used by the subject to monitor his own progress in facilitating or inhibiting certain bioelectric frequencies.
Also, as shown in FIGS. 1 and 3, the invention can further be used without a feedback or signaling means 33 simply to accurately and easily monitor certain selected bioelectric frequencies from an organism 5 or rabbit 11 as shown. It should be indicated also, that a number of different EEG type channels can be feed into the invention for purposes of monitoring various areas provided the proper software and hardware modifications are adapted as known in the art of EEG monitoring and recording. A large number of cables, plugs, and jacks necessary for proper operation of the invention are not herein described as those accessory items are commonly known in the art of data processing with a microcomputer.
The software to be used operates with respect to the parameters as described below and as embodied in Appendix A, as well as with the hardware described. Those skilled in the art will find the following considerations helpful.
Data collection by the software allows wrap-around in its storage, so there can be no meaning assigned to > or < in comparison of the pointers. Only == or != are useful comparisons.
Data collection proceeds continuously whenever the system is enabled. The pointer "ad -- ptr" always points to the next storage location to be used. This pointer is incremented by the interrupt handler, and is never changed by others except at the start of data collection, when it is set to the start of raw data memory.
Data filtering also proceeds continuously under most circumstances. The pointer filtered always points to the next datum to be applied to the filters. It is incremented by the collar of the filter programs, and is never changed by others except at the start of data collection or the start of data review.
Plotting may be started, stopped, reversed, restarted, etc. Two pointers are involved:
(1) "plotted", which points to the next datum to be plotted; and
(2) "plotptr", which is updated by interrupt service to indicate that it is time to plot another point when plotting at normal speed. These pointers are incremented or decremented according to plotting direction: "int runn" is +1 for forward plotting, -1 for reverse, and 0 for for stopped. Thus adding "runn" to the pointer changes it appropriately.
There are a number of points to considering in constructing the program: setting up a patient file, connection to the patient, starting the program, and running the program.
Setting Up a Patient File
An example of a patient file is shown below. New files may be created and edited with a test editor which can be incorporated with the system. The example file contains notes about the file contents. When a new patient file is being set up these notes can be erased from the new file.
EXAMPLE
c:/adinp/adcoef
20 100 Raw data trace scale and artifact suppression level
20 30 Middle trace scale and threshold
20 20 Bottom trace scale and threshold
Notes:
The patient's name must appear as the first line of this file.
adcoef names a file where filter coefficients are to be found. It MUST appear as the second line of this file. scale and artifact suppression level must be in line 3. scale and threshold for the middle trace must be in line 4.
scale and threshold for the bottom trace must be in line 5.
Any other notes may be placed later in this file, and the file can then be read by the DOS command:
type patient
Notes can be added by use of any word processor that produces clean ASCII files, but not such as wordstar.
Starting the Program
If the computer is off, open the floppy disk drive 57 and turn the power on. The computer 27 will go through an elaborate self-testing program; then it will look to drive A: to see if it can read a disk there. If the door is open, it cannot read from drive A: so it will read the hard disk, drive C:. It will go through some more testing and loading, and finally it will show the DOS "prompt" on the screen.
C>
Insert a patient's existing disk, or create a new one, in drive A: and close the door. Type "EEG" at the keyboard and follow it with the "Enter" key.
The program can be loaded from the hard disk 55, and a file called "patient" on the floppy disk can be read. If that file is not found, the program will quit with a message stating: "Cannot find patient file."
If the necessary file is there, a display will indicate the same. The display shows the name of the patient file on line 12. This normally comes from disk drive A, so it will show: "a:patient opened.", but the system can also be set up to take the file from drive B or C, or a subdirectory of C.
The name of the patient appears on line 14 of the display, and below line 14 is scaling information and the name, size and date of the last file saved on the disk. Then, the display shows the name of the new file that will be created if you save data resulting from current session, and indicates how much more data can be placed on the disk.
The program then asks whether the information shown is correct. A separate disk for each patient, and often several disks for one patient is advisable.
If you answer yes by typing "Y", the computer 27 will go on to load more information and display a menu. If you answer "N" (or any other key) the program will allow you to change the disk or switch to a different drive or to quit.
RUNNING THE PROGRAM
The numbers representing "raw input", "low pass filtered input", and the three displayed values "top", "mid" and "bot", have multiple scaling factors applied either inherently or by intention. Below are these relationships.
Inputs in can be defined as follows: "raw"=completely raw input to the amplifier, measured in microvolts. "sig"=signal value after amplification, analog/digital conversion, conversion to 16 bit twos complement notation and low pass filtering. "Sig" is in arbitrary units, and `sig` numbers will generally be larger than the corresponding number of microvolts Sig is stored in memory and is applied to the 4-7 Hz and to the 12-15 Hz filters, which are referred to here as the middle and bottom filters.
Outputs can be defined as follows:
"top"=deflection of the top trace in response to "sig".
"mid"=deflection of the middle trace in response to the output of the middle filter when a steady state in-band signal of amplitude sign is applied.
"bot"=deflection of the bottom trace in response to the output of the bottom filter when a steady state in-band signal of amplitude sign is applied.
Scaling is important and described below. Because the middle and bottom filters may be changed and scaling may be changed, and the new filters and scales may be applied in review of existing data, it is convenient to perform scaling as part of the filtering process. Therefore, "mid" and "bot" are generated directly from the filters, ready for display, so we can also define:
"mid"=output of the middle filter with "sig" as an input.
"bot"=output of the bottom filter with "sig" as an input.
It is undesirable to alter the values of the original data by scaling. Therefore, the output of the low pass filter, "sig", is separately scaled immediately before plotting, converting it from microvolts to a trace deflection measured in pixels.
Scaling factors must be properly set. Scaling occurs, in part as a side effect of other functions, such as signal amplification, analog to digital conversion and filtering, and in part because the system operator chooses to set a scale for convenience in viewing.
The detailed system design is concerned with trace deflection measured in pixels, but the system operator is more comfortable thinking about a scale in terms of microvolts per centimeter, or some other grid unit. Therefore, a relationship is established as follows: "grid"=the number of pixels corresponding to the scale chosen by the user. A likely value is 20, so that if the user selects a scale of 50 microvolts, then a signal deflection of 50 microvolts will generate a plot deflection of 20 pixels.
The computer 27 provides for input of three scaling values from the patient file or by manual operation during a run. (The operator presses the `F4` key and then enters three numbers.) These values are identified as: "iscale[top]", "iscale[mid]", "iscale[bot]" which are signal levels in microvolts representing a deflection of `grid` pixels on the display monitor 45.
Note that with a given signal, a large "iscale" generates a smaller picture. The relationship is that a trace on the monitor 45 for example of two grid units in height represents a signal of 2 "iscale" microvolts.
Other arbitrary scaling factors can be used. In order to achieve the desired scaling on the display monitor 45, in the face of other scaling factors that are not fully known or understood, a set of factors (one each for "top", "mid" and "bot") is chosen experimentally that will achieve the desired result. These values are related to the amplifier 21, the selector means 29 and possibly some other factors, but all are independent of the operator and the patient, so they are stored in a filter coefficient file and are not subject to change by the operator. They relate the arbitrary `sig` units stored in memory to true microvolt measurements, and are called (in the computer program) "fullscal[trac]". Therefore:
microvolts=sig/fullscal[trace].
If the scale chosen by the operator is equal to the grid size, then one pixel will correspond to one microvolt. If the operator chooses a different scaling, it must be applied as well. ##EQU1##
Several factors for the top trace are combined into a signal factor. For convenience this factor is stored in the coefficient array.
coeff[top][16]=grid/(iscale[top]*fullscal[top])
so that the multiplication in the plotting program is: ##EQU2## The "fullscal[trace]" values for the middle and bottom traces contain the same relationship of `sig` units to microvolts and also compensate for gain of the filters. As above, the grid size and the operator selected scaling are combined with "fullscal[trace]" into a single factor. For convenience this is stored in the filter coefficient array as:
coeff[trace][16]=grid/(iscale[trace]*fullscal[trace]
These factors are applied to the datum (in `sig` units) at the filter inputs so that the filter output is directly in pixels.
Thresholds must be established for the system. Each of the traces has an associated threshold value which leads to a decision: clamping of the filters in the case of the top trace, inhibition of the middle trace and reward of the bottom trace. Therefore, "thresh[top]", "thresh[mid]", "thresh[bot]" and decision values in microvolts, i.e., input from patient file and displayed as numbers.
For the top trace, the actual decision is based on the signal level stored in the memory in the arbitrary `sig` units. Therefore, the top trace's microvolt threshold is converted to these units by:
sigthres=thresh[top]* fullscal[top]
For the other traces the decision is based on the filter outputs, which are already in pixels, so the microvolt thresholds are converted to pixels by:
m.thres=thresh[mid]* grid/iscale[mid]
b.thres=thresh[bot]* grid/iscale[bot]
A similar conversion is made on the top trace threshold for the purpose of graphic display of the threshold.
topthres=thresh[top]* grid/iscale[top]
These calculations of thresholds and scaling factors are made in the function `chscale()` which are part of the module `thrhold.c`.
Reward logic of the program is critical to proper operation. The digital filters in "philtre.asm" generate two values: "bottom.led" and "middle.led", representing the integrated amplitude of the filtered signal divided by the threshold set for that signal. (Thus a number>1.0 means that the signal is greater than the threshold.) Indicator lights of the signaling means 33 and a counter (not shown) depend on these two values. A counter can be used to keep track of the number of times the subject has been rewarded over the test period.
Three indicator lights 38 may be provided in addition to the counter: they are referred to as red, yellow and green. Red is the inhibit indicator controlled by the undesired frequency through the 5 Hz filter and the variable "middle.led". Yellow is the enhance indicator controlled by the desired frequency. The green light signals that a reward is being posted to the counter.
The red light is turned on if "middle.led" is greater than 1.0, indicating that the 5 Hz signal exceeds the threshold. Actually, "middle.led" must become greater than 1.0 by some fixed increment to turn the red light on, and less than 1.0 by the same amount to turn the indicator off. At exactly 1.0 or very close to that value the indicator does not change. This will reduce flickering of the indicator.
The yellow light is continuously variable. Its brilliance is proportional to: ##EQU3## which is equal to "bottom.led"=-1.0.
The yellow light is lighted independently of the 5 Hz inhibit signal. Both lights, however, will go off if a muscle or eye blink artifact is detected, because the inputs to the filters are clamped for one second upon detection of the artifact as part of the suppression means 39.
The green light signals a reward. When the yellow light is on continuously for 0.5 second during which the red light is off, then the green light is turned on. An audible signal is given, and the counter is incremented. The green light stays on for 0.5 second and is then, off until the next reward. The program allows time setting an interval after one reward before the next one can start to be earned, so that the frequency of rewards can be limited if desired.
Obviously, the approach described herein can be greatly modified by the clinician or the subject
It should be appreciated for the foregoing description that the present invention provides an improved, more simplistic, more accurate, and less time intensive monitoring and/or control of particular bioelectric frequencies of organisms. The apparatus of the invention can be assembled from components readily available and easily assembled. Furthermore, diagnostic evaluation and patient use is greatly improved. Furthermore, the use of power spectral analysis and analog active band pass signal filtering can be eliminated.
Although the present invention has been described in detail with reference only to the presently-preferred embodiments, it will be appreciated by those of ordinary skill in the art that various modifications can be made without departing from the invention. Accordingly, the invention is limited only by the following claims.
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An improved method and apparatus for displaying and either inhibiting or promoting selected bioelectrical frequencies emitted by a living organism. The method includes the steps of detecting an analog bioelectrical signal, converting the signal to discrete digital signals representing corresponding frequencies and numerically analyzing the digital signals to determine the different bioelectrical frequencies emitted by the organism. Furthermore, a threshold amplitude associated with a selected digital signal can be established an auditory or visual signal can be sent to the organism to indicate whether the bioelectrical frequency under study is within or outside the threshold amplitude. With this information the organism can be taught to inhibit or facilitate the bioelectrical frequency. The apparatus comprises a pair of electrodes, an analog signal amplifier, an analog to digital converter, a selector to select a frequency of interest, a display monitor, and a computer to distinguish the digital signals as different frequencies, display the frequencies, and determine when the frequency is falling inside or outside a predetermined range. Also, a magnetic medium recording device is used to capture data. Finally, a lighting or sounding circuit is used to tell the organism whether the frequency under study is being inhibited or facilitated.
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[0001] This application is a continuation application of my co-pending application Ser. No. 12/006,168 filed Dec. 31, 2007 and titled Foil Composite Card, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The invention is directed to the manufacture of a multi-layered (composite) card, or any like instrument or document.
[0003] The term “card” or “cards” as used herein, and in the appended claims, is intended to include a large variety of documents and instruments such as a financial cards, identification (including a National ID or Driver's License) cards, electronic passport pages, gift cards, documents for holding permanent and long lasting records such as medical records or security cards, or other plastic cards used for promotion of a product or organization.
[0004] Various means of producing an improved composite card are disclosed in U.S. Pat. No. 6,644,552, titled Composite Card and issued to John Herslow, the applicant of this application, the teachings of which are incorporated herein by reference. However, there remains a demand for increasing the security of the cards (documents and/or instruments) being formed and used. For example, FIG. 4 of the '552 Patent, shows security elements formed in a top layer 17 and FIG. 6 of the '552 Patent discusses the addition of holographic material and other security indicia after the sheets are cut into standard cards.
[0005] Thus, to increase the security of a card, it is known to form holograms on the card. Generally, the holograms may be formed by a hot stamping method at, or near, the top (or bottom) surface (level) of the card. A disadvantage to so placing the holograms is that a counterfeiter may be able to alter the card without the tampering being readily apparent to someone examining or accepting the card. Also, positioning the hologram close to the top or the bottom surface of the card creates an asymmetry in its construction, whereby, when the temperature varies, different portions (layers) of the card may be placed under different degrees of tension and contraction resulting in stresses which tend to distort the card and/or the hologram (e.g., the card fails to remain flat). Still further, when the hologram is placed at, or near, the top or the bottom surfaces it may be easily and inadvertently scratched or marred.
[0006] Due to the highly sensitive nature of the “secure” cards, of interest, it is critical that they be made tamper resistant and sturdy and to last for a long time (e.g., more than 5 years) even where high temperature levels (hot or cold) and a high degree of humidity are encountered. It is also desirable that they be relatively inexpensive to fabricate and, very importantly, that the card be virtually impossible to be altered without destroying the card or the easy detection of the alteration.
SUMMARY OF THE INVENTION
[0007] Accordingly, composite cards formed in accordance with the invention include a security layer formed at the center, or core layer, of the cards. Cards embodying the invention may include a hologram, or diffraction grating formed at, or in, the center, or core layer, of the card with symmetrical layers formed above and below the center or core layer.
[0008] A hologram may be formed by embossing a designated area of the core layer with a diffraction pattern and vapor depositing a very thin layer of metal or metal compound (e.g., aluminum, zinc sulfide, etc . . . ) on the embossed layer. Then, additional layers are selectively attached to the top and bottom surfaces of the core layer. In accordance with the invention, for each additional layer attached to the top surface of the core layer there is a corresponding like layer attached to the bottom surface of the core layer for producing a highly symmetrical structure (sandwich).
[0009] In accordance with one embodiment of the invention, all the layers are made of a clear synthetic (e.g., plastic) material, whereby the pattern formed on, or within, the core layer may be seen by looking down at the top of the card or by looking up at the bottom of the card.
[0010] The layer of metal or metal compound deposited on the core layer may be made very thin to provide a “see-through” effect, under appropriate light conditions. However, where the layer of metal or metal compound deposited on the core layer is of “standard” thickness, the pattern may only be seen from the top or the bottom side of the core.
[0011] After the hologram is formed, a laser may be used to remove selected portions of the metal formed on the embossed layer to impart a selected pattern or information to the holographic region. In accordance with the invention, this step in making a card or a set of cards may be performed when the card or cards being processed are attached to, and part of, a large sheet of material, whereby the “lasering” of all the cards on the sheet can be done at the same time and relatively inexpensively.
[0012] In accordance with the invention a hologram may be formed in the core portion of card and if the hologram includes a metal layer, laser equipment may be used to modify and/or alter the metal pattern at selected stages in the process of forming the card. Alternatively, after the sheets are die-cut into cards, each card may be individually “lasered” to produce desired alpha numeric information, bar codes information or a graphic image.
[0013] Embodiments of the invention may include the use of a polyester film, or any other carrier, which includes a metallic or a high refractive index (HRI) transparent holographic foil that is pre-laminated between two sheets of a material (which could be PVC, PET or other thermo-plastic resin) that has a thermo-plastic adhesive (which may have, but not necessarily has, been previously applied). The pre-laminated holographic foil can have an unlimited number of patterns and may also be configured to include one, or several individual, hologram designs repeated in rows and columns across an entire sheet. The holographic design may also have the appearance of full metal, or partial metal and partial white coverage (white reflecting hologram) on each individual card in the matrix. Utilizing this holographic foil pre-laminate in concert with standard plastic card materials, enables a plastic card manufacturer to produce “full-face” foil pattern design cards, or “full-face” registered hologram cards.
[0014] These cards would include the holographic foil pre-laminate as the center sheet in a standard card composition. Utilizing the center sheet composition with a metal layer, the subsequent plastic card could be laser engraved using a standard YAG laser or any other suitable laser, thus removing the metal or material coatings of the holographic layer in one or more of the following: an alpha numeric, barcode or graphic design. The end result is an inexpensive foil composite card that has a unique individualized holographic layer that has been permanently altered.
[0015] If a potential counterfeiter attempted to disassemble the card in order to compromise the integrity of the information contained on, or in, the card, it would cause a change in the hologram resulting in the hologram being irreparably damaged. Therefore, plastic cards formed in accordance with the invention are truly tamper resistant and are more secure foil cards than any of the known commercially available cards.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] In the accompanying drawings (which are not drawn to scale) like reference characters denote like components, and:
[0017] FIG. 1 is a cross sectional diagram of part of a card (instrument) embodying the invention;
[0018] FIG. 2 is a diagram detailing some of the steps in forming a card embodying the invention;
[0019] FIG. 2A is a diagram detailing the application of an embossing layer to a core layer to form a card embodying the invention;
[0020] FIG. 3 is a cross sectional diagram of part of a card embodying the invention where the core layer includes a transparent material having a high refractive index;
[0021] FIGS. 3 a , 3 b , 3 c , 3 d , are cross sectional diagrams of steps in forming a card embodying the invention;
[0022] FIG. 4 is a diagram of the cross section of part of a card embodying the invention to which a laser beam is applied to form an additional ablated pattern in a metal layer in accordance with the invention;
[0023] FIG. 5 is a diagram of a top view of a card including a holographic portion formed in accordance with the invention;
[0024] FIG. 6 is a cross sectional diagram of a card shown in FIG. 5 where all layers are made of clear (transparent) materials;
[0025] FIG. 6A is a cross sectional diagram of a card embodying the invention where one, or more, of the layers block the light;
[0026] FIG. 7 is a top view of a sheet containing an array of cards illustrating that a laser beam can be applied to all of the cards on the sheet;
[0027] FIG. 8 is a cross sectional diagram of a card with an integrated circuit (IC) chip and antenna embodying the invention;
[0028] FIG. 9 is a cross sectional diagram of a dual interface card embodying the invention;
[0029] FIG. 10 is a cross sectional diagram of a card with a lasered window embodying the invention;
[0030] FIG. 11 is a cross sectional diagram of another card with a lasered window embodying the invention; and
[0031] FIG. 12 is a cross sectional diagram of still another card with a lasered window embodying the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0032] Referring to FIGS. 1 , 2 and 2 A, there is shown a core 20 comprised of a base layer 21 of a plastic material, which may be, for example, oriented polyester terephthalate (OPET) or polypropylene, or polystyrene, or any number of acrylics and/or a combination of these materials. The base layer 21 is shown to have an upper surface 21 a and a lower, or bottom, surface 21 b. For purpose of illustration, a pattern is shown to be formed on, or above, surface 21 a of layer 21 . However it should be understood that, alternatively, the pattern could be formed on surface 21 b. Two different methods of forming a pattern are shown in FIGS. 2 and 2A . The surface 21 a of layer 21 in FIG. 2 is embossed with a diffractive or holographic pattern. In FIG. 2A , the surface 21 a of layer 21 is coated with an embossing layer 200 which is then embossed with a diffractive pattern, 200 a.
[0033] A layer 22 of aluminum (or any suitable metal or metal compound such as Zinc Sulfide) may then be vapor deposited on the diffraction pattern to form a hologram. The use of vapor deposition is very significant in that it permits a very thin layer 22 , a few atoms thick, to be formed on surface 21 a and thus complete the formation of the hologram, using small amounts of metal. Using vapor deposition, the thickness of the layer can be made very thin so it is nearly transparent and can provide a “see-through” effect. Alternatively, the metal layer can be made a little thicker so as to be more opaque.
[0034] As detailed in step 3 of FIG. 2 , a clear adhesive primer layer 23 a, may be coated over the patterned and metallized top surface ( 21 a ) and a similar clear adhesive primer layer 23 b may be coated over the bottom surface ( 21 b ) of the layer 21 . The core 20 is completed by attaching these clear adhering layer ( 23 a, 23 b ) above and below the embossed base layer 21 . The clear layer 23 a, 23 b, is a primer coating. It may be polyethylenamine or an acrylic based, or other, organic adhesive compound with solvent or water based carriers. The primer coatings 23 a, 23 b are fairly thin and yet fairly strong/sturdy. They also function to promote adhesion to layers 24 a, 24 b which are attached to the core 20 .
[0035] As detailed in step 4 of FIG. 2 clear PE adhesive layers 24 a, 24 b may then be formed/attached to the top (outer) surfaces of their respectively layers 23 a, 23 b. Layers 24 a, 24 b may be of polyethylene (PE) material, or polypropylene (PP), or high density polypropylene (HDPP), or ethylene Vinyl Acetate (EVA), or any of the different forms of PET or any of like materials, or mixtures of these materials. The clear materials used to form layers 24 a, 24 b may contain other clear adhesion promoting compounds (e.g., ethyl acrylates, acrylic acid, etc . . . ). The layers 24 a, 24 b may be fairly thick and function to attach to the thin embossed hologram layer and coatings of core 20 . For handling purposes, buffer layers 25 a, 25 b may then be formed/attached to the top (outer) surfaces of layers 24 a, 24 b to complete what is defined as subassembly 30 . For example, buffer (carrier) layer ( 25 a, 25 b ) may be laminated to the top and bottom of adhesive layers 24 a, 24 b. Subassembly 30 , is thick enough to be handled by automatic credit card manufacturing equipment.
[0036] In one embodiment, the base layer 21 was approximately 0.002 inches thick and the adhesive backed layers ( 23 a, 23 b ) were each made to be approximately 0.0001 to 0.0003 inches thick. In other embodiments the layers 23 a, 23 b could be made either thinner or much thicker.
[0037] In still other embodiments, adhesive layers can be coated over the buffer or carrier layer and the two (i.e., the carrier and buffer layers on each side of a holographic layer) can be combined with the holographic layer. That is, adhesive can be applied to either side of the carrier foil interface and then pre-laminated together (3 sheets laminated to become one laminate; i.e., the prelaminate prior to platen lamination. Thus, the carrier sheet can hold the sub-assemblies for transfer to substrates for forming cards.
[0038] Examining FIG. 2 in greater detail note some of the steps used in forming the core 20 .
[0039] As shown, for example, in step 1 , the base component may be a sheet 21 of plastic (e.g., PET or OPET or polypropylene, or polystyrene, or polymethyl, methacrylate, etc . . . ) material whose thickness typically ranges from 0.0005 inches to more than 0.005 inches. In one embodiment layer 21 was made, for example, 0.002 inches thick.
[0040] Then, as shown in step 2 A, which may be termed an embossing step, a diffraction pattern may be formed on one side of layer 21 . A diffraction pattern may be formed directly in the plastic layer 21 by embossing (e.g., stamping) pattern(s) therein. Forming the pattern in a sheet of plastic (or in an embossing layer, as discussed below) is easier and less wearing on the embossing (stamping) equipment than forming a like pattern in a metal layer.
[0041] Then, as shown in step 2 B a hologram is formed on one surface ( 21 a ) of plastic sheet 21 by vapor deposition of a metal layer (e.g., aluminum onto the diffraction pattern. Thus, the hologram may be formed by embossing the top surface 21 a to form a diffraction pattern and then metallizing the pattern. The surface 21 a may be coated by the vapor deposition of aluminum (or similar light reflective materials such as nickel, silver, zinc, or other like materials). A significant advantage of using vapor deposition (although many other methods may be used) is that very small amounts of the metal (light reflective material) need to be used to form the hologram resulting in a significant savings in the cost of manufacturing the card (or instrument). Also, very thin layers allow a controllable amount of light to pass through. This enables the manufacture of a card, or document, in which an image (hologram) formed on a card is reflected (i.e., is visible) while also enabling a viewer to “see-through” the image.
[0042] Then, as shown in step 3 of FIG. 2 , clear adhesive or “primer” coats 23 a, 23 b may be applied to the top and bottom surfaces 21 a, 21 b, respectively, of plastic sheet 21 . The primer coat also functions to fill in the ridges resulting from the formation of the diffraction grating. The clear layers 23 a, 23 b which may be of the type described above, may be attached to the top and bottom surfaces of “embossed” plastic sheet 21 on which the aluminum has been vapor deposited. Primer layers 23 a, 23 b may be attached to base layer 21 by any one of a number of methods, such as, for example, gravure coating, roller coating, flexography or other like methods. The primer secures the bond to both sides of the holographic sheet (the embossed side and the blank side). This completes the formation of what is defined herein as the core assembly 20 .
[0043] Then, as shown in step 4 of FIG. 2 , the PE layers 24 a, 24 b, or any other suitable layer, as noted above, which function as an additional buffer between that bond and the outer buffer layers 25 a, 25 b are attached to the core assembly. The PE layers 24 a, 24 b may also include an adhesive which promotes adhesion to the clear primer layers 23 a, 23 b attached to the top and bottom surfaces of layer 21 . Layers 24 a, 24 b, 25 a, 25 b may be attached to each other and to the underlying layers by any one of a number of methods such as, for example, platen lamination, hot roll lamination, liquid adhesive lamination.
[0044] Thus, as shown in step 4 of FIG. 2 , a clear buffer layer 25 a is attached to the PE layer 24 a and a clear buffer layer 25 b is attached to the PE adhesive layer 24 b. All of layers 24 a and 24 b and layers 25 a, 25 b function as buffers, providing additional strength to the structure and at the same time protecting the hologram from being damaged or tampered with. Adding layers 25 a and 25 b completes the sub-assembly 30 which may then be customized to form cards with additional information.
[0045] By forming the hologram at, and within, the core level, the hologram will not be easily, or inadvertently, damaged since several additional layers will be attached to the top and bottom of the holographic layer. It is also not subject to easily being tampered or altered. Forming the hologram at the center of the structure minimizes the possibility of tampering while fully protecting the hologram. Another significant advantage of forming the hologram at the core of the structure is that the top and bottom surfaces stay flat due to equal shrinking and/or expansion of all the layers. Note that the card structure is formed so as to be symmetrical about the core layer.
[0046] FIG. 2A illustrates another method of forming the hologram. As shown in Step 1 A of FIG. 2A , a clear embossing layer 200 may be coated directly over a layer 21 (or 210 ). Alternatively, a primer coating may be formed on layer 21 / 210 and then the embossing layer 200 may attached/formed to the primer coating. The embossing layer may be composed, for example, of siloxane, acrylic, vinyl, linear polyester, urethane or any like materials and may be several (e.g., less than 0.5 to more than 5) microns thick. The embossing layers may also be deposited as liquids and radiation cured, possibly in two steps—first as a soft easily embossable coating which then becomes hard and impervious. As shown in step 2 A of FIG. 2A , a diffraction pattern is embossed (formed) in the embossing layer/coating 200 to form a desired pattern. Forming a pattern in the embossing layer may be desirable since it is even easier and less wearing on the embossing (stamping) equipment than forming a like pattern directly in the PET layer (as per FIG. 2 ). After the pattern is embossed on and within the embossing layer 200 , the sheet may be processed as per steps 2 B, 3 and 4 shown in FIG. 2 .
[0047] [Note that a hologram may be formed by, for example, embossing a pattern in a carrier base material (e.g., a hard polyester) or by embossing the pattern in a coating previously applied to the carrier base material, or by embossing the pattern in a metal which was previously deposited onto the base carrier material or by depositing the metal onto a soft coating and then embossing.]
[0048] Referring back to FIG. 1 , note that the core 20 may be part of a subassembly 30 which includes attaching layers 24 a, 24 b of clear PE and buffer layers 25 a, 25 b to the top and bottom surfaces of the core 20 . Layers 25 a, 25 b, may range in thickness from 0.001 to 0.005 inches, or more, and may be composed of PVC like materials.
[0049] The subassembly 30 may then be used to form a card, or any instrument, by attaching a layer 27 a, 27 b of clear or white PVC material to the top and bottom surfaces of the subassembly 30 . As illustrated in FIG. 1 , information can be printed either on the outer surface (the surface facing away form the core) of layers 27 a, 27 b or on the inner surface or both. The printed information may include, for example, fixed data fields and advertising, and/or any other desired information. The card (or instrument) may be completed by adding clear PVC laminating films 29 a, 29 b to the top and bottom surfaces of the card.
[0050] FIG. 3 is a cross-sectional diagram (not to scale) of a card embodying the invention. FIG. 3 includes a core comprised of a layer 210 which may be (but not be) of the same material as layer 21 . In FIG. 3 , the top surface 210 a of layer 210 is embossed with a diffraction pattern giving a unique pattern to the structure. A high refractive index (HRI) layer 212 can then be vapor deposited on the embossed layer. Due to the HRI property of layer 212 , there is no need to further metallize the layer. The HRI layer may be formed of zinc sulfide or zinc oxide or any material having like properties. Clear primer layer 23 a is attached to the top of HRI layer 212 overlying layer 210 and primer layer 23 b is attached to the bottom of layer 210 .
[0051] Then, as shown in FIG. 1 , clear layers 24 a and 24 b, which may be of PE or any other suitable materials, are attached to layers 23 a and 23 b, respectively and additional layers ( 25 a, 25 b ) of clear (translucent) material may be attached to the top and bottom layers of layers 24 a, 24 b to form the subassembly 30 . Additional layers 27 a, 27 b may be attached to the top and bottom layers of the sub-assembly. Information may be written or printed in any known manner on, or in, the layers 27 a, 27 b. Subsequently, laminating films 29 a, 29 b, may be attached to the top and bottom intermediate layers 27 a, 27 b to produce a card 40 whose core contents can not be altered without essentially destroying the card.
[0052] FIGS. 3A , 3 B, 3 C, 3 D and 3 E illustrate the forming/coating of an embossing layer 200 on stock (e.g., PET) material 210 ( FIG. 3A ), then embossing layer 200 with a diffraction pattern 200 a ( FIG. 3B ), then vapor depositing an HRI layer 212 a on the diffraction pattern ( FIG. 3C ), then coating clear primer layers 23 a, 23 b above layer 212 a and below layer 210 ( FIG. 3D ) to form a core assembly 20 . Then clear PE adhesive layer 24 a is formed above prime layer 23 a and clear PE adhesive layer 24 b, is formed below layer 23 b ( FIG. 3E ). Note that the steps and thicknesses of the layers to form the basic structures discussed above are summarized in Table I, below.
[0053] FIG. 4 includes a cross-sectional diagram (not to scale) of a portion of a card embodying the invention, which may be part of a sheet (not shown) on which a large number of cards are formed, and depicts a piece of laser equipment 410 for “lasering” (e.g., engraving or vaporizing) metal layer 22 . The core assembly 20 is shown to have a layer 22 of aluminum deposited and embossed as discussed for FIGS. 1 , 2 , and 2 A, above. Portions of the metal layer may be vaporized (see sections 401 a, 401 b, 401 c ) by the laser equipment 410 such that portions of the metal are selectively removed or “ablated” by “lasering” (e.g., eliminating or vaporizing) the metal to form any number of different patterns (e.g., graphic as well as alpha numeric information may be generated). The clear layers 29 a, 27 a, 25 a and 24 a may be selected to be transparent to the laser wavelength. Consequently, the laser beam can pass through the clear layers of the card to “write” on the holographic layer below the top surface of the card. The laser 410 may be applied at several different stages of the card manufacturing process to form the desired patterns. Thus, the laser may be applied to “write” on the metal layer after the core 20 is formed and before the attachment of the carrier layers 24 a, 24 b and 25 a, 25 b. Alternatively, the laser 410 may be applied to form the desired pattern in the metal layer after the layers 24 a, 24 b, and 25 a, 25 b are attached to the core layer, and before layers 27 a and 27 b are attached. Still further, the laser may be applied to form the desired pattern in the metal layer after the layers 27 a, 27 b are attached and before the layer 29 a, 29 b, are attached. Finally, the laser may be applied to form the desired pattern in the metal layer after the layers 29 a, 29 b are attached, when the cards may be part of a full sheet or in individual card shape.
[0054] FIG. 5 shows a top view of a card 100 illustrating that the hologram may be ted within a designated window or area 101 , shown in portion 601 . Alternatively the hologram may extend the full length and/or width of the card 100 . Note that alpha numeric information may be produced by lasering within the holographic layer (e.g., layer 22 in FIG. 4 shown in portion 602 ). Also, alpha numeric information may be produced by printing information on, or within, layers 27 a, 27 b, as discussed above.
[0055] FIG. 6 is a cross-sectional diagram (not to scale) of card 100 of FIG. 5 and is intended to show that the layers above and below the holographic layer, 21 , 22 / 212 , may be transparent or translucent to yield a “see-through” card with the hologram portion 601 and the lasered portion 602 being visible from the top side or from the bottom side of the card. Note that if layers 27 a, 27 b are made of a white material a bright light may be needed to observe the “see-through” effect.
[0056] FIG. 6A is a cross-sectional diagram (not to scale) intended to show that the layers above the holographic layer 21 , 22 / 212 , may be transparent or translucent so the holographic pattern may be seen from the top. At the same time, one or more of the layers below the holographic layer (e.g., 27 b or 29 b ) may be opaque so as to block the hologram from being seen from the bottom. Making the top portion of the card transparent and the bottom portion opaque is by way of illustration and the reverse could be done instead.
[0057] FIG. 7 shows the application of a laser beam generated by laser equipment 410 to a sheet 5 containing a large array of cards 100 in sheet form embodying the invention. The laser may be applied to the entire sheet of cards which may be at the core stage, the sub-assembly stage, or any of the stages thereafter. Being able to apply the laser beam in this manner, at any time before the cards are separated from a sheet, is economically advantageous and saves much in the cost of handling and also adds significant additional security.
[0058] FIG. 8 illustrates that cards embodying the invention, shown in the various figures, may be modified by the addition of a semiconductor chip containing selected electronic circuits (an integrated circuit, IC) within the body of the card in, or within, a layer 30 dedicated to include an antenna carrier, with the antenna being connected to the chip module. This enables the manufacture of a radio frequency identification (RFID) card. Note that the metal layer 22 / 212 can act as a radio frequency shield to reduce reception from that side of the RFID antenna.
[0059] FIG. 9 illustrates that the chip (IC) and an antenna and carrier may be formed within a layer of the card and that, in addition, the chip may be accessed (read) by providing an external contact 901 along one side of the card. This type of card may be referred to as a dual interface card since it enables information on the card to be read or written via RFID and contact.
[0060] FIG. 10 illustrates that a window or opening can be formed by lasering through the metal layer within core layer 20 to enable the color or pattern of an underlying layer (e.g., 27 b ) to be seen from the top side of the card. Lasering through the metal layer forms (or opens) a window exposing an underlying layer (e.g., 27 b ) which may be black or white or colored or be of any preset pattern.
[0061] FIG. 11 illustrates that a window or opening can be formed by lasering the metal layer within core layer 20 to enable a preprinted image formed on an underlying layer (e.g., 27 b ) to be seen from the top side of the card. Here again lasering through the metal layer forms a window enabling the seeing or reading of a pre-printed pattern on an underlying layer (e.g., 27 b ).
[0062] FIG. 12 illustrates that a window or opening can be formed by lasering through the metal layer within core layer 20 to provide a “see-through” condition. That is, lasering through the metal layer forms a window which provides visibility through both sides (top and bottom) of the card. This may be viewed by applying a light source such as a flashlight in direct contact with one side of the card and viewing the light pattern on the other side.
[0000]
TABLE I
Example of Steps and materials in forming core, sub assembly and card
step
I
II
III
IV
1
Start with
Start with
Start with
Start with base/central
base/central layer
base/central
base/central
layer 21/210
21 of PET/OPET
layer 21/210
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of PET/OPET material
material
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material
1A
Deposit
Deposit embossing layer
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one surface of
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2
Emboss one surface
Emboss top
Emboss one
Emboss top surface of
of base layer 21 with
surface of
surface of base
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pattern
embossing
layer 21 with
with pattern 200a
layer 200 with
pattern
pattern 200a
3
Vapor deposition of
Vapor
Vapor
Vapor deposition of HRI
metal 22 on pattern
deposition of
deposition of
coating 212 on pattern
metal 22 on
HRI coating 212
pattern
on pattern
4
Apply clear primer
Apply clear
Apply clear
Apply primer clear coats
coats 23a, 23b to
primer coats
primer coats
23a, 23b to top and
top and bottom
23a, 23b to top
23a, 23b to top
bottom Where primer
Thickness:
and bottom
and bottom
coat 23a, 23b
.00002-.0002
Thickness:
Thickness:
Thickness:
.00002-.0002
.00002-.0002
.00002-.0002
5.
Form clear PE
Form clear PE
Form clear PE
Form clear PE adhesive
adhesive layers 24a,
adhesive layers
adhesive layers
layers 24a, 24b fairly
24b-fairly thick,
24a, 24b fairly
24a, 24b fairly
thick, sticky
sticky
thick, sticky
thick, sticky
Thickness:
Thickness:
Thickness:
Thickness:
.0005-.005
.0005-.005
.0005-.005
.0005-.005
6.
Form clear buffer
Form clear
Form clear
Form clear buffer layer
layer 25a, 25b of
buffer layer
buffer layer
25a, 25b of PVC material
PVC material
25a, 25b of
25a, 25b of
thickness
thickness
PVC material
PVC material
.0008-.005
.0008-.005
thickness
thickness
.0008-.005
.0008-.005
7.
Form clear white
Form clear
Form clear
Form clear white PVC
PVC layer white PVC
white PVC layer
white PVC layer
layer 27a, 27b
layer 27a, 27b
27a, 27b
27a, 27b
Thickness .004 to .012
Thickness .004 to
Thickness .004
Thickness .004
.012
to .012
to .012
8.
Form PVC
Form PVC
Form PVC
Form PVC laminating
laminating film 29a,
laminating film
laminating film
film 29a, 29b
29b
29a, 29b
29a, 29b
Thickness .0008 to .005
Thickness .0008 to
Thickness
Thickness
.005
.0008 to .005 —
.0008 to .005
All dimensions in inches
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Composite cards formed in accordance with the invention include a security layer comprising a hologram or diffraction grating formed at, or in, the center, or core layer, of the card. The hologram may be formed by embossing a designated area of the core layer with a diffraction pattern and depositing a thin layer of metal on the embossed layer. Additional layers may be selectively and symmetrically attached to the top and bottom surfaces of the core layer. A laser may be used to remove selected portions of the metal formed on the embossed layer, at selected stages of forming the card, to impart a selected pattern or information to the holographic region. The cards may be ‘lasered’ when the cards being processed are attached to, and part of, a large sheet of material, whereby the “lasering” of all the cards on the sheet can be done at the same time and relatively inexpensively. Alternatively, each card may be individually “lasered” to produce desired alpha numeric information, bar codes information or a graphic image, after the sheets are die-cut into cards.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of application Ser. No. 12/612,336, filed Nov. 4, 2009, entitled “DC Bus Boost Method and System for Regenerative Brake” in the name of Lixiang Wei et al.
BACKGROUND
The present invention relates generally to the field of electric motor drives such as those used to control electric motors and similar loads. More particularly, the present invention relates to systems and methods for using switched converters to rectify alternating current (AC) into direct current (DC), boost the overall voltage of a DC bus, and provide for regenerative braking capabilities while reducing the number of components in the system.
Power rectifier systems are used in a wide range of applications. For example, power converters that perform rectification are used with centrifuges, magnetic clutches, pumps and more generally, in electric motor drive controllers to rectify and condition incoming AC voltage and to supply DC voltage to the motor. Many electric motor controllers also include some type of motor braking ability, in which energy from the motor is re-converted while slowing the driven load. The energy resulting from the braking operation can either be fed into a resistor, which will convert the energy into heat, or fed back into the supply network. Electric motor controllers with regenerative braking ability can feed the energy back into the supply network. This regenerative braking ability is very useful in reducing energy usage and in decreasing operational costs. Electric motor drives may also provide for the ability to boost DC voltage during certain low-voltage conditions such as sagging line voltage, motor starting, and heavy motor loading. The added boost in DC voltage during these periods allows for maintaining normal operating conditions and also increases the life of the motor. However, one drawback of electric motor drives that provide for motor drive, regenerative braking, and DC voltage boosting is that they require many extra components, lose energy due to constant switching activity, and are costly.
BRIEF DESCRIPTION
Embodiments of the present invention provide novel techniques for using a fundamental front end (FFE) rectifier to provide for AC rectification, regenerative braking, and DC voltage boosting. The FFE rectifier is simple to operate, uses less expensive components, and is more energy efficient in its switching activity than other types of switched converters. In particular, the FFE rectifier can incorporate a low impedance reactor (typically 3% impedance) and exhibits less energy loss due to switching than comparable rectifiers such as active front end (AFE) rectifiers. Cost can be minimized by reducing the number of system components and by lowering the operational expenses where possible.
In one embodiment, a method for controlling an electric motor via a controller and a rectifier is provided. The rectifier includes a positive solid state switch and a negative solid state switch for each of three phases of voltage. The rectifier may convert the three input phases of alternating current voltage to direct current voltage which may then be applied to a direct current bus. The method includes the detection of the voltage of the direct current bus and the voltage of each phase of input voltage, the identification of the phase of input voltage having the highest absolute voltage, the cycling of the positive and negative solid state switches of an identified phase, and the placing of a solid state switch for the two other phases in a conducting stated based upon which other phase exhibits the greater voltage difference from the identified phase.
In a second embodiment, a system is provided which includes a controller controlling an electric motor and a rectifier. The rectifier includes a positive solid state switch and a negative solid state switch for each of three input phases of alternating current power. The rectifier is capable of converting three input phases of alternating current power to direct current power applied to a direct current bus. A detector is also included which is capable of detecting the voltage of the direct current bus and the voltage of each input phase. The controller can use the detector to detect the voltage of the direct current bus and the voltage of each phase of input power. The controller can then identify the input phase having the highest voltage and can cycle the positive and negative solid state switches of the rectifier at the identified phase. The controller can then place a solid state switch of the rectifier for the two other phases in a conducting state based upon which other phase exhibits the greater voltage difference from the identified phase.
In a third embodiment, a method is provided for controlling an electric motor via a controller and a rectifier. The rectifier includes a positive and a negative solid state switch for each of three phases of power. The rectifier converts three input phases of alternating current power to direct current power applied to a direct current bus. The method detects the voltage of the direct current bus, and the voltage of each input phase of input power. The method identifies the phase of input power having the highest voltage, and cycles the positive and negative solid state switches of an identified phase. The method places a solid state switch for the two other phases in a conducting state based upon which other phase exhibits the greater voltage difference from the identified phase. The method also determines a duty cycle for cycling the positive and negative solid state switches of the identified phase based on electric power requirements, and wherein the positive and negative solid state switches of the identified phase are cycled at the determined duty cycle.
DRAWINGS
These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
FIG. 1 is a schematic diagram of an exemplary embodiment of a rectifier being shown as a component in a larger circuit that is used to drive a three-phase motor.
FIG. 2 is a three-phase voltage diagram alongside a switching diagram of a set of rectifier switches.
FIG. 3 is an exemplary flow chart of the methodology used to select a set of rectifier switches to which control signals are applied.
FIG. 4A illustrates a timing diagram of a set of duty cycles that may be used for pulse width modulation (PWM) of rectifier switches in accordance with an embodiment of the present invention.
FIG. 4B illustrates a PWM control signal used to drive one of the rectifier switches.
FIG. 4C illustrates a PWM control signal used to drive a different rectifier switch.
FIG. 5 is an exemplary flow chart that may be used to calculate the duty cycle d for pulse width modulation of switches of a rectifier.
DETAILED DESCRIPTION
FIG. 1 illustrates an embodiment of a three-phase motor controller 10 . The three-phase motor controller 10 may include an insulated gate bipolar transistor (IGBT) rectifier circuit 12 coupled to an inverter circuit 14 , which may be used to drive a three-phase motor 16 . In the illustrated embodiment, the rectifier circuit and the inverter circuit are controlled by a controller 18 . Three phases of AC voltage from the supply mains 20 are converted into DC voltage by the rectifier 12 . The DC voltage is then converted to controlled frequency AC voltage by the inverter circuit 14 to drive the motor 16 . In one embodiment of the invention the rectifier 12 may provide for AC rectification, braking regeneration, and DC voltage boosting. The rectifier circuit 12 comprises a set of solid state switches Sap 22 , San 24 , Sbp 26 , Sbn 28 , Scp 30 , and Scn 32 , each provided with a fly-back diode. In the present discussion, the subscripts “a”, “b” and “c” are used to designate each of three phases of voltage, while the subscripts “p” and “n” are used to designate “positive” and “negative” sides of the DC bus output of the converter circuitry 12 (although such designations are by convention only). During rectification, the switches of the circuit need not be controlled (i.e., switched). This allows for the diode components of the IGBT switches Sap 22 , San 24 , Sbp 26 , Sbn 28 , Scp 30 , and Scn 32 to act as a full wave rectifier that converts the incoming AC voltage 20 into DC voltage. The resulting DC voltage is transferred to a common DC bus and may then be converted into AC voltage by the inverter 14 . A DC bus capacitor Cdc 34 is connected between the two DC bus lines and is used to create a low impedance source which also helps filter DC ripples. Line reactor components comprised of inductors La 36 , Lb 38 , and Lc 40 are used as a filter to smooth converted power signals and to improve the harmonics of the circuit.
In another phase of operation, the rectifier 12 allows for energy resulting from the braking of the three-phase motor 16 to be redirected back into the supply mains 20 . As will be appreciated by those skilled in the art, during regenerative braking, the motor 16 behaves as a three-phase generator. Consequently, the switches of the rectifier 12 are switched by controller 18 in such a way as to allow the alternating current flowing through the main bus to pass back into the supply network. Each one of the positive switches Sap 22 , Sbp 26 , and Scp 30 is turned on when its respective phase voltage is the most positive of the three (upper half of the respective wave). Similarly, each of the negative switches San 24 , Sbn 28 , and Scn 32 is turned on when its respective phase voltage is the most negative of the three (lower half of the respective wave). This switching activity is then able to recapture the energy resulting from the braking activity.
In yet another phase of operation, the rectifier boosts the DC voltage applied to the DC bus. FIG. 2 is helpful in detailing how the rectifier is able to provide for a boost in DC voltage. FIG. 2 is a phase diagram of the three input line phases Va 42 , Vb 44 , and Vc 46 showing the input phases going through a full phase cycle (i.e., 0°-360°). The input line voltages are plotted on the abscissa 60 against the elapsed time (msec) which is plotted on the ordinate 62 . In an exemplary embodiment of the invention, switching schemes as represented by diagrams 64 , 66 , and 68 may be used to boost the available DC bus voltage produced by the rectifier 12 . In particular, switching diagram 64 is a timing diagram that shows when the switches Sbn 28 , Sap 22 , Scn 32 , Sbp 26 , San 24 , and Scp 30 should be controlled with a PWM switching pattern set at duty ratio d. Switching diagram 66 is a timing diagram that shows when the switches Sbp 26 , San 24 , Scp 30 , Sbn 28 , Sap 22 , and Scn 32 should be controlled with a PWM switching patter set at a duty ratio 1-d. The switches found on switching diagram 68 are not controlled with PWM switching, but are rather controlled as shown in FIG. 2 (i.e., placed in a conducting or non-conducting state by application or removal of an appropriate gate drive signal from the controller). A method that results in the switch timing described in switching diagrams 64 , 66 and 68 will result in both the rectification of AC voltage through all regions 1 - 6 ( 70 - 80 ) of the full phase cycle as well as the addition of voltage from two AC line mains which in turn will boost the DC voltage output of the rectifier 12 . An FFE rectifier implementing such a timing of switches requires that only one leg (i.e., two switches) of the three AC legs be controlled by PWM switching. This saves switching energy as compared to active front ends circuits, which would require constant switching of all three legs (i.e., six switches). It is to be noted that the values of line voltage (along the abscissa 60 ) and the times (along the ordinate axis 62 ) illustrated in the figure are but one possible embodiment of the invention. Other alternate voltages values and timeline time measurements may be used.
FIG. 3 is a flow diagram of an exemplary flow diagram for a process that may be used by the controller 18 to implement the switch timing described in switching diagrams 64 , 66 , and 68 of FIG. 2 . The embodiment shown in FIG. 3 may allow for the controller 18 to combine voltage from the AC line mains Va, Vb, and Vc during the occurrence of the highest line-to-line voltage Vab 82 , Vbc 84 , or Vca 86 in each region 1 - 6 of the full phase cycle of FIG. 2 . The resulting voltage combination may then be used to boost DC voltage. The controller 18 first finds the absolute values of the three line-to-line voltages Vab 82 , Vbc 84 , and Vca 86 , as indicated by blocks 88 , 90 , and 92 . The absolute values of the three line-to-line voltages are then compared at block 94 , and the largest of the three values is chosen. As a first example, if Vab 82 is the largest value then the controller 18 determines whether Vab 82 is greater than zero, as indicated at block 96 . If Vab 82 is a positive value, then the absolute values of line-to-line voltages Vbc 84 and Vca 86 are compared at block 102 . If |Vbc| is found to be greater than |Vca|, then switch Sbn 28 is selected to be controlled with a PWM duty ratio of d, as indicated at block 114 . The opposite leg switch Sbp 26 is also selected to be controlled with PWM duty ratio of 1-d in order to maintain full-wave DC rectification. Switch Sap 22 will also be turned on at the same block 114 . All other switches of rectifier 12 , San 24 , Scp 30 , and Scn 32 will be unswitched during this period of operation. This switching arrangement allows for the voltage combination of Va 42 with Vb 44 during the second half of region 1 of FIG. 2 , which results in a boost in DC voltage over the standard operating DC voltage output of rectifier 12 .
Returning to block 102 , if |Vbc| is not found to be greater than |Vca|, then switch Sap 22 is selected to be controlled with a PWM duty ratio of d at block 116 . The opposite leg switch San 24 is also selected to be controlled with PWM duty ratio of 1-d in order to maintain full-wave DC rectification. Switch Sbn 28 will also be turned on at the same block 116 . All other rectifier switches, Sbp 26 , Scp 30 , and Scn 32 will be unswitched. This switching arrangement allows for the voltage combination of Va 42 with Vb 44 during the first half of region 2 of FIG. 2 , which results in a boost in DC voltage over the standard operating DC voltage output of rectifier 12 .
Continuing the example, if at block 96 the controller 18 determines that line-to-line voltage Vab 82 is not greater than zero, then the absolute values of line-to-line voltages Vbc 84 and Vca 86 are compared at block 104 . If |Vbc| is found to be greater than |Vca|, then switch Sbp 26 is selected to be controlled with a PWM duty ratio of d at block 118 . The opposite leg switch Sbn 28 is also selected to be controlled with PWM duty ratio of 1-d in order to maintain full-wave DC rectification. Switch San 24 will also be turned on at the same block 118 . All other rectifier switches, Sbp 26 , Scp 30 , and Scn 32 will be unswitched. This switching arrangement allows for the voltage combination of Va 42 with Vb 44 during the second half of region 4 of FIG. 2 , which results in a boost in DC voltage over the standard operating DC voltage output of rectifier 12 .
Continuing with block 104 , if |Vbc| is not found to be greater than |Vca|, then switch San 24 is selected to be controlled with a PWM duty ratio of d at block 120 . The opposite leg switch Sap 22 is also selected to be controlled with PWM duty ratio of 1-d in order to maintain full-wave DC rectification. Switch Sbp 26 will also be turned on at the same block 120 . All other rectifier switches, Sbn 28 , Scp 30 , and Scn 32 will be unswitched. This switching arrangement allows for the voltage combination of Va 42 with Vb 44 during the first half of region 5 of FIG. 2 , which results in a boost in DC voltage over the standard operating DC voltage output of rectifier 12 .
As a second example, if at block 94 the largest absolute value of the line-to-line voltages Vab 82 , Vbc 84 , and Vca 86 is determined to be Vbc 84 , then the controller 18 determines whether Vbc 84 is greater than zero at block 98 . If Vbc 84 is a positive value, then the absolute values of line-to-line voltages Vca 86 and Vab 82 are compared at block 106 . If |Vca| is found to be greater than |Vab| then switch Scn 32 is selected to be controlled with a PWM duty ratio of d at block 122 . The opposite leg switch Scp 30 is also selected to be controlled with PWM duty ratio of 1-d in order to maintain full-wave DC rectification. Switch Sbp 26 will also be turned on at the same block 122 . All other rectifier switches, Sbn 28 , Sap 22 , and San 24 will be unswitched. This switching arrangement allows for the voltage combination of Vb 44 with Vc 46 during the second half of region 3 of FIG. 2 , which results in a boost in DC voltage over the standard operating DC voltage output of rectifier 12 .
Continuing with block 106 , if |Vca| is not found to be greater than |Vab|, then switch Sbp 26 is selected to be controlled with a PWM duty ratio of d at block 124 . The opposite leg switch Sbn 28 is also selected to be controlled with PWM duty ratio of 1-d in order to maintain full-wave DC rectification. Switch Scn 32 will also be turned on at the same block 124 . All other rectifier switches Scp 30 , Sap 22 , and San 24 will be unswitched. This switching arrangement allows for the voltage combination of Vb 44 with Vc 46 during the first half of region 4 of FIG. 2 , which results in a boost in DC voltage over the standard operating DC voltage output of rectifier 12 .
If at block 98 the controller 18 determines that Vbc 84 is not greater than zero, then the absolute values of line-to-line voltages Vca 86 and Vab 82 are compared at block 108 . If |Vca| is found to be greater than |Vab| then switch Scp 30 is selected to be controlled with a PWM duty ratio of d at block 126 . The opposite leg switch Scn 32 is also selected to be controlled with PWM duty ratio of 1-d in order to maintain full-wave DC rectification. Switch Sbn 28 will also be turned on at the same block 126 . All other rectifier switches, Sbp 26 , Sap 22 , and San 24 will be unswitched. This switching arrangement allows for the voltage combination of Vb 44 with Vc 46 during the second half of region 6 of FIG. 2 , which results in a boost in DC voltage over the standard operating DC voltage output of rectifier 12 .
Continuing with block 108 , if |Vca| is not found to be greater than |Vab|, then switch Sbn 28 is selected to be controlled with a PWM duty ratio of d at block 128 . The opposite leg switch Sbp 26 is also selected to be controlled with PWM duty ratio of 1-d in order to maintain full-wave DC rectification. Switch Scp 30 will also be turned on at the same block 128 . All other rectifier switches, Scn 32 , Sap 22 , and San 24 will be unswitched. This switching arrangement allows for the voltage combination of Vb 44 with Vc 46 during the first half of region 1 of FIG. 2 , which results in a boost in DC voltage over the standard operating DC voltage output of rectifier 12 .
If at block 94 the largest absolute value of the line-to-line voltages Vab 82 , Vbc 84 , and Vca 86 is determined to be Vca 86 , then the controller 18 determines whether Vca 86 is greater than zero at block 100 . If Vca 86 is a positive value, then the absolute values of line-to-line voltages Vab 82 and Vbc 84 are compared at block 110 . If |Vab| is found to be greater than |Vbc| then switch San 24 is selected to be controlled with a PWM duty ratio of d at block 130 . The opposite leg switch Sap 22 is also selected to be controlled with PWM duty ratio of 1-d in order to maintain full-wave DC rectification. Switch Scp 30 will also be turned on at the same block 130 . All other rectifier switches, Scn 32 , Sbp 26 , and Sbn 28 will be unswitched. This switching arrangement allows for the voltage combination of Va 42 with Vc 46 during the second half of region 5 of FIG. 2 , which results in a boost in DC voltage over the standard operating DC voltage output of rectifier 12 .
Continuing with block 110 , if |Vab| is not found to be greater than |Vbc|, then switch Scp 30 is selected to be controlled with a PWM duty ratio of d at block 132 . The opposite leg switch Scn 32 is also selected to be controlled with PWM duty ratio of 1-d in order to maintain full-wave DC rectification. Switch San 24 will also be turned on at the same block 132 . All other rectifier switches, Sap 22 , Sbp 26 , and Sbn 28 will be unswitched. This switching arrangement allows for the voltage combination of Va 42 with Vc 46 during the first half of region 6 of FIG. 2 , which results in a boost in DC voltage over the standard operating DC voltage output of rectifier 12 .
If at block 100 the controller 18 determines that Vca 86 is not greater than zero, then the absolute values of line-to-line voltages Vab 82 and Vbc 84 are compared at block 112 . If |Vab| is found to be greater than |Vbc|, then switch Sap 22 is selected to be controlled with a PWM duty ratio of d at block 134 . The opposite leg switch San 24 is also selected to be controlled with PWM duty ratio of 1-d in order to maintain full-wave DC rectification. Switch Scn 32 will also be turned on at the same block 134 . All other rectifier switches, Scp 30 , Sbp 26 , and Sbn 28 will be unswitched. This switching arrangement allows for the voltage combination of Va 42 with Vc 46 during the second half of region 2 of FIG. 2 , which results in a boost in DC voltage over the standard operating DC voltage output of rectifier 12 .
Continuing with block 112 , if |Vab| is not found to be greater than |Vbc|, then switch Scn 32 is selected to be controlled with a PWM duty ratio of d at block 136 . The opposite leg switch Scp 30 is also selected to be controlled with PWM duty ratio of 1-d in order to maintain full-wave DC rectification. Switch Sap 22 will also be turned on at the same block 136 . All other rectifier switches, San 24 , Sbp 26 , and Sbn 28 will be unswitched. This switching arrangement allows for the voltage combination of Va 42 with Vc 46 during the first half of region 3 of FIG. 2 , which results in a boost in DC voltage over the standard operating DC voltage output of rectifier 12 .
It is to be noted that the methodology in FIG. 3 is but one possible embodiment of a methodology that may be used in the present invention to select appropriate switching of rectifier legs through all the regions of a full phase cycle. An alternate embodiment of a methodology could use the same switching diagrams 64 , 66 , and 68 found in FIG. 2 but would select when to PWM and when to turn on or off the switches based on the values of line-to-neutral voltages Va 42 , Vb 44 , and Vc 46 . Yet another embodiment of a methodology could select when to PWM and when to turn on or off the switches based on a set of software timing flags in combination with line-to-line voltages Vab 82 , Vbc 84 , and Vca 86 or in combination with line-to-neutral voltages Va 42 , Vb 44 , and Vc 46 . Any switching methodology that results in the switching activity depicted in switching diagrams 64 , 66 , and 68 of FIG. 2 may be used.
The duty ratios d and 1-d mentioned in previous embodiments of the current invention is explained in more detail in FIGS. 4A , 4 B, and 4 C. FIG. 4A depicts a timeline of time-varying duty ratios. The duty ratio d 142 of a switch is defined as the pulse duration divided by the pulse period. The ratio of the pulse duration over the pulse period may then be expressed as the percentage of time that the switch is in active operation (i.e., switched to a conducting state). For example, a switch that turns on for 10 ms out of 100 ms would have a duty ratio d=0.10 (10%). FIG. 4A depicts duty ratios from 0 to 1.0 (100%). An embodiment of the current invention calculates the duty ratio d 142 that will be used as described in previous sections to PWM a switch in one of the six legs of the rectifier 12 . The switch found on the inverse leg of the switch being driven with duty ratio d 142 will be driven with duty ratio 1-d 152 .
FIG. 4B shows typical control signal switching for a switch Sx 144 that is being controlled via PWM by controller 18 using a duty ratio of d 142 . Switch Sx 144 could be any one of the switches Sap 22 , San 24 , Sbp 26 , Sbn 28 , Scp 30 , Scn 32 that are found in the rectifier 12 . The duty ratio of d 142 can be transformed to an equivalent PWM control signal at a certain modulating frequency with the aid of the equation Frequency=1/Period. The exemplary frequency range for motor control of the current invention is between 2 and 4 kHz. The duty ratio d 142 is converted into a PWM control signal 148 which is used to drive switch Sx 144 .
FIG. 4C shows typical control signal switching for a switch Sy 150 that is being controlled via PWM by controller 18 using a duty ratio of 1-d 152 . Switching of switch Sy 150 is the inverse leg of that for switch Sx 144 shown in FIG. 4B . For example, if switch Sx 144 corresponds to switch Sap 22 , then switch Sy 150 will correspond to switch San 24 , and vice versa. Switch Sy 150 could be any one of the switches Sap 22 , San 24 , Sbp 26 , Sbn 28 , Scp 30 , Scn 32 that are found in the rectifier 12 as long as it is an opposite of switch Sx 144 . Here again, the duty ratio of 1-d 152 can be transformed to an equivalent PWM control signal at a certain modulating frequency, by the equation Frequency=1/Period. The frequency used for duty ratio d 142 and duty ratio 1-d 152 is the same and is typically between 2 and 4 kHz. The duty ratio 1-d 152 is converted into a PWM control signal 154 which is used to drive switch Sy 150 . In one embodiment of the invention, the PWM control signals 148 of FIG. 4B are used to control all the switches in FIG. 3 having a duty cycle of d. The complementary PWM control signals 154 of FIG. 4C are then used to control all the switches FIG. 3 having a duty cycle of 1-d.
The duty cycle d 142 determines the magnitude of the DC voltage boost that may be achieved. FIG. 5 is a flow diagram in an exemplary embodiment of the invention which may be used by the controller 18 to calculate the duty cycle d 142 which then may be used to create the PWM control signals 148 . The controller 18 first finds the absolute values of the three line-to-line voltages Vab 82 , Vbc 84 , and Vca 86 at blocks 158 , 160 , and 162 . The absolute values of the three line-to-line voltages are then compared at block 164 and the largest of the three values is assigned to the variable Vin 166 . The equation for d
d = 1 - k · V d c * - V i n V i n
is solved at block 168 . The variable V*dc is set to be nominally below the standard non-boosted DC bus voltage. Typically, when the input line-to-line voltage is 480 Vac, the V*dc voltage is set to 600 volts and may be increased to up to 629 volts for applications requiring an operational DC bus voltage of 630 volts. The constant k is in the range 0<k<1. The constant k may be set depending on the desired system stability under various conditions and is typically set to an exemplary value of 0.9.
In another embodiment of the invention, controller 18 may automatically boost the DC voltage of the DC bus by employing embodiments of the current invention. Controller 18 can detect low voltage conditions such as when the DC Bus voltage falls below a percentage range, for example, below 5% of a rated or steady state voltage. Controller 18 may then boost the DC bus voltage to a desired level. Similarly, controller 18 may detect when one or more of the three phases of AC input voltage falls below a certain voltage, for example, during brownout conditions. Controller 18 may then boost the DC bus voltage thus allowing the electric motor to continue to operate normally. Controller 18 can also detect when the DC voltage and/or the AC input voltage has returned to a normal operating range, for example within 5% of operating voltage, and automatically turn off the boosting of DC voltage. In yet another embodiment of the invention, controller 18 may automatically solve for d 142 . The controller 18 may solve for d continuously during electric motor operation and then use d in conjunction with embodiments of the current invention to boost the DC bus voltage to a desired level.
While only certain features of the invention have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.
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Embodiments of the present invention provide novel techniques for using a switched converter to provide for three-phase alternating current (AC) rectification, regenerative braking, and direct current (DC) voltage boosting. In particular, one of the three legs of the switched converter is controlled with a set of pulse width modulation (PWM) control signals so that the input AC phase having the highest voltage is rectified and one of the switches in the two other legs is turned on to allow for added voltage. This switching activity allows for voltage from multiple AC line mains to be combined, resulting in an overall boost of the DC voltage of the rectifier. The DC voltage boost can then be applied to the common DC bus in order to ameliorate voltage sags, help with motor starts, and increase the ride-through capability of the motor.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation application of U.S. patent application Ser. No. 10/974,263 filed Oct. 27, 2004 now U.S. Pat. No. 7,535,730; which is a divisional application of U.S. patent application Ser. No. 10/355,436, filed on Jan. 31, 2003, now U.S. Pat. No. 6,816,388, the contents of which are hereby incorporated by reference in its entirety.
TECHNICAL FIELD
This disclosure relates in general to the field of computers, and more particularly to a daughter card service position.
BACKGROUND
As the value and use of information continues to increase, individuals and businesses seek additional ways to process and store information. One option available to users is information handling systems. An information handling system generally processes, compiles, stores, and/or communicates information or data for business, personal, or other purposes thereby allowing users to take advantage of the value of the information. Because technology and information handling needs and requirements vary between different users or applications, information handling systems may also vary regarding what information is handled, how the information is handled, how much information is processed, stored, or communicated, and how quickly and efficiently the information may be processed, stored, or communicated. The variations in information handling systems allow for information handling systems to be general or configured for a specific user or specific use, such as financial transaction processing, airline reservations, enterprise data storage, or global communications. In addition, information handling systems may include a variety of hardware and software components that may be configured to process, store, and communicate information and may include one or more computer systems, data storage systems, and networking systems.
Information handling systems typically require maintenance and servicing. For example, a system administrator may desire to replace a motherboard on the information handling system due to a system upgrade or a faulty component. Current designs of information handling systems, however, require the administrator to remove several wires and cables. As such, manufacturers strive to make improvements to information handling systems. One improvement includes a modular design that reduces or eliminates the internal wires or cables within the information handling system such as a modular based computer system.
The modular based computer system uses modular components, such as daughter cards, that couple directly to each other via connectors. Typically, the daughter cards are placed along guide tracks, which allow the connector on the daughter cards to align with another component to connect and disconnect the daughter cards. For example, a modular based computer system may include a motherboard that has several slots. Each slot is able to receive a connector from a daughter card by moving the daughter card along a guide track to connect to the motherboard. By using modular components with connectors, the information handling system may reduce the amount of internal wiring within the system.
In most modular based computer systems, a system administrator removes all the daughter cards connected to the motherboard in order to perform maintenance on the information handling system. Typically, the cards are lifted out of the system and set aside to allow the motherboard to be removed without the danger of the cards moving back into a connected position with the motherboard. If care is not taken with the removed daughter cards, the daughter cards may be subject to damage or loss. For example, a daughter card may accidentally fall from a counter top and become damaged.
In addition to damage to the daughter card from outside of the information handling system, the daughter cards may be subject to further damage due to electrical shock from inadequate electrical grounding. Because each card is built as a modular component, each card may develop static electricity. In some instances, the static electricity may affect the operation of the card due to improper grounding.
SUMMARY
Thus, a need has arisen for a daughter card with a service position.
A further need has arisen for a daughter card to include a grounding device while connected to a motherboard.
In accordance with the teachings of the present invention, the disadvantages and problems associated with a daughter card have been substantially reduced or eliminated. In some embodiments of the present invention an information handling system includes a chassis and a printed circuit board placed in the chassis. The chassis includes a guide slot formed in the chassis. The guide slot includes at least two opposing channels aligned adjacent the printed circuit board and a guide tab formed in one of the opposing channels. A card electrically couples to the printed circuit board when placed in an attached position. The card includes a first edge and a second edge that slides between the opposing channels of the guide slot such that the card aligns to couple to the printed circuit board. The card also includes a first detent formed in either the first edge or the second edge. The first detent releaseably interacts with the guide tab formed in the opposing channels such that the guide tab contacts the first detent when the card is placed in an intermediate position.
In other embodiments, a card for coupling to a printed circuit board includes a first edge and a second edge forming opposite outer boundaries of the card, a connector, and a detent. The first edge and the second edge interact with a guide slot such that the card slides in the guide slot along the first edge and the second edge. The connector may be formed on a third edge of the card to communicatively couple the card to the printed circuit board when the card is placed in an attached position. The detent is formed along either the first edge or the second edge to engage with the guide slot to support the card in an intermediate position.
In further embodiments, a method of removing a printed circuit board from a computer system includes moving a card from an attached position to an intermediate position by sliding the card along a guide slot in the computer system such that a connector on the card uncouples from the printed circuit board. The method automatically causes a guide tab to interact with a detent formed along an edge of the card when the card reaches the intermediate position such that the card is maintained apart from the printed circuit board. The method allows for removal of the printed circuit board from the computer system.
The present disclosure contains a number of important technical advantages. One technical advantage is providing a system or method that maintains a daughter card in an intermediate position or a service position. When the card is moved from an attached position to an intermediate position, a detent on the card interacts with a guide tab on the guide slots to maintain the card at the intermediate position. In some embodiments, the guide tab is designed to extend into the detent to prevent the card from sliding along the guide slots. The intermediate position allows for the printed circuit board such as a motherboard to be removed from the computer system.
Another technical advantage is providing an electrical ground for the card while attached to the printed circuit board. Providing a grounding pad on the card allows for the guide tab to contact the grounding pad when the card is placed in the attached position. In some embodiments, the guide tab may be electrically coupled to the chassis of the computer system. Thus, when the card is placed in the attached position, the guide tab may contact the grounding pad to provide a ground for the card.
All, some, or none of these technical advantages may be present in various embodiments of the present invention. Other technical advantages will be apparent to one skilled in the art from the following figures, descriptions, and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of the embodiments of the present disclosure and advantages thereof may be acquired by referring to the following description taken in conjunction with the accompanying drawings, in which like reference numbers indicate like features, and wherein:
FIG. 1 illustrates a perspective view of a portion of a computer system having modular computer components according an example embodiment of the present disclosure;
FIG. 2 illustrates a perspective view of a daughter card inserted into guide slots according to the present disclosure;
FIG. 3 illustrates a front perspective view of guide slot showing a guide tab according to an example embodiment of the present disclosure;
FIG. 4 illustrates a rear perspective view of guide slot including a guide tab according to an example embodiment of the present disclosure;
FIGS. 5A and 5B illustrate a rear view of a daughter card inserted between guide slots in an attached position according to an example embodiment of the present disclosure; and
FIGS. 6A and 6B illustrate a rear view of a daughter card inserted between guide slots at a service position according to an example embodiment of the present disclosure.
DETAILED DESCRIPTION
Preferred embodiments of the present disclosure and their advantages are best understood by reference to FIGS. 1 through 6B , where like numbers are used to indicate like and corresponding parts.
For purposes of this disclosure, an information handling system may include any instrumentality or aggregate of instrumentalities operable to compute, classify, process, transmit, receive, retrieve, originate, switch, store, display, manifest, detect, record, reproduce, handle, or utilize any form of information, intelligence, or data for business, scientific, control, or other purposes. For example, an information handling system may be a personal computer, a network storage device, or any other suitable device and may vary in size, shape, performance, functionality, and price. The information handling system may include random access memory (RAM), one or more processing resources such as a central processing unit (CPU) or hardware or software control logic, ROM, and/or other types of nonvolatile memory. Additional components of the information handling system may include one or more disk drives, one or more network ports for communicating with external devices, as well as various input and output (I/O) devices, such as a keyboard, a mouse, and a video display. The information handling system may also include one or more buses operable to transmit communications between the various hardware components.
FIG. 1 illustrates a perspective view of a portion of computer system 10 having modular computer components. Computer system 10 may be a type of information handling system including a rack mounted computer system such as a server. Typically, computer system 10 includes motherboard 14 that has modular components such as daughter card 20 connected to motherboard 14 via connectors 22 (as shown below in more detail). Computer system 10 may include guide slots 16 that may form a part of computer system 10 or may be coupled to chassis 12 .
Chassis 12 may include the structural frame of computer system 10 . However, in some instances, chassis 12 may further include the housing or case of computer system 10 . In some embodiments, chassis 12 provides an electrical ground for computer system 10 .
Motherboard 14 may be a printed circuit board with receiving slot 22 a (shown below in more detail) that mate with connector 22 on daughter cards 20 . Computer system 10 uses guide slot 16 to align daughter card 20 to motherboard 14 . Motherboard 14 may also include handle 15 that allows a user to remove motherboard 14 from computer system 10 . In some embodiments, daughter cards 20 are lifted out of receiving slot 22 a to allow motherboard 14 to be removed from computer system 10 .
FIG. 2 illustrates a perspective view of daughter card 20 inserted into guide slots 16 . Daughter card 20 may connect at a receiving slot on motherboard 14 to allow computer system 10 to access daughter card 20 via connector 22 .
Typically, daughter cards 20 are computer boards that may include computer components. Examples of computer components include a network connection, a video component, a input/output component such as a graphics controller, memory 24 such as RAM, a co-processor, a power supply, storage media (e.g., hard disk drives), media drives including an optical drive or any other computer component suitable for placement on daughter card 20 . In one example embodiment, daughter card 20 includes a memory riser card having memory 24 that connects to motherboard 14 to increase the amount of available computer memory for computer system 10 .
Computer system 10 may access daughter card 20 via connector 22 . Connector 22 is formed and sized to mate with a receiving slot on motherboard 14 . Connector 22 includes a plurality of signal contacts that are used to mate with receiving slot 22 a . Typically, connector 22 is formed along connector edge 27 of daughter card 20 such that connector edge 27 is placed next to motherboard to allow daughter card 20 to connect with motherboard 14 . In certain embodiments, connector 22 may connect with a receiving slot on motherboard 14 if daughter card 20 is placed in guide slot 16 at the proper orientation to motherboard 14 .
Guide slots 16 align daughter card 20 to a proper orientation for attaching to motherboard 14 using connector 22 . Typically, first edge 23 and second edge 25 of daughter card 20 are set in opposing guide slots 16 to align daughter card 20 for placement onto motherboard 14 .
Daughter card 20 may include latch 18 to prevent movement of daughter card 20 along guide slots 16 . When daughter card 20 has been inserted into guide slot 16 such that a connection to motherboard 14 is made via connector 22 , latch 18 may be moved to a locked position to engage guide slot 16 to hold daughter card 20 connected to motherboard 14 . In some instances, latch 18 may be used to provide an additional force to hold daughter card 20 against motherboard 14 .
FIG. 3 illustrates a front perspective view of guide slot 16 showing guide tab 30 . Guide slot 16 may be formed as a part of chassis 12 . Alternatively, guide slot 16 may be formed as a separate component and connected to chassis 12 through screw hole 31 . In some embodiments, guide slot 16 is formed from a U-shaped channel that receives first edge 23 of daughter card 20 .
Typically, first edge 23 of daughter card 20 enters guide slot 16 at guide opening 35 . Guide opening 35 may be larger than channel 34 to allow a user to properly set daughter card 20 in guide slot 16 . As the user inserts daughter card 20 into channel 34 of guide slot 16 , daughter card 20 may encounter guide tab 30 .
Guide tab 30 may be coupled to guide slot 16 to interact with first detent 28 (shown below in more detail) on daughter card 20 . Guide tab 30 may be formed from a flexible material such as metal or any other suitable material operable to deflect from an original position and apply pressure against daughter card 20 . In one example embodiment, guide tab 30 is a stainless steel leaf spring able to apply pressure in first detent 28 to support daughter card 20 in an intermediate position.
In certain embodiments, guide tab 30 is forced behind channel 34 to allow daughter card 20 to move to along guide slot 16 . As first detent 28 passes over guide tab 30 , guide tab 30 may extend into first detent 28 to maintain daughter card 20 in a releaseable intermediate position, also known as a service position.
FIG. 4 illustrates a rear perspective view of guide slot 16 including guide tab 30 . Guide slot 16 may include mounting surface 38 , which may be used to connect guide slot 16 to chassis 12 via screws 31 a placed in screw holes 31 to properly align daughter card 20 to motherboard 14 . In some embodiments, mounting surface 38 aligns guide slot 16 substantially perpendicular to motherboard 14 to properly align daughter card 20 to connect with motherboard 14 .
Guide slot 16 may be formed from a rigid material such as plastic that is able to guide daughter card 20 for connecting with motherboard 14 . While guide tab 30 may be formed as a part of guide slot 16 , guide tab 30 is typically constructed as a separate component and attached to guide slot 16 via tab mount 39 .
Because guide tab 30 may be mounted at tab mount 39 , guide tab 30 may deflect and move in relation to tab mount 39 , which may allow daughter card 20 to move along guide slot 16 . For example, guide tab 30 may deflect back away from daughter card 20 as daughter card 20 is inserted in guide slot 16 . Thus, as guide tab 30 moves along the edge of daughter card 20 and encounters first detent 28 , guide tab 30 may return to an undeflected position and extend into first detent 28 .
In some embodiments, guide tab 30 is constructed from an electrically conducting material to provide a ground between chassis 12 and daughter card 20 . In these instances, guide slot 16 is typically constructed from a non-conducting material, which may be used to electrically insulate guide tab 30 . For example, guide tab 30 may include contact area 30 a that may be placed around tab mount 39 to allow guide tab 30 to form a ground with chassis 12 .
Because guide tab 30 may be used to ground daughter card 20 to chassis 12 , guide tab 30 may contact ground pad 32 (shown below in more detail) on daughter card 20 when placed in an attached position. For example, when daughter card 20 is attached to motherboard 14 , guide tab 30 may be placed in second detent 26 (as shown below in more detail) on daughter card 20 that includes a ground pad 32 . Thus, the ground circuit would be disconnected if daughter card 20 is moved from the attached position.
FIGS. 5A and 5B illustrate a rear view of daughter card 20 inserted between guide slots 16 in an attached position. Daughter card 20 may include connector 22 formed on connector edge 27 . First edge 23 and second edge 25 may be inserted into guide slots 16 , which may be used to form opposing channels to direct daughter card 20 into proper alignment for connecting with motherboard 14 .
First detent 28 may be formed along either of first edge 23 or second edge 25 to interact with guide tab 30 . While first detent 28 may be placed at any location along first edge 23 of daughter card 20 , first detent 28 is placed to allow for clearance to remove motherboard 14 from computer system 10 without interference from daughter card 20 . In one example embodiment, first detent 28 may be formed along both first edge 23 and second edge 25 .
In the attached position, connector 22 on daughter card 20 may be seated onto receiving slot 22 a on motherboard 14 to provide communications between computer system 10 and daughter card 20 . Latch 18 on daughter card 20 may be placed in a closed position to engage a part of guide slot 16 to prevent removal of daughter card 20 .
Referring to FIG. 5B , guide tab 30 is placed in a second detent 26 on daughter card 20 to interact with ground pad 32 . In certain embodiments, guide tab 30 may be used to ground daughter card 20 in the attached position. In one example embodiment, second detent 26 includes an L-shaped bracket to form ground pad 32 . The bracket is connected to ground for daughter card 20 , which permits contacts with guide tab 30 in the attached position.
FIGS. 6A and 6B illustrate a rear view of daughter card 20 inserted between guide slots 16 at a service position. Moving daughter card 20 to a service position, or intermediate position, causes connector 22 to disconnect from motherboard 14 . At the service position, daughter card 20 remains coupled to chassis 12 of computer system 10 but permits motherboard 14 to be removed from computer system 10 .
Typically, a system user moves daughter card 20 from the attached position, as shown in FIGS. 5A and 5B , to a service position before removing motherboard 14 . In one instance, daughter card 20 is attached to motherboard 14 at a substantially perpendicular orientation. The user may lift daughter card 20 from the attached position to disconnect connector 22 from motherboard 14 . In order to disconnect daughter card 20 from motherboard, guide tab 30 may be deflected to a position that allows daughter card 20 to move along first edge 23 . When guide tab 30 moves over first detent 28 , guide tab 30 extends into first detent 28 to provide lateral support for daughter card 20 to prevent daughter card 20 from moving along guide slot 16 .
The lateral support imparted by guide tab 30 may include a spring force of the material extending into first detent 28 . In another embodiment, a frictional force between guide tab may create the lateral support 30 and first detent 28 . The frictional force may be varied depending upon the coefficient of friction, the geometry of guide tab 30 and the shape of first detent 28 . In one example embodiment, first detent 28 includes a rounded edge to allow a user to easily remove guide tab 30 away from a service position.
Although the present disclosure has been described with respect to a specific embodiment, various changes and modifications will be readily apparent to one skilled in the art. The present disclosure is not limited to the illustrated embodiment, but encompasses such changes and modifications that fall within the scope of the appended claims.
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An information handling system includes a chassis having a guide slot and a printed circuit board placed in guide slot of the chassis. The guide slot includes at least two opposing channels aligned adjacent the printed circuit board with a guide tab formed in one of the opposing channels. A daughter card electrically couples to the printed circuit board when placed in an attached position. The daughter card includes a first edge and a second edge that slides between the opposing channels of the guide slot such that the card aligns to couple to the printed circuit board. The card also includes a first detent formed in either the first edge or the second edge. The first detent releaseably interacts with the guide tab formed in the opposing channels such that the guide tab contacts the first detent when the card is placed in an intermediate position.
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CROSS REFERENCES TO RELATED APPLICATIONS:
[0001] None
FEDERALLY SPONSORED RESEARCH:
[0002] Not Applicable
SEQUENCE LISTING OF PROGRAM:
[0003] Not Applicable
BACKGROUND OF THE INVENTION
[0004] 1. Field of Invention
[0005] The present invention relates to internal blowout preventers used on oil and gas drilling rigs. More particularly, the present invention relates to a mud-saver valve that can be used in connection with internal blowout preventers on drilling rigs. More particularly still, the present invention relates to a mud-saver valve that can be used in connection with top drive units.
[0006] 2 . Description of Related Art
[0007] Drilling rigs, such as those used to explore for oil and gas, are typically comprised of a supportive rig floor, a derrick extending vertically above said rig floor, and a traveling block which can be raised and lowered within said derrick. A wellbore typically extends downward beneath the derrick into subterranean strata. During drilling operations, such drilling rig equipment is used to move tubular goods into and out of said wellbore.
[0008] Frequently, boring drill bits and/or other equipment are lowered into wellbores, and manipulated within said wellbores, via tubular drill pipe. For example, oil and gas wells are usually drilled by rotating a boring bit located at the bottom of a length of tubular components known as a drill string. Rotation of the drill bit is typically accomplished by applying torque to the drill string at the drilling rig and transmitting such torque via the drill string to the subsurface boring bit located within the wellbore. Such torque may be generated at the drilling rig by a rotary table and kelly or, alternatively, by a large motor known as a top drive unit.
[0009] Top drive units, which are typically movable vertically within the derricks of drilling rigs, generally include a pipe gripping apparatus having at least one set of toothed inserts for gripping the outer surface of a section of pipe. Top drive units also typically include means for connecting to a section of pipe, as well as a motor for rotating or spinning such pipe about its longitudinal axis. In most cases, fluid can be communicated through such top drive units and into the inner flow path of pipe sections connected to such top drive units.
[0010] During drilling operations, a fluid known as drilling mud is normally pumped down the longitudinally extending bore of the tubular drill string, and circulated up the annular space which is formed between the external surface of said drill string and the internal surface of the wellbore. In order for drilling mud to accomplish its intended objectives, it is often necessary to adjust or control certain characteristics of such drilling mud. Thus, chemicals and/or other additives are often mixed into such drilling mud. Common drilling mud additives include gelling agents (e.g., colloidal solids and/or emulsified liquids), weighting materials, and other chemicals which are used to maintain mud properties within desired parameters. On a rig equipped with a top drive unit, mud is often pumped through the top drive unit and into the drill string situated below the top drive unit.
[0011] Many drilling muds, and/or drilling mud additives can be environmentally damaging. Further, exposure to such muds and/or additives can have a harmful effect on the health of rig personnel. Thus, it is often undesirable, and in many cases a violation of applicable environmental regulations, to release such muds and/or additives directly into the surrounding environment. As such, it is generally beneficial to limit or restrict spillage of drilling mud and mud additives on a rig.
[0012] In the course of drilling, it is often necessary to disconnect and separate various components of the drill string, usually at or near the level of the drilling rig floor. When such components are disconnected and separated, drilling mud and/or other fluids situated within the drill string above the point of separation may spill out into the surrounding area. Such spillage is highly undesirable because it can have harmful effects on the environment, as well as the health of rig personnel working in the area.
[0013] On “standard” drilling rigs utilizing a rotary table and kelly to rotate a drill string, a discrete mud-saver valve may be used to prevent such spillage of drilling mud and/or other fluids. On such rigs, mud-saver valves are typically installed between the kelly and drill string. On rigs employing top drive units, existing mud-saver valves have proven to be ineffective and/or unusable. In such cases, a device known as an internal blowout preventer (“IBOP”) is commonly used to prevent spillage of drilling mud and other fluids. However, use of IBOP's for this purpose is generally not desirable.
[0014] In many cases, upper and lower IBOP's are installed as tubular components of the drill string within the structure of the top-drive unit itself. In such cases, the upper IBOP is typically actuated by an external hydraulic cylinder and linkage arrangement, while the lower IBOP is typically manually operated and includes a short tubular saver-sub at the lower threaded connection. The overall length and outside diameter of the upper IBOP/lower IBOP/saver-sub assembly cannot be increased because it must be positioned within the structure of the top-drive unit. As a result, there is no room to add an existing prior art mud-saver valve to the top drive unit or attached drill string.
[0015] Due to such length restrictions, a common practice is to actuate an IBOP to control the spillage of drilling mud on top drive rigs when the top drive unit is separated from the drill string. However, IBOP's must control the flow of the well in the event of a blowout. Thus, IBOP's must be tested frequently and must not leak. If the IBOP's are repeatedly actuated in order to prevent mud spillage (that is, if the IBOP's are being used as mud-saver valves), the life and reliability of such IBOP's can be significantly reduced. Moreover, the position of the IBOP's within a top drive assembly makes such valves very difficult and time-consuming to replace.
[0016] In light of the foregoing, it is evident that there exists a significant need for a mud-saver valve that can be used on top-drive rigs. Such a mud-saver valve should preserve the life and integrity of the upper and lower IBOP's, without adding to the combined length of said existing upper and lower IBOP's. Further, the mud-saver valve should be automatically actuated by change of pressure within the drill string, such as when mud pumps are turned off prior to disconnecting a top drive unit from a section of pipe.
[0017] Ideally, a mud-saver valve for top-drive rigs should be integral to the lower IBOP, and operation of the mud-saver valve should not wear or damage the IBOP, or otherwise reduce or compromise the reliability or integrity of such IBOP. Furthermore, because the mud-saver valve must be positioned near the top of the drill string, the structure of the valve must be capable of transmitting the maximum loads that may be applied to the drill string. Such loads include internal hydraulic pressure, applied torsion, and axial loading from the weight of the drill string. In other words, inclusion of the mud-saver valve members should not significantly reduce the capacity of the system to handle loads commonly observed in the drilling process.
[0018] Several objects and advantages of the present invention include, but are not necessarily limited to, the following:
(a) To provide a mud-saver valve integral to the lower IBOP used on top-drive rigs that does not increase the overall length or outside diameter of the IBOP assembly and related components of the top-drive unit; (b) To provide a mud-saver valve that is automatically actuated by change of pressure within the drill string; and (c) To provide a mud-saver valve that does not reduce the load-carrying capacity of the drill string.
SUMMARY OF THE INVENTION
[0022] The mud-saver valve of the present invention comprises an independent means for blocking the flow of fluid through the inner bore of an IBOP, such as an IBOP attached to a top-drive unit. The mud-saver valve of the present invention generally comprises a tubular body having a central through-bore, a rotatable ball having a through-bore, and right and left rotating concave cup members. The ball is rotatably disposed within the through-bore of the body such that the ball may be rotated from an open to a closed position. When the ball is in the open position the through-bore of the ball is axially aligned with the through-bore of the body, thereby permitting the flow of fluid through the aligned bores of said ball and body. When the ball is in the closed position, the through-bore of the ball is oriented perpendicular to the through-bore of the body, thereby preventing fluid flow through the through-bore of such ball. When the ball is rotated, the mud-saver valve of the present invention operates much like existing ball valves or IBOP's which are generally known in the art.
[0023] The rotating concave cup members of the present invention are rotatably disposed about the periphery of said ball valve. When the ball is in the open position, said concave cup members may be rotated from an open to a closed position along the outer surface of the ball, thereby obstructing and sealing the through-bore of said ball. Such concave cup members rotate in a manner similar to the closing of eyelids about an eyeball. In the closed position, such concave cup members block the flow of mud or other fluids through the body of the mud-saver valve regardless of the position of the ball. In the preferred embodiment, such concave rotating cup members are actuated by a spring-biased piston.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 depicts a side view of a typical prior art top drive unit comprising a pipe handler, an upper IBOP, a lower IBOP and a saver sub.
[0025] FIG. 2 depicts a side cross-sectional view of the mud-saver valve assembly of the present invention.
[0026] FIG. 2A is a detail view of a portion of the side cross-sectional view of FIG. 2 .
[0027] FIG. 3A is a side cross-sectional view of the mud-saver valve assembly with a ball in the open position, and bowl-shaped cups in the closed position.
[0028] FIG. 3B is a side cross-sectional view of the mud-saver valve assembly of the present invention with a ball in the open position, and bowl-shaped cups in the open position.
DETAILED DESCRIPTION OF INVENTION
[0029] FIG. 1 shows a block sketch of a typical top drive unit 300 comprising, generally, top drive motor 310 , upper IBOP 320 , mud-saver sub 124 and pipe handler 330 . The positional relationship between top drive motor 310 , upper IBOP 320 , and pipe handler 330 is depicted. Note that these members, as well as tubular drill string 340 , are generic and are not specifically included in the present invention. Mud-saver valve 10 , and saver sub 124 , both of the present invention, are positioned between upper IBOP 320 and pipe handler 330 . As described previously, saver sub 124 must not extend below pipe handler 330 . Thus, FIG. 1 illustrates the length restriction of the overall length of mud-saver 10 and saver sub 124 referenced previously.
[0030] FIG. 2 depicts a side cross-sectional view of the preferred embodiment of mud-saver valve 10 of the present invention. Mud-saver valve 10 comprises a substantially cylindrical body 100 having a through-bore 166 , a ball 108 rotatably disposed within said body 100 , a seat 106 , and two stems 110 extending outward from the sides of ball 108 . Upper threaded member 168 is disposed at the top of body 100 to facilitate connection to other threaded components, such as an IBOP of a top drive unit. Ball 108 has through-bore 156 of approximately the same diameter as through-bore 166 of body 100 , and two parallel flat surfaces 158 . Flat surfaces 158 of ball 108 are parallel to the axis of through-bore 156 of ball 108 .
[0031] Ball 108 is rotatably disposed within through-bore 166 of body 100 . In a first position, as depicted in FIG.2 , through-bore 156 of ball 108 is axially aligned with through-bore 166 of body 100 . Stems 110 are rotatably and sealably disposed within body 100 and are retained by stem retainers 112 . Stem seal 146 is disposed on the outside diameter of each stem 110 . Stem 110 , stem retainer 112 , and stem seal 146 , as well as their relationship to ball 108 , are depicted in detail in FIG. 2A .
[0032] Referring back to FIG.2 , boss 152 protrudes from the inner face of each stem 110 and mates in each flat surface 158 of ball 108 ; as such, rotation of stems 110 cause rotation of ball 108 between an open position and a closed position. The outer surface of stems 110 have hexagonal indentions 154 which may accept a standard wrench (not shown in FIG. 2 ) to rotate stems 110 and thus, ball 108 .
[0033] Seat 106 is disposed above ball 108 and is biased downward against the outer surface of ball 108 by wave spring 104 . Seat 106 has a concave surface 160 that sealingly engages against the outer surface of ball 108 . Spacer 102 is disposed between wave spring 104 and internal shoulder 164 of body 100 . As depicted in FIG.2 , ball 108 remains in its open position, whereby through-bore 156 of ball 108 is axially aligned with through-bore 166 of body 100 . Right rotating cup member 115 (not depicted in FIG. 2 ) and left rotating cup member 114 are rotatably disposed about the outer surface of ball 108 . Left rotating cup member 114 and right rotating cup member 115 are mirror images of one another.
[0034] Actuating piston 116 is slidably disposed within through-bore 166 of body 100 , and translates axially within sleeve 120 . Piston seal 144 and lower piston seal 140 are disposed between the outer surface of actuating piston 116 and the inner surface of sleeve 120 . Upper sleeve seal 139 and lower sleeve seal 138 are disposed between the outer surface of sleeve 120 and inner surface of body 100 . Sleeve 120 is coaxial to body 100 and is prevented from movement by sleeve retaining pin 118 . Spring 122 biases actuating piston 116 upward toward ball 108 .
[0035] Saver sub 124 is attached to the lower end of body 100 . Body 100 has lower threads 134 that engage upper threaded member 132 of saver sub 124 . Saver sub seal 136 is disposed between the outer surface of upper threaded member 132 of saver sub 124 and the inner surface of body 100 . Saver sub 124 has lower threads 130 that can engage an adjacent threaded component, such as a component of the drill string. In the event of a problem with lower threads 130 , saver sub 124 can be easily repaired or replaced without affecting the other components of mud-saver valve 10 of the present invention.
[0036] FIG. 3A and FIG. 3B depict cross-sectional views of certain components of mud-saver valve 10 of the present invention rotated 90° from the view depicted in FIG. 2 . Rotating cup members 114 and 115 have a closed position shown in FIG. 3A and an open position shown in FIG. 3B . Ball 108 is omitted from FIG. 3A to better show certain details of actuating piston 116 and rotating cup members 114 and 115 ; however, it is to be observed that mud-saver valve 10 of the present invention depicted in FIG. 3A contains ball 108 .
[0037] Referring to FIG. 3A , cup members 114 and 115 each have a concave shell member 222 and side members 220 . Each concave shell member 222 has a concave inner surface 224 and an outer surface 226 . Side members 220 of rotating cup members 114 and 115 are oriented parallel to flat surfaces 158 of ball 108 (best seen in FIG. 2 ). Each side member 220 has an enlarged circular member 210 with a concentric through-hole 212 . A rounded lever 214 extends radially outward from each enlarged circular member 210 . Stems 110 of ball 108 are rotatably disposed within through-holes 212 of circular members 210 , allowing rotating cup members 114 and 115 to rotate independently about lateral stems 110 , and allowing concave shell members to rotate about the outer periphery of ball 108 . Although not depicted on FIG. 3A , it is to be observed that such components also exist on the opposite side of mud-saver valve 10 , said components being obscured from view in FIG. 3A .
[0038] Application of downward vertical force to levers 214 will cause rotating cup members 114 and 115 to rotate to an open position, while upward vertical force applied to of levers 214 will cause rotating cup members 114 and 115 to rotate to a closed position. Lever 214 depicted in FIG. 3A is attached to left cup member 114 , while another such lever (not depicted in FIG. 3A ) is attached to right cup member 115 .
[0039] Spherical shell member 222 of each rotating cup member 114 and 115 has a forward sealing edge 230 . In a closed position, sealing edge 230 of right rotating cup member 115 bears against sealing edge 230 of left rotating cup member 114 . In the preferred embodiment, sealing edge 230 of left rotating cup member 114 has a circumferential recess 232 at outer spherical surface 226 . Sealing edge 230 of right rotating cup member 115 has a circumferential recess 228 at inner spherical surface 224 . In a closed position, sealing edge 230 of left rotating cup member 114 overlaps sealing edge 230 of right rotating cup 115 .
[0040] Actuating piston 116 is sealably disposed within sleeve 120 . Actuating piston 116 has an upper piston seal 144 and a lower piston seal 140 . The outside diameter of upper piston seal 144 is larger than the outside diameter of lower piston seal 140 . As such, a cylindrical volume 240 is defined by the differential area between upper piston seal 144 and lower piston seal 140 and the axial length between upper piston seal 144 and lower piston seal 140 . Sleeve 120 has radial bore 242 disposed between upper sleeve seal 139 and lower sleeve seal 138 . Similarly, body 100 has radial bore 244 . In the preferred embodiment, cylindrical volume 240 between upper piston seal 144 and lower piston seal 140 communication with pressure observed outside of body 100 .
[0041] Actuating piston 116 has a concave upper surface 248 . The radius of curvature of concave upper surface 248 is approximately equal to the radius of curvature of outer spherical surfaces 226 of rotating cup members 114 and 115 . Two elongated extension arms 218 extend upward from the upper surface of actuating piston 116 (although only one such extension arm 218 is visible in FIG. 3A ). Each extension arm 218 has slot 216 to receive levers 214 of rotating cup members 114 and 115 , respectively. Actuating piston 116 has a first position, depicted in FIG. 3A , wherein actuating piston 116 is in a fully upward position and rotating cup members 114 and 115 are in their closed position. Actuating piston 116 has a fully downward second position, depicted in FIG. 3B , wherein rotating cup members 114 and 115 are in their closed position.
[0000] Operation
[0042] During drilling operations, fluid such as drilling mud is pumped through the bore of a top drive unit (including the mud-saver valve of the present invention) and drill string. Restriction to the flow of such fluid results in a higher pressure within the drill string and mud-saver valve 10 of the present invention compared to pressure observed on the outside of such components. When it is desired to disconnect or break-out a connection between components of the drill string at or near the rig floor, mud pumps are typically shut off, and pressure within the drill string and mud-saver valve 10 decreases to static head pressure; such static head pressure results from the vertical length of the fluid column within the drill string above the rig floor (i.e., the point where such drill string components are to be disconnected). On many rigs, this height may be 90 feet or more.
[0043] As described previously, actuating piston 116 has a larger diameter at upper piston seal 144 than at lower piston seal 140 . Cylindrical volume 240 between upper piston seal 144 and lower piston seal 140 communicates with pressure observed outside body 100 via radial bore 244 . Actuating piston 116 is upwardly biased by spring 122 . When mud is being pumped, both the top and the bottom of actuating piston 116 are exposed to high internal pump pressure. As such, downward force is exerted by such internal pressure acting against the area of the larger upper piston seal 144 . A lesser upward force is exerted by the same internal pump pressure acting against the area of smaller lower piston seal 140 . The differential area between the larger upper piston seal 144 and the smaller lower piston seal 140 is acted upon by pressure communicated through radial hole 242 of sleeve 120 and radial hole 244 of body 100 . Spring 122 also exerts an upward force on actuating piston 116 .
[0044] Compression spring 122 is designed such that internal pressure (such as, for example, internal pressure resulting from rig mud pumps) greater than a predetermined trip pressure overcomes the upward bias of spring 122 . Actuating piston 116 is held in a lower position, with extension arms 218 exerting downward force on levers 214 of rotating cup members 114 and 115 , thereby holding rotating cup members 114 and 115 in their open position.
[0045] When such internal pressure drops, such as when rig mud pumps are shut off, pressure observed within mud-saver valve 10 drops below such predetermined trip pressure. Under this scenario, upward bias of spring 122 overcomes the net downward force of the internal pressure acting against the differential area between larger upper piston seal 144 and small lower piston seal 140 . Actuating piston 116 moves upward by the force exerted by spring 122 . As such, extension arms 218 exert upward force on levers 214 of rotating cup members 114 and 115 , thereby moving rotating cup members 114 and 115 into their closed Ooined) position.
[0046] The net upward force applied to actuating piston 116 exerts upward force on lever 214 of rotating cup members 114 and 115 , causing sealing edges 230 of rotating cup members 114 and 115 to seal against each other. The net upward force of spring 122 also forces concave surface 248 of actuation piston 116 against outer surface 226 of shell members 222 of rotating cup members 114 and 115 , thereby creating a seal between rotating cup members 114 and 115 and actuating piston 116 . In the closed position, head pressure above mud-saver valve 10 is completely sealed, and fluid contained within the assembly is prevented from draining out of the assembly and on the rig floor or surrounding environment.
[0047] The above disclosed invention has a number of particular features which should preferably be employed in combination, although each is useful separately without departure from the scope of the invention. While the preferred embodiment of the present invention is shown and described herein, it will be understood that the invention may be embodied otherwise than herein specifically illustrated or described, and that certain changes in form and arrangement of parts and the specific manner of practicing the invention may be made within the underlying idea or principles of the invention.
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A mud-saver valve having an independent means for blocking the flow of fluid through the bore of a ball valve. The mud-saver valve has a tubular body having a central through-bore, a rotatable ball having a through-bore, and pressure actuated right and left concave cup members that can rotate about the periphery of said ball regardless of the position of the ball. When the ball is in the open position, the concave cup members may be rotated from an open to a closed position along the outer surface of the ball, thereby blocking the through-bore of the ball and preventing the flow of fluid through such bore.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to method and means for manufacturing wire cable for torque transmission application and more particularly but not by way of limitation to a method and means for producing cable using preformed spring stock for the wrappings.
2. History of the Prior Art
There is widespread use of wire wound torque transmission cables where it is desirable to induce rotary motion at a remote location from the rotary power source. Normally, such cables are manufactured by various processes and apparatus which wrap a plurality of wires onto either a solid or hollow flexible mandrel. If it is desired that the finished product be a solid torque transmitting cable, the mandrel is usually flexible and becomes a part of the finished cable.
On the other hand, if the torque transmitting cable is to be hollow, the mandrel must either be removed after the winding process or the mandrel must be flexible and also hollow.
After the wrapping process about a mandrel is done, it is extremely difficult to remove the mandrel from the finished product. Further there is a tendency for the wire after it has been wrapped to spring open if either end is released.
Heretofore, the general method of removing the mandrel is to allow the winding to spring open to a certain extent. While this allows easy removal of the mandrel, it changes the size of the finished torque transmission cable which gives rise to obvious quality control problems in both sizes. Another problem associated with such cables is that of internal stress present between successive layers of windings which tend to decrease the efficiency of torque transmission and the life of the cable. There has also been a problem associated with the winding of very small wire by the prior art methods.
SUMMARY OF THE INVENTION
The present invention is particularly designed and constructed to produce a wire wound torque transmitting cable for overcoming the above disadvantages associated with prior art cable winding process and means.
The present invention comprises a process for manufacturing a torque transmitting cable having a plurality of oppositely wound layers of wire, each layer consisting of a plurality of individual wire windings. The process includes a first step of forming a spring or using stock spring and dispensing that spring onto a relatively smooth mandrel. By forming the spring at the production site, it may be applied to the mandrel directly out of the spring winding machine. A plurality of springs may be utilized for the first layer by setting the pitch with respect to the diameter of the wire from which the coils are made such that the layer is substantially uniform. The inner diameter of the springs making up the first layer is such that the mandrel provides support for the springs but may be longitudinally removed therefrom.
The second layer of windings is applied utilizing a spring or coil guide device which comprises a plurality of elongated tube members which are parallel with respect to each other but arranged in a circular pattern such as the barrels of a Gatling gun, each of the tubes being capable of carrying a preformed coil which will become a second layer of the torque transmission cable. This second set of N 2 coils are wound in the opposite direction from the first set. The inner diameter of each of the second springs is substantially equal to the outer diameter of the first set of springs.
The coil guide device further includes a centrally disposed tube for loosely carrying the mandrel having the first layer of wire disposed thereon.
The coil guide device has, at one end thereof, a coil feed head which has a plurality of channels or passages for directing the coil ends centrally toward the center tube and the wound mandrel therein.
The secured coil ends are then manually attached to the first layer of winding adjacent one end of the mandrel. The mandrel is then rotated and simultaneously withdrawn from the center tube thereby snuggly wrapping the second layer of coils onto the first layer.
If it is desirable to add successive layers, each successive layer is added by repeating the second step. It is desirable that each successive layer be made up of coils wound in the opposite direction from the next previous layer.
When the cable is finished, the mandrel is slipped out of the cable and is reusuable provided a hollow cable is desired. The ends are usually further stress relieved by striking against a surface and are then trimmed to the desired length. The ends of the finished cable are then usually tinned and attached to a desired fitting.
The finished cable has little or no internal forces associated therewith as with prior art cables. The reason for the lack of internal or binding forces between layers is that each layer of the present process is finished and the cable removed from the winding fixture, both ends are free to relax thereby relieving any winding stresses. It is further apparent that the cable sizing may be accurately maintained by the proper manufacture of the individual coils and is therefore not so dependent on the tightness of the wrappings. Since by the present method, size and quality may be strictly maintained, cables having various desired design characteristics may be readily manufactured under the present process.
BRIEF DESCRIPTION OF THE DRAWINGS
Other and further advantageous features of the present invention will hereinafter more fully appear in connection with a detailed description of the drawings in which;
FIG. 1 is an elevational view of a mandrel being wound with a first wire layer.
FIG. 2 is an elevational view of a mandrel segment supporting a first wrapped layer.
FIG. 3 is a diagrammatical view of a typical spring coil.
FIG. 4 is an elevational view of a wire winding apparatus for winding subsequent layers of wrap.
FIG. 5 is an elevational view depicting a second or subsequent layer of winding along with a size comparison.
FIG. 6 is a detailed view of the winding apparatus of FIG. 4.
FIG. 7 is a partial sectional view of the wire feed head and cap preparatory to a subsequent winding operation.
FIG. 8 is a sectional view of the wire feed head after the subsequent winding operation is begun and the cap is attached.
FIG. 9 is an end sectional view of the wire feed head as shown in FIG. 7.
FIG. 10 is a sectional elevation view taken across broken lines 10--10 of FIG. 6 depicting alternate guide support means.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings in detail reference character 10 generally indicates a wire winding apparatus for the manufacture of flexible torque transmission cable. The cable may comprise several layers of wire wrapping as will be hereinafter set forth, and each layer may be wound by a separate apparatus of which 10 is typical.
Referring now to FIG. 1 reference character 12 generally indicates an alternate wrapping apparatus and procedure that has been found useful for wrapping the first layer of the cable. An ordinary spring or coil forming device 14 is utilized to receive at its input wire stock 16 to form said wire stock 16 into a helical coil 18 at its output. As a characteristic of the output coil 18, there is a rotation of the coil that is indicated by the rotational vector 20.
As a temporary support apparatus for the cable being constructed, an elongated mandrel 22 is loosely disposed within a hollow tube 24, all in alignment with the output of the coil forming device 14. The mandrel 22 may be a metal rod having an outer diameter which is substantially equal to the desired inner diameter of the final cable being produced. However, the first layer should not be tightly wound since the mandrel may be subsequently removed.
Referring now to FIG. 3, each individual coil of wire for each layer has certain characteristics which is set by adjusting a coil forming apparatus such as 14. The coil produced is a cylindrical helical coil having an inside diameter (Id) which is substantially equal to the diameter of the mandrel 22 or the previous layer. The outside diameter (Od) is naturally equal to the inside diameter plus two times the wire diameter (Wd). The pitch (P) of the coil 18 or subsequent coil is set in accordance with the number (N) of the desired coils to form the particular first layer. Therefore, if it is desired to have N coils to make up a particular layer, the pitch is set by the coil forming apparatus such as 14 to be approximately equal to or slightly greater than N times the wire diameter (Wd), or by the equation P ≧ NWd.
Naturally, if it is desired to use a single wire to wrap the first layer, N would be equal to one and the pitch would be approximated by the diameter of the wire (Wd) being used.
Tests and actual manufacturing have revealed that there is a practical limit on (N) for a given wire diameter and stiffness. For instance in the first layer of wire where the wire diameter Wd is 0.018 inches, it has been found that N should not exceed 4. It has further been found that as the wires are threaded on the first layer in the manner hereinafter set forth that the driver end of the wire tends to expand slightly due to greater driving torque as the entire length of the wire is threaded on the mandrel. However, it has been found that for manufacturing purposes a 0.002 inch difference between the two ends is acceptable.
Utilizing the apparatus as schematically depicted in FIG. 1, a first wire coil 18a is started on the end 26 of the mandrel 22 and is allowed to rotatingly feed directly out of the coil forming apparatus 14 onto the mandrel 22 being contained loosely in the tube 24. After the coil 18A is in place, a second coil 18B is fed onto the end 26 of the mandrel 22, wherein it will rotatingly move onto the mandrel 22 as shown in FIG. 1. The wire coil 18C is then added in the same manner and each subsequent coil is added until the desired number (N) of the coils are moved onto the mandrel 22 which will appear as shown in FIG. 2 thereby forming a single layer 28 on the mandrel. The layer 28 will obviously have an outer diameter (Od) equal to the outer diameter of each of the coils taking up the layer.
A second or subsequent layer 30 may be added on top of the layer 28. However, each individual coil making up the layer 30 could be wound in the opposite direction from the coils 18 and should be wound in the opposite direction if torque transmission is desired in either direction, as indicated by the rotational vector 32. If wrappings are for a subsequent layer are to be made in the same directions, their pitch should be significantly different than the previous layer so that the wires do not try to work themselves in between the wires of the previous layer. Each of the coils making up the layer 30 would naturally have an inside diameter substantially equal to the outside diameter of the previous layer. The pitch of each such coil would be calculated by the aforementioned equation or should be such that the pitch is substantially equal to or greater than the inside diameter.
Referring now to FIG. 4, the winding apparatus 10 comprises a coil guide means generally indicated by reference character 34 and a winding apparatus 36.
The coil guide means 34 generally comprises a coil guide feed head 38 having one end of each of a plurality of elongated parallel tube members 40, said tube members being arranged circumferentially around the coil guide head 38. The plurality of tubes 40 are held in spaced relationship by a number of mounting plates 42, 44 and 46. Then each of these mounting plates is suspended by hanger means 48, 50 and 52 respectively from a framework 54.
A coil forming apparatus 56 is shown in FIG. 4 and is substantially identical to the coil forming apparatus 14 of FIG. 1. The coil forming apparatus 56 may be one of several used to feed coiled wire 58 into each of the tubes 40. Each coil forming apparatus receives its wire stock 60 from a wire dispensing spool apparatus generally indicated by reference character 62. It might be desirable to have a coil forming apparatus such as 56 for feeding each of the tubes 40 simultaneouly. Naturally, coil stock may be purchased separately and fed into the tubes since the coil forming operating is not an essential part of the winding apparatus 10.
The winding apparatus 36 generally comprises a platform means 64 having an upper track surface 66 which is substantially parallel to the tube bundle 40 of the coil guide means 34. A trolley apparatus generally indicated by reference character 68 is reciprocally disposed on the track surface 66 and is provided with a drive motor 70 and connecting drive chain 72.
The trolley apparatus 68 comprises a mandrel gripping chuck 74 which may be rotationally driven by a separate drive motor 76 carried by the trolley 68. The chuck 74 is positioned to be in substantially coaxial alignment with the coil guide feed head 38 for a purpose that will be hereinafter set forth. The winding apparatus 36 further comprises a synchronization device 76 which is operably connected between the trolley drive motor 70 and the chuck drive motor 76 so that the longitudinal movement of the trolley must be synchronized with the rotational movement of the chuck 74 for a purpose that will hereinafter be set forth.
Referring now to FIGS. 7, 8 and 9, the coil guide head 38 comprises a cylindrical body portion 80 having an outward face 82 which is in the shape of a conic frustum. The body 80 contains a centrally disposed bore 84 therethrough and is attached around the outer periphery thereof to one end of the plurality of tube members 40. The conic shaped face 82 of the guide head is provided with a plurality of radially extending, radially spaced passage ways or grooves 86, the outer ends thereof being in substantial alignment with the end of each tube member 40. The inner ends of the passage ways 86 terminate near the bore 84.
A plurality of longitudinally and outwardly extending guide pegs are secured to the face 82 of the guide head around the outer periphery of the bore 84, one such peg 88 being centrally disposed in alignment with the radial slots 86 of each passage way. The angle that the coil guide face 82 makes with the longitudinal axis of the bore 80 which is shown as angle "A" in FIG. 7 is designed to be substantially equal to the pitch angle of the coil 58 being used for the winding. Although this is not an essential limitation to the device, it has been found that the coils wind onto the mandrel 22 with more ease, if the angle of the face 82 meets this criteria.
The guide head 38 includes a cap member 90 which may be cylindrical in shape having a bore 92 therethrough, one end of the cap member 90 being provided with a conical recess 94 for receiving the conical shaped face 82 of the guide head therein. The cap in FIG. 7 is depicted with a bushing insert 96 which facilitates the moving of the wound mandrel therethrough. The cap 90 and guide head body 80 are provided with aligned threaded bores 98 and 100 repsectively for attachment of the cap to the guide head body 80 by a suitable bolt 102 as shown in FIG. 8.
Referring now to FIG. 10 one of the separator discs 42 is depicted in an end view for supporting the tubes 40 in space relationship with respect to each other. As hereinbefore set forth, FIG. 10 is a sectional view taken along the broken lines 10-10 of FIG. 6 and further depicts centrally disposed tube 104 which extends rearwardly from the guide head 38 and is in substantial alignment with the bore 84 thereof. The tube 104 is primarily for the purpose of supporting the mandrel 22 that is to be wound. The hanger means 48, 50 and 52 as shown in FIG. 4 is shown in section at FIG. 10. The hanger means 48 comprises cables 48 and 48A for supporting the separator disc 42. The hangers 48 and 48A extend outwardly and upwardly to suitable attachment frame 54. This hanger support provides an automatic alignment feature, aligning the central bore 84 of the guide head with the chuck 74 of the winding apparatus in the following manner:
When the tube bundle is supported by a plurality of hangers 48, 50 and 52 in the manner shown in FIG. 4, and whereby these cables such as cables 48 and 48A extend upwardly and outwardly from the tube bundle, it is difficult for the tube bundle to swing transversely with respect to the frame member 54. Further, since the tube bundle is supported at three different locations it is difficult for it to rotate about a vertical axis which would throw it out of alignment with the chuck 74 of the winding apparatus. However, this hanger arrangement will allow tube bundle one degree of freedom of movement whereby it can move by pendulum action longitudinally with respect to the winding apparatus.
This suspension acts as both a shock absorber due to any drag that might occur while withdrawing the mandrel from the guide head and will also cause the entire bundle to swing in order to better align itself with the rotating chuck 74 of the trolley. Hence, it can be said that the bundle of tubes 40 are mounted by a pivotal means having one degree of rotational freedom, that degree of rotational freedom being about a horizontal axis transverse to the longitudinal axis of the tube member 40.
In operation, a first layer 28 of windings may be wound onto a mandrel 22 in accordance with the method and means hereinbefore described with respect to FIGS. 1 and 2 of the drawings. The wrapped mandrel is then inserted through the central tube 104 of the tube bundle 40 so that one end thereof extends through the guide head 38 as shown in FIG. 7. The ends of the wire coils 58 are then passed through the tubes 40 and into the passageways 86 thereof. Each coil 58 is then passed around its appropirate guide peg 84 as shown in FIG. 9 and manually wrapped around the outer layer 28 of cable as shown in FIG. 7 thereby forming a second layer 30. The guide head cap 90 is then put in place and the bolts 102 are installed. The cable ends are then clamped firmly in place to the mandrel by a suitable clamping means 106. At this point, the chuck 74 is attached to the end of the mandrel 22. Continued wrapping of the layer 30 is accomplished by rotating the mandrel 22 and simultaneously with the drawing head from the guide head longitudinally as shown in FIG. 8.
The rotational drive motor 76 of the trolley 68 and the drive motor 70 for longitudinal movement of the trolley 68 are then initiated by a suitable switch which is part of the synchronization means 78.
Upon initiation of the rotational and longitudinal trolley drive, the mandrel is rotated about its own axis and longitudinally moved out of the guide head 84 in a manner such that one rotation thereof occurs simultaneously as the rod is withdrawn by a distance equal to the pitch of the coils being wound thereon.
Each individual coil 58 is maintained in a correct rotational alingment with respect to its own axis by means of the peg members 88 which is most apparent in FIG. 9 of the drawings. The speeds of the drive motors 70 and 76 are not critical so long as their synchronization is maintained. After the winding operation is completed, a subsequent winding may be placed on the layer 30 by simply repeating the operation with a mechanism sized to the desired wrap diameter. Further, the winding of each successive layer of wire to form the cable should be in the opposite direction to that of the next previous layer as hereinbefore set forth.
It is further to be understood that each layer of the proposed cable may be wound on either the apparatus depicted in FIG. 4 or that depicted in FIG. 1 or any combination thereof. However, it is unknown by the inventors whether it is practical to wind subsequent layers by the apparatus of FIG. 1. After the winding operation is complete, the clamp 106 is removed and the mandrel 22 can be withdrawn therefrom. Normally the ends are fixed together by a tinning operation or other suitable means such as by a suitable fitting to hold the wires in place or a combination of those two operations.
Whereas, the foregoing invention has been described in particular relation to the drawings attached hereto, other and further modifications apart from those shown are suggested herein and may be made within the spirit and scope of the invention.
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Apparatus and method for manufacturing a wire wound flexible torque transmission cable. The apparatus includes multiple wire guides to facilitate the winding of a plurality of preformed spring or wire coil members onto a mandrel or a previously wrapped layer. The apparatus further includes a means for synchronously moving the wrapped mandrel longitudinally and rotatingly with respect to the wire guide for accomplishing the winding process. The cable winding process generally includes the steps of winding a plurality of wires to form a single layer, each wire being in the form of a preformed cylindrical helical coil stock. Multiple layers of wire are similarly wound on the next previous layer, the windings normally being in a reverse direction from the next previous layer.
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BACKGROUND OF THE INVENTION
The present invention provides novel compositions of matter and processes for their preparation. Particularly, the present invention relates to novel chemical intermediates and associated processes for the preparation of both known and novel precursors of khellin and other furochromone analogues, which have demonstrated lipid-altering and antiatherosclerotic activity. See. U.S. Pat. No. 4,284,569. Furthermore, these chenmical intermediates can be used in the preparation of certain benzofurans and benzothiophenes which have been shown to inhibit the synthesis of leukotrienes and/or inhibit the action of lipoxygenase in mammalian metabolism. See application, Ser. No. 561,601, filed Dec. 14, 1983 now abandoned. The synthesis of the compounds, which are noted herein as D-3 and D-4 is shown herein in Chart D.
Khellin and related compounds are known to exert a wide variety of pharmacological effects. Khellin has been reported to exhibit useful antiatherosclerotic activities. Moreover, numerous analogues of khellin likewise are known to exert useful antiatherosclerotic effects. For example, 7-methylthiomethyl-4,9-dimethoxyfurochromone is described in U.S. Pat. No. 4,284,569 as such a useful antiatherosclerotic substance.
The leukotrienes are a class of unsaturated fatty acid compounds which are derived from arachidonic acid by the action of lipoxygenase. See, e.g., Samuelsson, Trends in Pharmacological Sciences 5:227 (1980); Samuelsson et al., Annu. Rev. Biochem. 47:997-1029 (1979). For a discussion of leukotriene nomenclature, see Samuelsson et al., Prostaglandins 19:645 (1980).
The leukotrienes have been discovered as potent constrictors of human bronchi. That is, certain leukotrienes are mediators of the action of slow-reacting substance of anaphylaxis (SRS-A). See, e.g., Dahlen, Nature 288:484 (1980). These compounds are therefore important mediators of bronchoconstriction in humans.
The role of leukotrienes as agonists in immediate hypersensitivity and other pathological conditions has led to research into inhibitors of leukotriene biosynthesis and leukotriene antagonists. See, e.g., Corey et al., Tet. Lett. 21:4243 (1980).
Im mammalian metabolism, arachidonic acid is transformed to 12-L-hydroperoxy-5,8,10,14-eicosatetraenoic acid by the action of 12-lipoxgenase. See Hamberg et al., Proc. Nat. Acad. Sci. 71:3400-3404 (1974). Similarly, 5-lipoxygenase transforms arachidonic acid into 5-S-hydroperoxy-6,8,11,14-eicosatetraenoic acid. Thus, an agent which inhibits the action of lipoxygenase would be useful in treating or preventing untoward conditions associated with lipoxygenase products.
Therefore, compounds which inhibit the action of lipoxygenase are useful in the treatment of inflammatory conditions where it is desirable to prevent migration of polymorphonuclear leukocytes to the inflammatory site. They are also useful in the treatment of asthma.
Methods for the total synthesis of khellin and related compounds are known. For example, pyrogallol has been employed as a starting material for the synthesis of furochromones such as khellin. See J. R. Clarke et al., J. Chem. Soc. 302 (1949), R. A. Baxter et al., J. Chem. Soc. S30 (1949), A. Schonberg et al., J. Am. Chem. Soc., 73:2960 (1951), V. V. S. Murti et al., Proc. of the Indian Acad. of Sci. 30A:107 (1949), and T. A. Geissman et al., J. Am. Chem. Soc. 73:1280 (1951). Also descriptive of the synthesis of khellin are E. Spath et al., Chem. Ber. 71:106 (1938), O. Dann et al., Chem. Ber. 93:2829 (1960), O. Dann et al., Ann. Chem. 605:146 (1957), and V. V. S. Murti et al., J. Sci. Ind. Res. (India) 8B:112 (1949). See also U.S. Pat. No. 2,680,119 describing the synthesis of khellin and related compounds.
Other references describing the synthesis of intermediates useful in the preparation of khellin for analogues include: R. Aneja et al., Chem. Ber. 93:297 (1960), R. Aneja et al., J. Sci. Ind. Res. (India) 17B:382 (1958), T. S. Gardner et al., J. Org. Chem. 15:841 (1950), and L. R. Row et al., Indian J. Chem. 5:105 (1967).
Accordingly, the references cited above describe the preparation of 1-(6-hydroxy-4,7-dimethoxy-5-benzofuranyl)-ethanone. Also known is the related compound 6-hydroxy-4,7-dimethoxy-5-benzofurancarboxylic acid, methyl ester, described by C. Musante Gazz. Chim. Ital. 88:910 (1958).
One method for the preparation of the lipoxygenase and/or leukotriene-inhibiting benzofurans and benzothiophenes is described in said application, Ser. No. 561,601, filed Dec. 14, 1983.
PRIOR ART
Methods of the total synthesis of khellin are known, as are certain chemical intermediates useful in its synthesis. For example, the total synthesis of furochromones from benzofurans has been accomplished by utilizing a substituted benzene ring from which to synthesize the fused benzofuran ring system. See A. Mustafa, "Benzofurans" (1974) and A. Mustafa, "Furopyrans and Furopyrones, Chapter 3: Furochromones" (1967). Also, pyrogallol has been employed as a starting material for the synthesis of khellin and antiatherosclerotic analogues thereof. See U.S. Pat. No. 4,459,420. See also L. R. Row, et al., Indian J. Chem. 5:105 (1967).
U.S. Pat. No. 4,434,296 provides a method whereby 3-furoic acid is transformed to the benzofuran intermediates useful in the synthesis of khellin and khellin analogues. In this method, 3-furoic acid is converted to an enaminone diester, which undergoes Dieckmann cyclization to yield a highly functionalized benzofuran. Methylation, Baeyer-Villager oxidation and conversion of the resulting hydroxy ester to khellinone and then khellin completes this synthesis. See R. B. Gammill and B. R. Hyde, J.Org.Chem. 48:3863 (1983). See also R. B. Gammill, C. E. Day, and P. E. Schurr, J. of Medicinal Chem. 26:1672 (1983); U.S. Pat. No. 4,284,569.
The present invention present a new 3-furoic acid route to khellin. One of the most important steps of the present invention is the oxidation of the methyl ketone to the intermediate quinone monoketal using thallium (III) nitrate or lead (IV) acetate.
Most of the previous reports of the oxidation of p-methoxyphenols to benzoquinone monoketals have relied on 2,3-dichloro-5,6-dicyanobenzoquinone, thallium (III) nitrate, and ferric chloride as the oxidants. See G. Buchi et al., J. Org. Chem. 43:3983 (1978). The use of thallium (III) nitrate to oxidize p-methoxyphenols containing a carbonyl or carboxyl function ortho- to the phenolic hydroxyl has been reported by Hart and Scheinmann. See T. W. Hart and F. Scheinmann, Tet. Lett. 21:2295 (1980). Oxidation of 2-formyl-4-methoxyacetophenone with thallium (III) nitrate afforded the quinone monoketal in which the aldehyde was also transformed to an acetal. No yield was reported for this oxidation. Similar treatment of 2-carbomethoxy-4-methoxyphenol afforded the methoxyl-substituted quinone monoketal in 97% yield as a crystalline solid.
For the thallium (III) nitrate oxidation of a system that yielded an ortho-quinone monoketal, see A. McKillop et al., J. Org. Chem. 41:282 (1976). For an example of an anodic oxidation to yield an ortho-quinone monoketal, see M. G. Dolson and J. S. Swenton, J. Am. Chem.-Soc. 103:2361 (1981).
F. R. Hewgill and S. L. Lee, J. Chem. Soc. 1556 (1968), report the oxidation of alkoxyphenols using lithium (IV) acetate and report the isolation of 2,5-di-t-butyl-1,4-benzoquinone by methanol recrystallization. A. E. Brother, T. M. Meijer, and H. Schmid., Helv. Chim. Acta. 35:910 (1952); F. Wessely and J. Kotlan, Monatsh. Chem. 84:124 (1953); F. Wessely and L. Holzer, Monatsh. Chem. 83:1253 (1952) disclose the preparation of quinol diacetates using lead (IV) acetate. Anodic acetoxylation of dimethoxybenzenes is disclosed in K. Yoshida et al., J. Org. Chem. 40:3805 (1975).
SUMMARY OF THE INVENTION
The present invention particularly provides:
(1) A process for preparing a compound of formula IV, wherein X is --O-- or --S--, which comprises:
cyclizing the compound of formula III using a Dieckmann-type cyclization.
(2) A process for preparing a compound of formula VII, which comprises:
(a) oxidizing a compound of formula VI with a compound selected from the group consisting of thallium (III) nitrate trihydrate and lead (IV) acetate, in methanol;
(b) reacting the product obtained in step (a) with allyl alcohol; and
(c) treating the product obtained in step (b) with acid.
(3) A process for preparing a compound of formula IX, which comprises:
(a) oxidizing a compound of formula VI with a compound selected from the group consisting of thallium (III) nitrate trihydrate and lead (IV) acetate in methanol; and
(b) treating the product obtained in step (a) with acid.
(4) A compound of formula III, wherein X is --O-- or --S--.
(5) A compound of the formula X
wherein R 1 is
(a) --OH,
(b) ═O, or
(c) --OCH 3 ;
wherein R 2 is --C(O)R 5 ;
wherein R 3 is
(a) --H,
(b) --OCH 3 , or
(c) --OCH 2 --CH═CH 2 ;
wherein R 4 is
(a) --H, or
(b) --OCH 3 ;
wherein R 5 is (C 1 -C 9 ) alkyl; wherein P, Q, and T are single or double bonds; with the provisos that:
(1) P and T are both double bonds and Q is a single bond when R 3 is --OCH 2 --CH═CH 2 and R 4 is hydrogen;
(2) P is a double bond and Q and T are both single bonds when R 3 and R 4 are both ═OCH 3 ; and
(3) Q is a double bond and P and T are both single bonds when R 3 is hydrogen and R 4 is other than hydrogen.
(6) A compound of the formula XI wherein X is
(a) --S-- or
(b) --O--;
wherein R 2 is
(a) --CO 2 CH 3 ,
(b) --CO 2 H, or
(c) --C(O)R 5 ;
wherein R 5 is (C 1 -C 4 )alkyl.
The carbon atoms content of various hydrocarbon-containing moieties is indicated by a prefix designating the minimum and maximum number of carbon atoms in the moiety, i.e., the prefix (C i -C j ) indicates a moiety of the integer "i" of the integer "j" carbon atoms, inclusive. Thus, for example, (C 1 -C 3 ) alkyl refers to alkyl of one to three carbon atoms, inclusive, or methyl, ethyl, propyl, and isopropyl.
Examples of alkyl of one to nine carbon atoms, inclusive, are methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, and nonyl, and isomeric forms thereof.
The compounds of the present invention will be named herein using the Chemical Abstracts numbering system (see "Naming and Indexing of Chemical Substances for Chemical Abstracts during the Ninth Collective Period (1972-1976)," a reprint of section IV from the Volume 76 Index Guide). When X is --O-- and --S--, the compounds of this invention are named as benzofurans and benzothiophenes, respectively.
The process of the present invention is more completely understood by reference to the charts below. In these charts, X is as defined above, and in Chart D, R is defined as (C 1 -C 9 )alkyl.
Chart A herein describes the method by which several novel intermediates to khellin and its analogues are prepared. Charts B and C herein describe two methods by which khellin is prepared from the intermediates obtained in Chart A. Chart D herein describes the method by which compounds with proven leukotriene and/or lipoxygenase-inhibiting activity are prepared from the intermediates obtained in Chart A.
With respect to Chart A, the dianion of the formula A-1 compound, 3-furoic acid, is transformed to the formula A-2 keto diester by treatment with succinic anhydride, followed by esterification of the crude diacid. This method is described more fully in R. B. Gammill and B. R. Hyde, J. Org. Chem. 48:3863 (1983).
Thereafter, the formula A-2 keto diester is converted to the novel formula A-3 ketal. This ketalization does not proceed under normal ketalization conditions (i.e., catalytic para-toluenesulfonic acid/ethene glycol/benzene). The formula A-2 keto diester is treated with trimethylorthoformate, methanol, and para-toluenesulfonic acid at reflux to afford the formula A-3 ketal in high yield. The oxygen analogue of the formula A-3 compound requires more refluxing time than does the sulfur analogue. This procedure is a modification of the procedure developed by Glatz et al., J. Am. Chem. Soc. 101:2171 (1979), and is described more fully in Example 2.
The formula A-3 ketal is cyclized to afford the novel benzofuran/benzothiophene ester of formula A-4. This Dieckmann-type cyclization proceeds in the presence of potassium tert-butoxide in tetrahydrofuran at -80° to 0° C. and is followed by acid treatment (preferably anhydrous hydrochloric acid) to yield the fully substituted and oxygen-differentiated benzofuran/benzothiophene of formula A-4. This cyclization, known as a Dieckmann condensation, represents a new method for the synthesis of highly functionalized benzofurans/benzothiophenes and provides methodology for the construction of an aromatic ring onto an existing furan ring. See R. B. Gammill and B. R. Hyde, J. Org. Chem. 48:3863-5 (1983). For a review of prior methods, see A. Mustafa, The Chemistry of Heterocyclic Compounds, Vol. 29 (1979); J. P. Schaefer, Organic Reactions 15:1-203 (1967).
The formula A-4 ester is hydrolyzed (e.g., using lithium hydroxide in aqueous tetrahydrofuran) to yield the formula A-5 acid. Lithium hydroxide is the preferred hydrolyzing agent as attempts to hydrolyze the formula A-4 ester with sodium hydroxide, barium hydroxide or potassium hydroxide, all gave lower yields of the formula A-5 acid. The carboxylic acid of formula A-5 is converted to the formula A-6 methyl ketone by standard methodology (e.g., treatment of the formula A-5 acid with methyl lithium in tetrahydrofuran at 0° C. for 4 hours).
Charts B and C provide alternative methods by which khellin (formula B-8 (C-8)) is prepared from the formula A-6 methyl ketone of Chart A.
In accordance with the procedure of Chart B, the formula A-6 compound of Chart A is employed as the formula B-1 starting material. This formula B-1 compound is oxidized with a compound selected from the group consisting of lead (IV) acetate and thallium (III) nitrate trihydrate, in a C 1 -C 4 alkanol solvent, (preferably, methanol with at least 5% trimethylorthoformate or a 1:1 mixture of methanol and trimethylorthoformate), to afford the formula B-2 novel intermediate quinone monoketal. These are the preferred oxidizing agents since sodium periodate, E. Alder and B. Berggren, Acta. Chem. Scand. 14:529 (1960), 2,3-dichloro-5,6-dicyanobenzoquinone, G. Buchi et al., J. Org. Chem. 43:3983 (1978), dimethylformamide complex of ferric chloride, S. Tobinaga and E. Kotani, J. Am. Chem. Soc. 94:309 (1972), and ceric ammonium nitrate, W. Durkheimer and L. A. Cohen, Biochemistry 3:1948 (1964), all failed to induce the above oxidation.
Under the acidic conditions of the oxidation, the formula B-2 intermediate rapidly adds methanol to yield the Michael adduct of formula B-3. The formula B-3 compound is treated with excess allyl alcohol at reflux and then with acid (e.g., anhydrous acid or a hydrated acid in an organic solvent) to give a compound of the formula B-5. See description of procedure in Example 6.
Methylation of the formula B-5 compound (e.g., using dimethyl sulfate/potassium carbonate/1,4,7,10,13,16-Hexaoxacyclooctadecane [also known as 18-crown-6]/tetrahydrofuran/reflux) yields the novel bensofuran of the formula B-6. See R. B. Gammill and B. R. Hyde, J. Org. Chem. 48:3863-5 (1983).
Treatment of the formula B-6 compound with a Lewis acid (e.g., anhydrous hydrogen bromide or boron trifluoride etherate in methylene chloride, and aluminum chloride in nitrobenzene) at -15° C. for 15 minutes results in the selective removal of the allyloxy group to yield the formula B-7 compound, which is known as khellinone.
The formula B-7 compound is then converted to khellin by Claisen condensation/acid-catalyzed cyclodehydration. This procedure is more fully described in U.S. Pat. No. 4,284,569.
In accordance with the procedure of Chart C, the formula A-6 compound of Chart A is employed as the formula C-1 starting material. This formula C-1 compound is oxidized using a compound selected from the group consisting of thallium (III) nitrate trihydrate or lead (IV) acetate, in a C 1 -C 4 alkanol solvent (e.g., preferably, methanol with at least 5% trimethylorthoformate or a 1:1 mixture of methanol and trimethylorthoformate) to afford the formula C-2 intermediate quinone monoketal. See Example 7. Under the acidic conditions of the oxidation, the formula C-2 intermediate rapidly adds methanol to the enone double bond to yield the formula C-3 adduct.
Treatment of the formula C-3 intermediate with acid (e.g., anhydrous acid or a hydrated acid in an organic solvent) effects the elimination of methanol to yield the formula C-5 compound.
Methylation of the formula C-5 compound (e.g., using dimethyl sulfate/potassium carbonate/1,4,7,10,13,16-Hexaoxacyclooctadecane [18-crown-6]/tetrahydrofuran/reflux), as in the conversion of the formula B-5 compound of the formula B-6 compound above, yields the formula C-6 compound. A similar procedure is described in R. B. Gammill and B. R. Hyde, J. Org. Chem. 48:3863-5 (1983).
Three alternative routes from the formula C-6 compound to the C-7 compound, which is known as khellinone, include: (1) Treatment of the formula C-6 compound with anhydrous hydrogen bromide in chloroform at elevated temperatures to afford a mixture of the formula C-7 compound, khellinone, and the formula C-5 compound. (2) Treatment of the formula C-6 compound with boron trifluoride etherate in methylene chloride at room temperature to afford the formula C-7 compound as the major product and the formula C-5 compound, as the minor product. (3) Treatment of the formula C-6 compound in methylene chloride with a nitrobenzene solution of aluminum chloride to afford the formula C-7 compound as the sole product.
The formula C-7 compound is then converted to khellin by Claisen condensation/acid-catalyzed cyclodehydration. This procedure is more fully described in U.S. Pat. No. 4,284,569.
As noted above, the compounds khellin and khellinone may be prepared. See formulas I and II. Khellinone is known to be useful in the preparation of a wide variety of antiatherosclerotic substances, like khellin and its analogues. See U.S. Pat. No. 4,284,569. Accordingly, the manner of the preparation and pharmacological use of these compounds are incorporated herein by refernce from the description of their preparation and use in U.S. Pat. No. 4,284,569.
Chart D depicts the preparation of the leukotriene and/or lipoxygenase-inhibiting compounds from the intermediates obtained in Chart A. In accordance with the procedure of Chart D, the formula A-5 compound of Chart A is employed as the formula D-1 starting material. The formula D-1 carboxylic acid is treated with an alkyl lithium (e.g., ethyl lithium, propyl lithium, and butyl lithium) in an ether solvent (e.g., ethyl ether, tetrahydrofuran, and dioxane) at or below room temperature and in an inert atmosphere (e.g. nitrogen and argon) to afford the alkyl ketone of formula D-2. The reaction is quenched with a saturated solution of ammonium chloride and extracted with an organic solvent (e.g., ethyl ether, ethyl acetate, and toluene). See M. J. Jorgenson, Organic Reactions 18:1-98 (1970); see also B. J. Wakefield, The Chemistry of Organolithium Compound (1974). This reaction was used above to convert the acid of formula A-5 to the methyl ketone of formula A-6 in the total synthesis of khellin.
The carbonyl group of the alkyl ketone of formula D-2 is reduced to afford the compound of formula D-3. Amalgamated zinc in concentrated hydrochloric acid, water and an inert solvent (e.g., ethanol and toluene) are added to the compound of formula D-2, and the mixture heated to reflux. The reaction is worked up by extracting with an organic solvent (e.g., toluene and ethyl acetate) and removing that solvent, in vacuo. See R. R. Read, and J. Wood, Organic Synthesis 3:444 (1955); M. S. Newman, W. C. Sagar, and C. C. Cochrane, J. Org. Chem. 23:1832 (1958).
The hydroxyl group of the compound of formula D-3 is acylated with a mixture of acetic anhydride and pyridine at room temperature for several hours. Removal of the solvents affords the compound of formula D-4. See said Ser. No. 561,601, filed Dec. 14, 1983.
As described above, the formula A-5 compound of this invention may be used to prepare a wide variety of benzofurans and benzothiophenes, which are useful as leukotriene and/or lipoxygenase inhibitors. Accordingly, the manner of the preparation and pharmacological use of these compounds are incorporated herein by reference from the description of their preparation and use in said Ser. No. 561,601, filed Dec. 14, 1983.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preparation of the novel benzofurans and benzothiophenes of the instant specification are more readily understood by the following examples:
EXAMPLE 1
A. 2-furanbutanoic acid, 3-(methoxycarbonyl)-α-oxomethyl ester (formula A-2: X is oxygen)
Refer to Chart A
Raid addition of succinic anhydride (1.1 equiv./tetrahydrofuran) to the dianion of 3-furoic acid of formula A-1 (2 equiv. of lithium diisopropyl amide/tetrahydrofuran/-78° C.) followed by esterification (hydrochloric acid/methanol or diazomethane/chloroform) of the crude diacid yields, after chromatography (silica gel, 5% ethyl acetate/chloroform), the title product as a colorless oil.
B. 2-Thiophenebutanoic acid, 3-(methoxycarbonyl)-α-oxo-/methyl ester (formula A-2: X is sulfur)
Refer to Chart A
3-Thiophene carboxaldehyde is oxidized (Ag 2 O/H 2 O) to 3-thiophene carboxylic acid of formula A-1. Treatment of the acid with lithium diisopropyl amide (2.2 equiv./tetrahydrofuran/-78° C.) affords a pale yellow dianion which, upon treatment with succinic anhydride (1.1 equiv./tetrahydrofuran), followed by esterification (hydrochloric acid/methanol or diazomethane/chloroform), yields the title product.
EXAMPLE 2
A. 2-Furanbutanoic Acid, α,α-dimethoxy-3-(methoxycarbonyl)-, methyl ester (Formula A-3: X is oxygen)
Refer to Chart A
The formula A-2 product of Example 1(A) (25.08 g), trimethylorthoformate (55.38 g), para-toluensulfonic acid (1.5 g) and methanol (200 ml) are heated at reflux for 48 hours. Pyridine (5 ml) is added, and the excess methanol and trimethylorthoformate removed in vacuo. The resulting oil is chromatographed over silica gel (1 kg, 25% ethyl acetate/hexane) to yield 25.16 g of the title product as a colorless oil.
Physical characteristics are as follows:
IR (cm -1 , film): 3140, 3120, 1735, 1585, 1510, 1290, 1195, 1165, 1110, 1070, 1055, 1030, 880 and 755.
1 H-NMR (δ, CDCl 3 ): 7.4, 6.7, 3.85, 3.6, 3.3 and 2.1-3.8.
Mass spectra (m/e): 286, 255, 223, 200, 199, 196, 195, 163, 153, 137 and 59.
UV (λ max , ethanol): 238.
Anal. Calc'd. for C 13 H 18 O 7 : C, 54.54; H, 6.29. Found: C, 54.36; H, 6.21.
B. Methyl-α,α-dimethoxy-3-methoxycarbonyl-2-thiophenebutanoate (Formula A-3: X is sulfur)
Refer to Chart A
The formula A-2 product of Example 1(B) (10.0 g, 39.0 ml), trimethylorthoformate (20.67 g), para-toluensulfonic acid (1.0 g) and methanol (100 ml) are refluxed under nitrogen for 8 hours. Additional trimethylorthoformate (approx. 15 g) is added and refluxing continued for 36 hours until the reaction is complete. After cooling the reaction to room temperature, pyridine (3 ml) is added and the excess methanol and trimethylorthoformate removed in vacuo. The resulting oil is chromatographed over 700 g of silica gel (230-400 mesh, 25% ethyl acetate/Skellysolve-B, [a commercially-available mixture of essentially n-hexane]) to yield 11.60 g of the title product as a colorless oil.
Physical characteristics are as follows:
IR (cm -1 , mull): 2950, 1735, 1708, 1437, 1285, 1267, 1194 and 1127.
1 H-NMR (δ, CDCl 3 ): 7.40, 7.28, 3.80, 3.55, 3.15, 2.65 and 2.15.
Mass spectra (m/e): 302, 271, 239, 217, 216, 215, 211, 179, 169, 139 and 59.
UV (λ max , ethanol): 244.
Anal. Calc'd. for C 13 H 18 O 6 S: C, 51.65; H, 5.96; S, 10.59. Found: C, 51.99; H, 5.93; S, 10.68.
EXAMPLE 3
A. 5-Benzofurancarboxylic acid, 4-hydroxy-7-methoxy-, methyl ester Formula A-4: X is oxygen)
Refer to Chart A
Potassium tert-butoxide (72.4 g) is dissolved in tetrahydrofuran (8.0 l) and cooled to -78° C. under an atmosphere of nitrogen. The formula A-3 product of Example 2(A) (84.0 g), also in tetrahydrofuran (250 ml), is added dropwise over 30 minutes. After stirring for 1.25 hours at -78° C., anhydrous hydrochloric acid is bubbled into the reaction mixture until the solution becomes transparent yellow. The cooling bath is removed and stirring is continued for 1 hour. Evaporation at 40° C., in vacuo, affords 78.3 g of crude solid. The product is purified by gravity-flow chromatography over 3.0 kg of silica gel. Elution with 50% ethyl acetate/Skellysolve-B affords 62.9 g of the title product as a white solid.
Physical characteristics are as follows:
Melting point: 127.8°-128.8° C.
IR (cm -1 , mull): 1361, 2927, 1479, 1203, 1666, 1069, 1450, 2949 and 1232.
1 H-NMR (δ, CDCl 3 ): 11.0, 7.55, 7.1, 6.9 and 3.9.
Mass spectra (m/e): 222, 191, 190, 175, 163, 162, 147, 134, 119 and 53.
Anal. Calc'd. for C 11 H 10 O 5 : C, 59.45; H, 4.50. Found: C, 59.10; H, 4.60.
Silica Gel thin-layer chromatography: R f =0.72 in 5% ethyl acetate/chloroform.
B. Benzo(b)thiophene-5-carboxylic acid, 4-hydroxy-7-methoxy-, methyl ester. (Formula A-4: X is sulfur)
Refer to Chart A
Potassium tert-butoxide (82.9 g) is dissolved in tetrahydrofuran (8.0 l) in a flame-dried 12-liter flask, under an atmosphere of nitrogen. The formula A-3 product of Example 2(B) (102.0 g), also in tetrahydrofuran (150 ml), is added dropwise over 1 hour. After stirring for 2 hours at -78° C., anhydrous hydrochloric acid is bubbled into the reaction mixture until the solution becomes transparent yellow. After evaporation at 50° C., in vacuo, the residue is triturated with methylene chloride (2 l) and the solid is filtered and discarded. The methylene chloride solution is filtered through a pad of magnesium sulfate and evaporated to afford 49.5 g of the title product.
Alternatively, potassium tert-butoxide (17.20 g) is dissolved in tetrahydrofuran (300 ml) and cooled to -78° C. under an atmosphere of nitrogen. The formula A-3 product of Example 2(B) (11.60 g), also in tetrahydrofuran (200 ml), is added dropwise over 20 minutes. The dry ice/acetone bath is removed and stirring continued for 1.5 hours. The reaction is quenched by addition of 2N hydrochloric acid (approx. 200 ml), which is extracted three times with ether. The combined extracts are dried over magnesium sulfate and the solvent removed, in vacuo, to yield a tan solid (9.3 g). The solid is chromatographed over 300 g of Florisil (1% ethyl acetate/methylene chloride) to yield 8.3 g of the title product as a white solid.
Physical characteristics are as follows:
Melting point: 139.4°-140.1° C.
IR (cm -1 , mull): 2958, 2926, 2854, 1666, 1449, 1431, 1358, 1266, 788 and 760.
1 H-NMR (δ, CDCl 3 ): 11.25, 7.65, 7.40, 7.10 and 3.90.
Mass spectra (m/e): 239, 238, 208, 207, 206, 191, 178, 163 and 135.
UV (λ max , ethanol): 229, 234, 241, 250, 279, 289, 339 and 349.
Anal. Calc'd. for C 11 H 10 O 4 S: C, 55.46; H, 4.20; S, 13.44. Found: C, 55.30; H, 4.28; S, 13.15.
EXAMPLE 4
A. 4-Hydroxy-7-methoxybenzo(b)furan-5-carboxylic acid (Formula A-5: X is oxygen)
Refer to Chart A
The formula A-4 product of Example 3(A) (12.1 g) is dissolved in tetrahydrofuran (100 ml). Lithium hydroxide (5.0 g), dissolved in boiling distilled water (25 ml), is added at room temperature and the solution brought to reflux for 2.5 hours. The reaction mixture is cooled to 0° C., and ice (approx. 100 ml) and concentrated hydrochloric acid are added to a pH of 1. The resulting gray precipitate is filtered, air-dried overnight and dried in vacuo for 2 days to yield 11.1 g of impure title product. 2.0 g of this product is applied to silica gel (200 g) and eluted with ethyl acetate to afford 1.65 g of light gray crystals. Recrystallization from ethyl acetate gives 1.4 g of the title product as a white solid.
Physical characteristics are as follows:
Melting point: 192°-195° C.
IR (cm -1 , mull): 1215, 1305, 1453, 2925, 1478, 1281, 1067, 1606, 1462, 1646 and 2953.
1 H-NMR (δ, dimethylsulfoxide): 7.60, 7.30 and 3.95.
Mass spectra (m/e): 208, 191, 190, 175, 162, 147, 134, 119, 63 and 53.
UV (λ max , ethanol): 224, 255 and 317.
Anal. Calc'd for C 10 H 8 O 5 : C, 57.69; H, 3.87. Found: C, 57.77; H, 4.01.
B. Benzo(b)thiophene-5-carboxylic acid, 4-Hydroxy-7-methoxy (Formula A-5: X is sulfur)
Refer to Chart A
The formula A-4 product of Example 3(B) (16.4 g) is dissolved in hot tetrahydrofuran (100 ml). Water (20 ml) and lithium hydroxide (15.0 g) are added and the solution heated at reflux for 10 hours. The reaction mixture is cooled to 50° C. and the tetrahydrofuran removed in vacuo. The resulting aqueous solution is diluted with water (to 500 ml) and cooled below room temperature with an ice bath, while concentrated hydrochloric acid is added to a pH of 1. The resulting precipitate is collected on a filter. The wet crystals are dissolved in ethyl acetate, dried over magnesium sulfate and the solvent removed, in vacuo, to yield 15.3 g of the crude title product. Recrystallization from acetonitrile yields 12.8 g of the title product.
Physical characteristics are as follows:
Melting point: 205°-208° C.
IR (cm -1 , mull): 2926, 2867, 2854, 1641, 1503, 1449, 1443, 1417, 1245 and 688.
1 H-NMR (δ, dimethylsulfoxide): 7.75, 7.20 and 3.95.
Mass spectra (m/e): 225, 224, 207, 206, 191, 178, 163, 150, 135 and 103.
UV (λ max , ethanol): 225, 271, 275, 289 and 337.
Anal. Calc'd. for C 10 H 8 O 4 S: C, 53.56; H, 3.60, S, 14.30. Found: C, 53.66; H, 3.80; S, 14.34.
EXAMPLE 5
A. Ethanone, 1-(4-Hydroxy-7-methoxy-5-benzofuranyl)-(Formula A-6: X is oxygen.)
Refer to Chart A
The formula A-5 product of Example 4(A) (8.32 g) is dissolved in tetrahydrofuran (250 ml) under an atmosphere of nitrogen and then cooled to 0° C. Methyl lithium (107 ml of 1.5M) is added dropwise over 3 hours and the solution stirred an additional 4 hours at 0° C. The reaction is quenched with saturated ammonium chloride (250 ml) and extracted three times with 100 ml of ether. The combined organic extracts are dried over magnesium sulfate and the solvent removed, in vacuo, to yield 7.22 g of crude title product. Chromatography over 500 g of silica gel (240-400 mesh, 25% ethyl acetate/Skellysolve-B) yields 4.15 g of the pure title product.
Physical characteristics are as follows:
Melting point: 102°-104° C.
IR(cm -1 , mull): 2925, 2954, 2855, 2860, 1478, 1368, 1606, 1373, 1469 and 1311.
1 H-NMR (δ, CDCl 3 ): 7.3, 7.05, 6.90, 3.90 and 2.55.
Mass spectra (m/e): 207, 206, 192, 191, 188, 173, 163, 145, 53 and 43.
UV (λ max , ethanol): 228, 233, 247, 270 and 348.
Anal. Calc'd. for C 11 H 10 O 4 : C, 64.07; H, 4.89. Found: C, 64.00; H, 5.04.
B. Ethanone, 1-(4-Hydroxy-7-methoxybenzo(b)thien-5-yl) (Formula A-6: X is sulfur.)
Refer to Chart A
The formula A-5 product of Example 4(B) (11.2 g) is dissolved in tetrahydrofuran (350 ml) under an atmosphere of nitrogen and then cooled to 0° C. Methyl lithium (1.25M, 160 ml) is added dropwise over 2.5 hours and the solution stirred an additional 4 hours (0°-15° C.). The reaction is diluted with saturated ammonium chloride (250 ml) and extracted three times with 100 ml of ether. The combined organic extracts are dried over magnesium sulfate and the solvent removed, in vacuo, to yield 11.35 g of crude title product. Chromatography over 750 g of silica gel (240-400 mesh, 100% ethyl acetate) yields 10.4 g of the title product.
Physical characteristics are as follows:
Melting point: 131.8°-132.2° C.
IR (cm -1 , mull): 2952, 2925, 2869, 2855, 1618, 1427, 1372, 1326, 816, 721 and 715.
1 H-NMR (δ, CDCl 3 ): 7.75, 7.50, 6.90, 4.00 and 2.70.
Mass spectra (m/e): 223, 222, 208, 207, 204, 189, 179, 161, 108 and 43.
UV (λ max , ethanol): 233, 239, 254, 281, 289 and 366.
Anal. calc'd. for C 11 H 10 O 3 S: C, 59.44; H, 4.54; S, 14.43. Found: C, 59.53; H, 4.72; S, 14.33.
EXAMPLE 6
5-Acetyl-5,6-dihydro-6,7,7-trimethoxy-4(7H)benzofuranone (Formula B-3 (C-3))
Refer to Charts B and C
The benzofuran ketone of formula A-6 (B-1) (C-1) of Example 5(A) (6.18 g) is dissolved in 300 ml of 50% methanol/trimethylorthoformate and the solution is cooled to 0° C. Thallium trinitrate trihydrate (18.4 g) is dissolved in 150 ml of 50% methanol/trimethylorthoformate and added dropwise to the ketone solution. After stirring for four hours at 0° C., the reaction mixture is allowed to settle and the clear supernate is decanted into a stirred mixture of methylene chloride (2 l) and saturated aqueous sodium bicarbonate (500 ml). The white solid residue is washed three times with 50 ml of methylene chloride and the washings are combined with the work-up mixture. The layers are separated and the aqueous phase is extracted three times with 100 ml of methylene chloride. The organic phases are combined and washed with saturated sodium bicarbonate (500 ml), dried over magnesium sulfate and evaporated at 40° C. in vacuo and then at 0.5 torr. Crystals are formed under vacuum and the yield is 6.98 g of the title product. One gram of the crude product is recrystallized twice from 2.5 ml of ethyl acetate to afford analytically pure material.
Physical characteristics are as follows:
Melting point: 113.2°-115° C.
Silica gel thin-layer chromatography: R f =0.18 in 25% ethyl acetate/Skellysolve-B.
IR (cm -1 , CHCl 3 ): 1615, 1570, 1455, 1390, 1145, 1095, 1080, and 845.
1 H-NMR (δ, CDCl 3 ): 15.63, 7.45, 6.75, 4.47, 3.53, 3.22, 3.16, and 2.25.
UV (λ max ): 208, 218, 264, and 318.
Mass spectra (m/e): 268, 253, 211, 206, 191, 179, 153, 141, 43, and 28.
Anal. calc'd. for C 13 H 16 O 6 : C, 58.20; H, 6.01. Found: C, 57.86; H, 6.01.
EXAMPLE 7
4(7H)-Benzofuranone, 5-acetyl-7,7-dimethoxy (Formula B-2 (C-2))
Refer to Charts B and C
A solution of thallium trinitrate trihydrate (18.65 g) in a 1:1 mixture of methanol/trimethylorthoformate (150 ml) is added dropwise to a solution of the formula A-6 (B-1) (C-1) product of Example 5(A) in a 1:1 mixture of methanol/trimethylorthoformate (300 ml) at 0° C. After stirring for 4 hours at 0° C., the reaction mixture is allowed to settle and the clear supernate is decanted into a stirred mixture of methylene chloride (2 l) and saturated aqueous sodium bicarbonate (500 ml). The white solid residue is washed three times with 50 ml of methylene chloride and the washings are combined with the workup mixture. The layers are separated and the aqueous phase is extracted three times with 100 ml of methylene chloride. The organic layers are combined, dried over sodium sulfate and filtered. The solvents are removed, in vacuo, at 40° C. to afford a brown oil. The oil is applied to Florisil (100 g) and eluted with 50% ethyl acetate/Skellysolve-B to afford 2.1 g of the title product.
Physical characteristics are as follows:
Melting point: 58°-64° C.
IR (cm -1 , mull): 3140, 2948, 1696, 1674, 1365, 1069, 1048, 1037, 898, and 765.
1 H-NMR (δ, CDCl 3 ): 7.54, 7.25, 6.79, 3.47, and 2.57.
UV (λ max , ethanol): 206, 218, 264, and 316.
Mass spectra (m/e): 236, 221, 208, 206, 205, 193, 177, 114, and 43.
Anal. Calc'd. for C 12 H 12 O 3 : C, 61.01; H, 5.12. Found: C, 61.16; H, 5.16.
Alternatively, the formula B-3 (C-3) product of Example 6 (0.25 g) is heated to 110° C. under oil pump vacuum (approximately 0.5 torr) for twenty minutes. The crude product (0.24 g) is recrystallized from ethyl acetate (1.5 ml) to afford 0.175 g of the title product.
Physical characteristics are as follows:
Melting point: 62°-64.2° C.
Silica gel thin-layer chromatography: R f =0.25 in 25% ethyl acetate/Skellysolve-B.
Spectral and analytical data are consistent with those reported above.
EXAMPLE 8
Ethanone, 1-(4-Hydroxy-7-methoxy-6-(2-propenyloxy)-5-benzofuranyl) (Formula B-5)
Refer to Chart B
The formula A-6 (B-1) product of Example 5(A) (2.06 g) is dissolved in a 1:1 mixture of methanol/trimethylorthoformate (500 ml) and cooled to 0° C. Thallium trinitrate trihydrate (6.22 g, in 50 ml of a 1:1 mixture of methanol/trimethylorthoformate) is added to that mixture dropwise over 10 minutes. The reaction is stirred for 5.5 hours and then poured into a mixture of methylene chloride and saturated sodium bicarbonate (350 ml/100 ml) with vigorous stirring. The organic layer is separated, dried over sodium sulfate and solvent removed, in vacuo, to yield 2.52 g of crude adduct of formula B-3. This material is dissolved in allyl alcohol (15 ml) and heated at reflux for 1.5 hours. The reaction is diluted with methylene chloride and 0.2 ml of a saturated hydrochloric acid solution of methylene chloride is added. The solution is stirred for 30 minutes and the solvent removed, in vacuo. Chromatography (silica gel, 10% ethyl acetate/Skellysolve-B) yields 1.29 g of the title product as a yellow oil.
Physical characteristics are as follows:
IR (cm -1 , film): 1632, 1465, 1437, 1391, 1365, 1348, 1291, 1127, 1061 and 972.
1 H-NMR (δ, CDCl 3 ): 9.48, 7.55, 6.96, 6.20, 5.40, 4.72, 4.02 and 2.72.
Mass spectra (m/e): 262, 221, 206, 203, 193, 173 and 163.
UV (λ max , ethanol): 238, 252, 271, 281 and 352.
Anal. calc'd. for C 14 H 14 O 5 : C, 64.11; H, 5.38. Found: C, 64.28; H, 5.46.
Alternatively, the benzofuran ketone quinone monoketal of formula B-2 of Example 7 (0.25 g) is dissolved in methylene chloride (1.0 ml) and allyl alcohol (0.12 g) is added at room temperature. Camphorsulfonic acid (0.025 g) is added and the solution immediately turns yellow. After standing for 0.5 hour, the crude title product is chromatographed over silica gel (15 g, 25% ethyl acetate/Skellysolve-B).
The title product (0.09 g) corresponds to those above by thin-layer chromatography (25% ethyl acetate/Skellysolve-B), 1 H-NMR, and mass spectroscopy.
EXAMPLE 9
Ethanone, 1-(4,7-dimethoxy-6(2-propenyloxy)-5-benzofuranyl) (Formula B-6)
Refer to Chart B
The formula B-5 product of Example 8, potassium carbonate (2.5 g), 1,4,7,10,13,16-hexaoxacyclooctadecane (18-crown-6) (0.2 g), and dimethyl sulfate (0.75 g) are added to tetrahydrofuran and the mixture heated at reflux for 30 minutes. The reaction is cooled to room temperature and solvent removed, in vacuo. The crude reaction is applied directly to a silica gel column (120 g) which, after elution with 50% ethyl acetate/Skellysolve-B, affords 1.1 g of the title product as a colorless oil.
Physical characteristics are as follows:
IR (cm -1 , film): 1706, 1479, 1433, 1423, 1354, 1346, 1267, 1137, 1070 and 988.
1 H-NMR (δ, CDCl 3 ): 7.60, 6.90, 6.15, 5.30, 4.65, 4.05, 3.95 and 2.50.
Mass spectra (m/e): 276, 235, 220, 207, 190, 177, 175, 119 and 43.
UV (λ max , ethanol): 214, 239 and 290.
Anal. Calc'd. for C 15 H 16 O 5 : C, 65.21; H, 5.84. Found: C, 65.23; H, 5.78.
EXAMPLE 10
Khellinone (Formula B-7)
Refer to Chart B
A methylene chloride solution (25 ml) of the formula B-6 product of Example 9 (1.0 g) is added to a methylene chloride solution (100 ml) saturated with anhydrous hydrogen bromide at -15° C. After stirring for 15 minutes, thin-layer chromatography (15% ethyl acetate/Skellysolve-B) indicates the reaction is complete. The reaction is poured into a saturated solution of sodium bicarbonate and the organic layer separated, dried over magnesium sulfate and solvent removed, in vacuo, to give the pure title product.
Physical characteristics are as follows:
Melting point: 97.5°-100° C.
IR (cm -1 , mull): 2956, 2926, 2855, 1620, 1470, 1445, 1381, 1303, 1152 and 1080.
1 H-NMR (δ, CDCl 3 ): 10.09, 7.50, 6.90, 4.13, 4.03 and 2.71.
Mass spectra (m/e): 236, 221, 206, 203, 191, 189, 175, 163, 119 and 43.
UV (λ max , ethanol): 205, 251, 280 and 359.
EXAMPLE 11
Khellin (Formula B-8)
Refer to Chart B
Sodium hydride (1.1 g, 50% oil dispersion) is added to a flame-dried 125-ml round-bottom flask under nitrogen. The sodium hydride is washed three times with 25 ml of hexane, and tetrahydrofuran (25 ml) is added. The formula B-7 product from Example 10 (1.7 g) is dissolved in ethyl acetate (15 ml) and this solution is added in 2-ml portions to the sodium hydride suspension. Effervescence is noted but no generation of heat (exotherm) is measured during the 5-minute addition time. After approximately 10 minutes, a substantial generation of heat causes the solvent to reflux gently. After 0.5 hour, the reaction returns to room temperature and is poured into 50 ml of 2N hydrochloric acid and approximately 50 g of ice. Ethyl acetate (100 ml) is added and the organic layer separated. The aqueous mixture is extracted three times with 50 ml of ethyl acetate and the organic layers are combined, dried over magnesium sulfate, and solvent removed in vacuo to yield 2.15 g of crude title product. This material is washed three times with 10 ml of ether to yield 1.60 g of analytically pure title product.
EXAMPLE 12
1-(4-Hydroxy-6,7-dimethoxybenzo[b]furanyl)ethanone (Formula C-5)
Refer to Chart C
A solution of lead (IV) acetate (0.50 g) in a 1:1 mixture of methanol and trimethylorthoformate (5 ml) is added dropwise, over 2 minutes, to a solution of the formula A-6 (C-1) product of Example 5(A) (0.21 g) in a 1:1 mixture of methanol and trimethylorthoformate (5 ml). After stirring at room temperature for 1.5 hours, a second portion of lead (IV) acetate (0.05 g) in 1 ml of the 1:1 mixture of methanol and trimethylorthoformate is added, and the mixture stirred for an additional hour. The reaction mixture is poured into methylene chloride (100 ml) and saturated aqueous sodium bicarbonate (25 ml) with vigorous stirring. The layers are separated and the aqueous phase is extracted three times with 5 ml of methylene chloride. The organic layers are combined, dried over sodium sulfate, filtered, and evaporated, affording 300 mg of the formula C-3 compound. This material is dissolved in methylene chloride (25 ml) and three small crystals (approx. 5 mg) of para-toluenesulfonic acid added. After 0.5 hour, the reaction mixture is applied directly to 20 g of silica gel and eluted with methylene chloride to afford an impure title product. Chromatography over 20 g of silica gel, and elution with 25% ethyl acetate/Skellysolve-B affords 0.20 g of the title product.
Alternatively, a solution of thallium (III) nitrate trihydrate (3.11 g) in a 1:1 mixture of methanol and trimethylorthoformate (25 ml) is added dropwise, over 0.5 hour, to a solution of the formula A-6 (C-1) product of Example 5(A) (1.03 g) in a 1:1 mixture of methanol and trimethylorthoformate (50 ml). After stirring at room temperature for 2.5 hours, the reaction is poured into a mixture of methylene chloride (500 ml) and saturated aqueous sodium bicarbonate (50 ml) with vigorous stirring. The layers are separated and the aqueous phase is extracted twice with 20 ml of methylene chloride. The organic layers are combined, dried over magnesium sulfate, filtered, and evaporated to afford 1.23 g of the formula C-3 compound. This material is dissolved in methylene chloride (25 ml) and para-toluenesulfonic acid (100 mg) added. After stirring at room temperature for 2.5 hours, the solvent is removed, in vacuo, at 40° C. and the product is chromatographed over 125 g of silica gel, eluting with 25% ethyl acetate/Skellysolve-B, to yield 0.90 g of the title product.
EXAMPLE 13
1-(4,6,7-Trimethoxy-5-benzofuranyl)ethanone (Formula C-6)
Refer to Chart C
In a flame-dried flask under nitrogen, the formula C-5 product of Example 12 (0.240 g), 1,4,7,10,13,16-hexaoxacyclooctadecane (18-crown-6) (0.024 g), potassium carbonate (0.3 g), dimethyl sulfate (0.14 g), and tetrahydrofuran (10 ml, anhydrous) are brought to reflux. After 4 hours, the reaction is cooled to room temperature and poured into a stirred mixture of methylene chlorie (50 ml) and water (25 ml). The layers are separated and the aqueous phase is extracted three times with 10 ml of methylene chloride. The organic phases are combined, dried over sodium sulfate, filtered, and evaporated to afford 0.310 g of crude product. Flash chromatography over silica gel (25 g, 10% ethyl acetate/Skellysolve-B) affords 0.232 g of the title product.
The product obtained in this example is identical to a previously prepared standard by comparison of NMR, IR, Mass spectra, and mobility on thin-layer chromatography (10% ethyl acetate/Skellysolve-B).
EXAMPLE 14
1-(6-Hydroxy-4,7-dimethoxy-5-benzofuranyl)ethanone (Formula C-7)
Refer to Chart C
A solution of the formula C-6 product of Example 13 (0.250 g) in methylene chloride (5 ml) is cooled to 0° C. Boron trifluoride etherate (1.0 ml) is added dropwise and the ice bath removed. After 4 hours, the crude product is partitioned between water (10 ml) and methylene chloride (20 ml) and the layers are separated. The aqueous phase is extracted three times with 10 ml of methylene chloride, and the organic layers are combined, dried over magnesium sulfate, filtered, and evaporated to afford 0.31 g of an orange semisolid. Flash chromatography over 25 g of silica gel (10% ethyl acetate/Skellysolve-B) affords 0.176 g of the title product.
Alternatively, a solution of the formula C-6 product of Example 13 (0.250 g) in methylene chloride (2 ml) is cooled to 0° C. in flame-dried flask under nitrogen. Aluminum chloride (4.2 ml of 1.9M solution in nitrobenzene) is added dropwise and the ice bath removed. After 4.75 hours, the crude product is partitioned between water (10 ml) and methylene chloride (20 ml) and the layers are separated. The aqueous phase is extracted three times with 10 ml of methylene chloride and the organic layers are combined, dried over magnesium sulfate, filtered, and evaporated to afford 0.31 g of an orange semisolid. Flash chromatography over 25 g of silica gel (10% ethyl acetate/Skellysolve-B) affords 0.140 g of the title product.
The product obtained in this example is identical to a previously prepared standard by comparison of NMR, IR, Mass spectra, and mobility on thin-layer chromatography (10% ethyl acetate/Skellysolve-B).
EXAMPLE 15
A. 5-Butyl-7-methoxy-4-benzofuranol, acetate (Formula D-4: X is oxygen; R is propyl)
Refer to Chart D
The formula A-5 (D-1) product of Example 4(A) (2.08 g) is added to a flame-dried flask under nitrogen. Anhydrous ethyl ether (200 ml) is added and the solution cooled to 0° C. with stirring. Propyl lithium (30 cc, 1M solution) is then added dropwise over 30 minutes and the resulting reaction stirred at 0° C. for four hours. The reaction is quenched by addition of a saturated solution of ammonium chloride followed by extraction with ether. The extract is dried with sodium sulfate and solvent removed in vacuo to yield the ketone of formula D-2.
The formula D-2 ketone (2.34 g) is added to amalgamated zinc (5 g) in concentrated hydrochloric acid (100 ml) and ethanol (100 ml) and heated to reflux for three hours. The reaction is cooled to room temperature and extracted with ether to yield the phenol of formula D-3.
The formula D-3 phenol (2.20 g) is added to an acetic anhydride/pyridine mixture (5 ml/50 ml) and stirred at room temperature for several hours. The reaction is poured into 2N hydrochloric acid and extracted with ether. The ether is dried and evaporated in vacuo to yield the formula D-4 compound.
B. 5-Butyl-7-methoxy-4-benzo(b)-thiophen-4-ol, acetate (Formula D-4: X is sulfur; R is propyl)
Refer to Chart D
Utilizing a procedure similar to that described in Example 15(a), the formula A-5 (D-1) product of Example 4(B) is converted to the title product. ##STR1##
Compounds D-3 and D-4 are useful in the treatment of asthma. For example, these compounds are useful as bronchodilators or as inhibitors of mediators such as SRS-A which are released from cells activated by an antigen-antibody complex. Thus, these compounds control spasm and facilitate breathing in conditions such as bronchial asthma, bronchitis, bronchiectasis, pneumonia and emphysema. For these purposes, these compounds are administered in a variety of dosage forms, e.g., orally in the form of tablets, capsules, or liquids; rectally in the form of suppositories; parenterally, subcutaneously, or intramuscularly, with intravenous administration being preferred in emergency situations, by inhalation in the form of aerosols or solutions for nebulizers; or by insufflation in the form of powder. Doses in the range of about 0.01 to 50 mg per kg of body weight are used 1 to 4 times a day, the exact dose depending on the age, weight, and condition of the patient and on the frequency and route of administration. For the above use these compounds can be combined advantageously with other anti-asthmatic agents, such as sympathomimetics (isoproterenol, phenylephrine, ephedrine, etc.); xanthine derivatives (theophylline and aminophylline); and corticosteroids (ACTH and prednisolone).
These compounds are effectively administered to human asthma patients by oral inhalation or by aerosol inhalation.
For administration by the oral inhalation route with conventional nebulizers or by oxygen aerosolization it is convenient to provide the instant active ingredient in dilute solution, preferably at concentrations of about 1 part of medicament to form about 100 to 200 parts by weight of total solution. Entirely conventional additives may be employed to stabilize these solutions or to provide isotonic media, for example, sodium chloride, sodium citrate, citric acid, sodium bissulfite, and the like can be employed.
For administration as a self-propelled dosage unit for administering the active ingredient in aerosol form suitable for inhalation therapy the composition can comprise the active ingredient suspended in an inert propellant (such as a mixture of dichlorodifluoromethane and dichlorotetrafluoroethane) together with a co-solvent, such as ethanol, flavoring materials and stabilizers. Instead of a co-solvent there can also be used a dispensing agent such as oleyl alcohol. Suitable means to employ the aerosol inhalation therapy technique are described fully in U.S. Pat. No. 2,868,691 for example.
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The present invention provides novel compositions of matter and processes for their preparation. More particularly, the present invention consists of novel chemical intermediates and associated processes for the preparation of khellin and other furochromone analogues, which have demonstrated antiatherosclerotic activity. These novel intermediates and processes can also be used for the preparation of benzofurans and benzothiophenes which inhibit the synthesis of leukotriene and/or lipoxygenase.
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FIELD OF THE INVENTION
[0001] The present invention relates to a mechanism for capping containers, and more particularly for a mechanism intended for applying screw-type caps on containers.
BACKGROUND
[0002] Commercial distribution and sale of viscous substances are as a rule performed with the substance in question contained in consumer adopted containers in the shape of cans, boxes, TetraPak®-type containers or bottles of different types. Most types of such containers are often in some way recloseable, e.g. by being provided with a lid for closing an opening in the container, or with a cap which can be tightly screwed to a threaded opening of the container and thereby sealing it. Different types of pourable substances that are packed in this way comprise beverages, oils, body and hair products, solvents, toners, corn flakes etc.
[0003] Consequently, capping is a frequently occurring procedure within the packaging industry, involving a cap being mounted to an opening in a container. This procedure is performed just after the moment when the containers are filled with their content, or at an earlier stage when the containers themselves are produced. A known method for capping of containers comprises the following steps, that generally are conducted in a repeated manner:
A cap is fed forward laying on a band, standing or rolling in a conduit, in a chute or the like; A chuck picks the cap up, alternatively the cap is fed to the chuck; The chuck lifts the cap and brings it to the opening on a container; The chuck mounts the cap on the container, e.g. by pressure or by rotation.
[0008] Capped containers are often manufactured in very large volumes, and therefore great effort is often made to increase production pace. A problem with known capping methods is that they comprise a number of time consuming steps, limiting the capping pace. Such steps include the step of moving the chuck from a place where the cap is picked up, to the place where it mounts the cap on the container. Such steps also include the step of waiting for a new cap until the gravity has worked on said cap and caused it to fall into position for being picked up.
[0009] U.S. Pat. No. 4,222,214 to Schultz discloses a chucking apparatus for applying caps to a threaded portion of a container at a constant torque. In a representative embodiment, caps are supplied to the apparatus by an inclined chute under the influence of gravity to a cylindrical rotating hollow cap guide which guide caps and also conveys rotating power to a chuck device, said chuck device being mounted on a lower portion of the cap guide. Caps are thus center fed to the chuck device, which device comprises a plurality of jaw members, each of which members are pivotable to a cap gripping position. A resilient member is arranged to engage the jaw members in response to fluid pressure, causing the jaw members to pivot to the cap gripping position. The chuck device is subsequently rotated in order to screw the cap gripped thereby onto a container. The required movement of the chuck device is accomplished by lowering the chuck or raising the container or by a combination of both methods.
[0010] U.S. Pat. No. 1,824,660 to Darner discloses a mechanism for capping bottles, particularly milk bottles. In an embodiment the mechanism is central fed with caps of the press-on type. The caps form a pile inside the mechanism. The mechanism also comprises spiral rods, which, when the mechanism is pressed down, rotates, and sharp edges of cams mounted at the lower end of said spiral rods, separates the lowermost cap from the caps in the rest of the pile. Comprised are also plungers that will press the bottle cap down into a neck of the bottle.
[0011] U.S. Pat. No. 1,233,469 to Heath discloses a machine for applying caps. In one embodiment caps are applied to receptacle mouths and the machine is spinning or curling the same thereon by means of a rotary cap spinning or curling device. The caps are arranged in a vertical stack or column feeding downwardly by gravity through a head of the machine and aligned with an axis of rotation of said spinning device.
[0012] U.S. Pat. No. 982,231 to Barry discloses a bottle capping machine of a manual lever-operated type, comprising a magazine tube, a receptacle holder and a capping device mounted on a carrier.
[0013] SU 1495,283 to Chulin et al discloses a screw-lid fitting device for jars comprising a lid receiver with folding flap at top of hollow chuck with lid stops round bottom. When the chuck comes down, upper arms of twin-arm levers disengage from endface of a cylinder. A spring pulls the lower arms of said levers towards each other, gripping the lid and unscrews/screws the lid as the chuck rotates.
[0014] An object of the present invention is to provide a capping mechanism capable of providing an increased capping rate compared to the prior art techniques. Furthermore, it is an object to provide a capping mechanism which can be used for various different sorts of containers and caps.
SUMMARY OF THE INVENTION
[0015] According to a first aspect, the objects according to the above are fulfilled by a capping mechanism, comprising an active feeder device having means for actively feeding caps forward arranged top-to-bottom along a feeding axis, and a chuck at an outlet end of the feeder, arranged to grip a cap and mount said cap to a container opening. Preferably, said means for actively feeding caps are devised to diametrically engage with a cap present in the feeder device, and to move the cap forward along the feeding axis during engagement.
[0016] In one embodiment, said feeder device comprises elongated feeder members movable in pairs relative to each other and arranged to alternately hold and release caps arranged between two members in a pair, thereby feeding said caps forward during a hold and move action of at least one pair of said members. Said chuck preferably has a central passage and comprises two or more adjustable chuck jaws arranged to hold the cap during a mounting act.
[0017] The feeder members preferably comprises two pairs of feeder jaws, each jaw of each said feeder jaw pair being moveable towards the other jaw, wherein one pair of jaws also is moveable in a direction parallel to the feeding axis.
[0018] According to a second aspect, the objects according to the above are fulfilled by a feeder device for a capping machine, which capping machine comprises a chuck arranged to grip a cap and mount said cap to a container opening, which feeder device comprises means for actively feeding caps forward arranged top-to-bottom along a feeding axis, to an outlet end proximal to the chuck. Preferably, said means for are actively feeding caps are devised to diametrically engage with a cap present in the feeder device, and to move the cap forward along the feeding axis during engagement. In one embodiment said feeder device comprises elongated feeder members movable in pairs relative to each other and arranged to alternately hold and release caps arranged between two members in a pair, thereby feeding said caps forward during a hold and move action of at least one pair of said members.
[0019] According to a third aspect, the objects according to the above are fulfilled by a method for feeding caps in a container capping machine, comprising the steps of:
supplying a cap to a feeder device; engaging the cap diametrically; feeding the cap, under engagement, along a feeding axis to an outlet position.
[0023] According to a fourth aspect, the objects according to the above are fulfilled by a capping mechanism, comprising an feeder device for feeding a cap forward, with a bottom of the cap facing a feeding axis, from an inlet position to an outlet position of said feeder device, and a chuck devised to receive a cap from a first side of said chuck at said outlet position, and to mount said cap to a container opening at a second side of said chuck, opposite said first side along said feeding axis, wherein said feeder device is devised to actively feed a cap to said outlet position.
[0024] Preferably, said feeder device comprises means for engaging about a first portion of a circumference of a cap present in the feeder device, and means for moving the cap forward along the feeding axis to said outlet position during engagement.
[0025] In one embodiment, said chuck comprises means for engaging about a second portion, different from said first portion, of said circumference when said cap is present in said outlet position.
[0026] Preferably, said first portion covers substantially diametrically opposing areas of the circumference of the cap.
[0027] In a preferred embodiment, said feeder device comprises first and second gripping jaws, devised to engage a cap in said inlet position by gripping substantially diametrically opposing areas of the circumference of the cap, and means for moving said gripping jaws along said feeding axis.
[0028] In one embodiment, cap supply means are devised to supply caps one by one to the inlet position of said feeder device. Said cap supply means are preferably devised to supply caps to the inlet position in a supply direction which has an angle to said feeding axis. In a more specific embodiment, said cap supply means are devised to supply caps to the inlet position in a supply direction which is substantially perpendicular to said feeding axis. Preferably, said cap supply means are devised to supply caps arranged side-by-side along said supply direction to the inlet position.
[0029] In a preferred embodiment, said feeder device comprises elongated feeder members movable in pairs relative to each other and arranged to alternately hold and release a cap arranged between two members in a pair, thereby feeding said cap forward during a hold and move action of at least one pair of said members.
[0030] More specifically, in such an embodiment said feeder members may be devised to grip and move two or more caps at a time, which caps are successively supplied to said inlet position and fed top-to-bottom by said feeder members to said outlet position.
[0031] According to a fifth aspect, the objects according to the above are fulfilled by a method for capping containers, comprising the steps of:
supplying a cap to an inlet position of a feeder device such that said cap is arranged with a bottom of the cap facing a feeding axis; gripping the cap by means of the feeder device engaging about a first portion of a circumference of the cap; feeding the cap, under engagement, along said feeding axis to an outlet position; receiving the cap from a first side of a chuck at said outlet position; gripping the cap by said chuck; and mounting the cap to a container opening at a second side of said chuck, opposite said first side along said feeding axis.
[0038] Preferably, said chuck grips said cap by engaging about a second portion, different from said first portion, of said circumference.
[0039] Furthermore, said first portion preferably covers substantially diametrically opposing areas of the circumference of the cap.
[0040] According to a sixth aspect, the objects according to the above are fulfilled by a method for feeding caps in a container capping machine, comprising the steps of:
supplying a first and a second cap to a feeder device, wherein said caps are arranged top to bottom; engaging the caps diametrically; feeding the caps, under engagement, along a feeding axis until the first cap reaches an outlet position; gripping the first cap in the outlet position with a chuck; removing the first cap from the outlet position by said chuck; and feeding the second cap, under engagement, along the feeding axis until it reaches the outlet position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0047] The present invention, including further features, aspects and advantages will become better understood from the following description with reference to the accompanying drawings, on which:
[0048] FIG. 1 shows a capping mechanism according to a first embodiment of the present invention;
[0049] FIG. 2 shows a detail of a feeder device of the mechanism in FIG. 1 , with one feeding jaw removed for enhanced clarity;
[0050] FIG. 3 shows the mechanism of FIG. 1 together with a container;
[0051] FIG. 4 shows the embodiment of FIG. 1 from the side; and
[0052] FIGS. 5-9 schematically illustrate a second embodiment of a capping mechanism according to the invention, and different method steps of a capping process according to this embodiment of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0053] FIGS. 1 to 4 illustrate a first embodiment of the present invention. Referring to FIG. 1 , caps 1 are supplied from above, oriented with the bottom (inside) facing left, side to side after each other, to an inlet opening 21 of a feeder device 20 . The caps 1 are placed in a feeder device 20 in an inlet position 21 . From this inlet position 21 caps are fed forward (left in the drawing) by the device 20 , in a piled arrangement in a pipeline kind of process. A piled arrangement is not necessarily a vertical pile, it means rather that the caps 1 are arranged top-to-bottom, i.e. the bottom of one cap faces the top of the preceding cap, according to the drawings. Furthermore, the caps are conveyed through the feeder with the bottom facing the direction of transportation. The feeder device 20 is also provided with an outlet end 22 . A feeder mechanism 23 - 26 is provided within the feeder device 20 , devised to actively feed caps from the inlet end 21 all the way to the outlet end 22 in a controllable pace. This feeder mechanism functions by actively gripping each cap present therein, preferably diametrically, and then displacing the cap by moving the gripping point towards the outlet end 22 . In one embodiment the feeding device comprises means for bringing caps forward with the help of a helical movement. This can be achieved by arranging two or more rotatable shafts parallel to the feeding axis 30 and spaced from each other such that they engage a cap present there between. The shafts can be provided with threads or the like, such that rotation of the shafts will result in the caps being forced forward in the feeding direction. In another embodiment the feeding may be provided by endless belts engaging diametrically opposite sides of a cap, and running in the feeding direction.
[0054] In the shown embodiment, however, said feeder device 20 comprises two pairs of members in the form of feeding jaws. A first pair 23 , 24 ( 24 not shown in FIG. 1 ) and a second pair 25 , 26 , respectively. In this embodiment, each pair of feeding jaws is arranged to grip caps present there between, preferably with a grip where said jaws make contact on diametrically opposite sides of caps. The first pair is also shiftable back and forward in the direction of a feeding axis 30 . The two pairs of feeding jaws are arranged approximately 90° in relation to each other around the feeding axis 30 . FIG. 4 illustrates, as seen from the inlet end 21 , the arrangement of the feeding jaws 23 - 26 about the feeding axis 30 . The feeding jaws grip and release by relative displacement towards and away from each other, respectively. Said jaws can grip and hold caps with the mere use of friction force, but preferably utilises a number of lugs 27 arranged for this purpose. The lugs are arranged at equidistant positions along the feeding device 20 , the distance between which is selected to fit the cap size in question. These lugs 27 will correct minor errors in alignment of the caps and prevent them from jamming the feeder device 20 .
[0055] The shown embodiment is devised to feed caps according to the following general principle:
The first pair of feeding jaws 23 , 24 grips the caps in the feeder including the one in the inlet position, while the second pair of feeding jaws 25 , 26 subsequently releases their grip around the caps in the feeder 20 ; The first pair of feeding jaws 23 , 24 moves forward, bringing the caps forward one positional step in the feeder along the feeder axis towards the outlet end 22 ; The second pair of feeding jaws 25 , 26 grips the caps in the feeder, and subsequently the first pairs of feeding jaws 23 , 24 releases its grip around the caps; The first pair of feeding jaws 23 , 24 is brought back along the feeding axis to enable said jaws 23 , 24 to stand by for gripping the caps and make the next cap in the inlet position 21 part of the piled arrangement of caps in said feeder.
[0060] A cap 10 that has reached the outlet end 22 is solely held by the second pair of feeding jaws 25 , 26 , and is still turned so that its bottom side preferably is facing outwards from the outlet end 22 . With bottom side is meant the side that is to be mounted to a container opening. FIG. 1 further illustrates how a chuck 40 is arranged at the output end 22 , and provided with a central passage for the caps. The chuck preferably comprises at least two chuck jaws 41 , 42 movable in a radial direction and said chuck jaws are so devised that they can grip the cap 10 at the same time as said cap is gripped by the second pair of feeding jaws 25 , 26 according to the drawing. The chuck 40 is furthermore devised to rotate, for the purpose of fixing it to a container opening. For this rotation the chuck is driven by a suitable transmission of a drive motor (not shown). FIG. 1 shows the feeder device 20 in a position subsequent to the last of the aforementioned steps. When the first pair 23 , 24 of feeding jaws is brought back, opposite the feeding direction, the chuck 40 is displaced in the same direction along the axis 30 , to a position radially outwardly of the cap 10 held by the second feeding pair 25 , 26 in the outlet end 22 . Once in the position outside the cap 10 , the chuck 40 grips the cap 10 by a relative inward displacement of the chuck jaws 41 , 42 towards the axis 30 , thereby assuming the position shown in FIG. 1 . When the chuck has gripped the cap 10 the second pair of feeding jaws 25 , 26 are moved outwardly releasing their grip around the cap. This step also forms a part of the feeding procedure described above. The drive motor mentioned above is preferably a servo drive motor capable of bringing the chuck 40 to an angular position that makes room for the second pair of feeding jaws 25 , 26 in the gaps between the chuck jaws 41 , 42 , when the chuck returns to fetch the next cap fed to the outlet end 22 .
[0061] FIG. 3 illustrates the mounting of a cap 10 to a container 50 , by means of the chuck 40 . The container 50 is arranged with an opening 51 in close proximity to, and in alignment with, the outlet end 22 and axis 30 . This is advantageous because the chuck 40 then only has to move the cap a minimum distance from the outlet end 22 towards the container opening 51 , clearing it from the outlet end position to which a new cap is fed. This distance is completely one-dimensional and aligned with the feeding axis 30 . The power for this linear motion may come from a linear motor, or from a suitable deflection of power from the rotation drive motor. The radial motion of the chuck jaws 41 , 42 can for example be produced by way of linear motors or pneumatics, in a manner well known to the skilled person.
[0062] The chuck 40 is brought into a position so that during the mounting of the cap, said chuck can rotate freely from the pair of feeding jaws 23 , 24 and 25 , 26 , at the same time as room has been left at the outlet end 22 at an outlet position in the second pair of feeding jaws 25 , 26 , for a new cap to be fed forward to the outlet end 22 . After a completed mounting the chuck is brought back to the position shown in FIG. 3 , and said chuck is able to repeat the described process for the next cap that has been brought into place ready to be fed to the chuck. A new container is in that connection preferably fed forward to the position shown in FIG. 3 .
[0063] FIGS. 5 to 9 illustrate a second embodiment of the present invention. In this embodiment, the feeder device is of a simpler design than in the previous drawings. In this embodiment, caps are supplied from above, oriented with the bottom (inside) facing left, side to side after each other, to an inlet position 121 of feeder device 120 . The caps are e.g. supplied from a chute (not shown). In FIG. 5 a first cap 101 is placed in the inlet position 121 . From this inlet position 121 , cap 101 is subsequently fed forward (left in the drawing) by the device 120 to a chuck 40 , with the bottom of said cap 101 facing the direction of transportation. A feeder mechanism 123 , 124 is provided within the feeder device 120 , devised to actively feed caps from the inlet position 21 to an outlet position 122 , at which outlet position said chuck grabs the cap. This feeder mechanism functions by actively gripping each cap present therein, preferably diametrically, and then displacing the cap by moving the gripping point towards the outlet position or end 122 . In the embodiment of FIGS. 5 to 9 , the feeder mechanism of said feeder device 120 comprises a pair of gripping members or jaws 123 , 124 . The pair of gripping members are arranged to grip a cap present there between on diametrically opposite sides of the cap. As is illustrated in FIG. 5 , a front end portion of each gripping member is devised with a shoulder-like gripping portion 125 facing the other gripping member. In the drawing, only the gripping portion 125 of the first gripping member 123 is clearly shown, but it should be noted that the second gripping member 124 has a corresponding structure facing gripping member 123 . Cooperating gripping portions 125 are devised support a cap placed in the inlet position 121 by means of the shoulders of the gripping members, such that the cap will not twist but rather assume a position with its bottom facing the feeding axis 30 . The gripping portions may optionally include further support structures, not only devised to support side and top portions of the cap, but also a front portion. For instance, the gripping portion 125 may include a recessed portion in the respective gripping member, providing shoulder edges both towards the top and bottom of a cap present between the gripping members. With such a solution, the gripping members must be capable of moving apart to an extent where the cap can be released forward along the feeding axis, when the cap has been fed to and gripped by the chuck, according to FIG. 8 described in more detail below. Alternatively, the capping mechanism may include a separate forward stopping member devised to prevent a cap supplied to the inlet position 121 to fall forward, which separate forward stopping member is withdrawn once the gripping members have engaged and gripped the cap.
[0064] FIG. 5 illustrates a starting position, in which the first cap 101 is positioned in the inlet position 121 . A cap stopping member is preferably arranged below the first cap 101 , if the device is oriented as illustrated, such that the first cap 101 rests towards said cap stopping member. The gripping jaws 123 , 124 are located at a distance or an angle from each other, such that the distance between gripping portions 125 is larger than the diameter of cap 101 . Preferably, the next cap 102 is does not rest on the first cap 101 , but is rather fixed in the illustrated position by cap locking means (not shown). The third cap 103 , and possibly further caps above the third, are rested one on the other, on the second cap 102 . The gripping jaws and the first cap 101 are placed behind chuck 40 .
[0065] FIG. 6 illustrates a second position, in which the gripping jaws have been placed in diametrical contact with the cap 101 . This is achieved either by displacing the gripping jaws towards each other, or by pivoting them, such that the gripping portions 125 are brought closer to each other.
[0066] FIG. 7 illustrates how the feeder device 120 has been displaced forward towards the chuck, such that the first cap 101 has been brought into an outlet position of the feeder device where it is to be handed over to the chuck. As indicated before, the second cap 102 is maintained in the previous position by cap locking means. As mentioned, the gripping jaws 123 , 124 of the feeder device 120 are diametrically arranged in relation to a cap positioned there between. Furthermore, as is also illustrated in the drawings, the gripping portions 125 of the gripping jaws each cover only a first portion of the circumference of the cap. The chuck, on the other hand, comprises at least two chuck jaws 41 , 42 which are displaceable in a radial direction from a centre feeding axis 30 , see FIG. 5 . These chuck jaws each cover a second portion of the circumference of the cap. The first and second portions of the circumference are complementary, and together they cover, at most, the entire circumference, though preferably less. Furthermore, when the capping mechanism is arranged in the position as shown in FIG. 7 , the chuck jaws are rotatably oriented such that the gripping jaws 123 , 124 and the chuck jaws 41 , 42 face different portions of the circumference of the cap. This way, both the gripping jaws 123 , 124 and the chuck jaws 41 , 42 are capable of gripping the cap, preferably perpendicularly in relation to each other.
[0067] FIG. 8 illustrates how the chuck jaws 41 , 42 have been displaced radially inwards, to grip the first cap 101 . Once the cap 101 has been gripped by the chuck jaws, the gripping jaws 123 , 124 of the feeder device 120 release their grip of the cap, and the gripping jaws are brought back to the position shown in FIG. 5 .
[0068] FIG. 9 illustrates application of the cap on a container opening (not shown). The cap 101 is applied by rotation of chuck 40 . At the same time, the chuck is preferably displaced forward towards the container opening at a rate corresponding to the pitch of cooperating threads on the inside of the cap and on the outside of the container opening, respectively, such that the container opening can be maintained in a substantially fixed position during application of the cap. In a preferred embodiment, rotation of chuck 40 also unlocks the cap locking means, such that the subsequent cap 102 enters the inlet position 121 . When the first cap 101 has been applied, chuck 40 returns the position of FIG. 6 , preferably by first releasing its grip of the first cap 101 , thereafter by rotating to the perpendicular orientation in relation to the gripping jaws 123 , 124 , and finally by a backwards linear translation. The capping mechanism is then returned to the state illustrated in FIG. 5 , and the process is thereafter preferably repeated, including the steps of removing the capped container opening and placing a new container opening in front of chuck 40 .
[0069] Several advantages are achieved with the present invention. It should be noted that many of the above actions performed by the participating parts can take place simultaneously, forming an efficient pipeline, or assembly-line way of operation of the capping mechanism, enabling a high capping pace. The feeding and the transport in the chuck of the cap take place in one and the same dimension, which results in a simple and thereby fail-safe process. Moreover, the displacement of the chuck 40 is very short, in the described embodiment basically not longer than the height of a cap or the pitch of the threaded portion of the cap, which enables an increased pace of capping compared to a solution in which the cap has to be picked up by the chuck and be transported sideways, compared to axis 30 , to the container opening 51 . The feature of feeding the caps top-to-bottom also enables, in most cases, a more compact design of the capping machine including the feeding device.
[0070] A technical effect of the present invention is that the feeding of caps does not rely on gravity. The supply of caps to the feeder device may rely on gravity, but may alternatively be achieved by actively supplying the caps by force to the feeder device. This means that the feeding apparatus, combined with a chuck, can be used for applying caps in any direction. It is well known that there are several types of containers which have side-mounted openings, e.g. the type illustrated in FIG. 3 , suitable for water closet cleaning fluids. This type of container cannot be capped by any of the aforementioned gravity-dependent solutions of the prior art. The use of gravity feeding further has the disadvantage that flat caps tend to jam in a feeding pipe if they are dropped top to bottom. Furthermore, some types of caps are conical, such that the top of one cap fits into the bottom of another cap. Both the weight of the caps and the fact that they are repeatedly dropped and halted, may cause them to engage and catch on to each other when arranged piled top to bottom.
[0071] In the shown embodiment, the cap is mounted by rotation into threaded engagement with the container opening 51 . However, it could of course also be advantageous to use the present invention on a push- or press-cap container design, suitable for a capping device where the chuck is arranged for example to push the capsule on to the container opening. A person skilled in the art also realises that the container on to which the cap is mounted is not necessarily a complete container, but alternatively only that part of the container on to which the container opening is formed, e.g. a bottle neck. The foregoing has described the principles, preferred embodiments and modes of operation of the present invention. However, the invention should not be construed as being limited to the particular embodiments discussed above. It should be appreciated that variations may be made in those embodiments by workers skilled in the art without departing from the scope of the present invention as defined by the following claims.
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A capping mechanism comprising an active feeder ( 20 ) device in which caps ( 1, 10 ) are fed actively forward arranged top-to-bottom along a feeding axis ( 30 ), and a hollow rotatable and linearly movable chuck device ( 40 ) arranged at the feeder's outlet end ( 22 ) and devised to grip a cap and mount said cap to a container opening. The feeder device preferably comprises movable members working in pairs (23, 24 and 25, 26 resp.) alternating to influence a row or pile of caps.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to PCT Patent Application PCT/US2008/055924, filed Mar. 5, 2008, which application is incorporated herein by reference, and claims the benefit of priority to U.S. Provisional Patent Application Ser. No. 60/893,182 filed Mar. 6, 2007, entitled Apparati and Methods for Electrokinetic Hydrogen Generation.
STATEMENT OF GOVERNMENTAL SUPPORT
This invention was made with US Government support under Contract DE-AC0205CH11231 awarded by the United States Department of Energy to The Regents of the University of California for the management and operation of the Lawrence Berkeley National Laboratory, and Contract No. CHE-0404571 between the National Science Foundation and The Regents of the University of California. The US Government has certain rights in this invention.
BACKGROUND OF THE INVENTION
1. Field of Invention
This invention relates to the utilization of electrokinetic phenomena to produce hydrogen gas and to generate electrical power. More particularly, the invention relates both a method and apparatus for the generation of hydrogen gases by flowing a liquid such as water through one or more metal orifices under hydrostatic pressure to thereby form charged liquid microjets, which jets upon collision with a target acting as a source of electrons results in the production of hydrogen gas. Also, via the microjet formation process, a streaming current is produced which may be converted into useable electric power.
2. Description of the Related Art
The renewability, high energy conversion efficiency and non-polluting chemistry of hydrogen-based energy sources have long been known. However, a principal obstacle to implementing a widespread so-called hydrogen economy has been the high costs required for hydrogen production. There are many known methods for producing hydrogen. These methods can be classified into technologies such as biological, chemical, electrochemical and thermal. Each of these known methods is commercially restricted by cost, production rate limitations, or a combination of both.
Currently, commercial supplies of hydrogen are provided by steam reformation of natural gas or coal gasification. These are both thermal processes and are the cheapest methods available. However, these processes consume fossil fuel, and the quantities of hydrogen produced using these processes are not sufficient to initiate and sustain a widespread hydrogen economy. Electrochemical production of hydrogen is another known alternative that is quite advanced, but is a very expensive process.
The combination of declining petroleum reserves and increasing release of carbon, especially carbon dioxide, into the atmosphere necessitates serious efforts to develop renewable and non-polluting chemistry energy economies such as a hydrogen economy. However, there must be cost effective processes available and developed to produce sufficient quantities of hydrogen gas that is needed.
A substantial potential source of hydrogen is water, since it is widely available and an inexpensive commodity. Each water molecule is made of two hydrogen atoms and one oxygen atom. The challenge is that of efficiently separating the hydrogen atoms from the oxygen atoms at low cost and collecting the hydrogen atoms, or molecules formed from them.
Electrokinetic effects refer to electrical effects caused by the relative motion between a liquid, such as water, and a surface. It is well known that electrokinetic charge separation can be effected in a flowing liquid where some of the constituents of the liquid dissociate, forming positive and negative ions. Several researchers have recently explored this phenomenon as a vehicle for electric power development.
For example, in Canadian Patent 24367304, Apparatus and Method for Producing Electrical Energy from Fluid Energy, Kostiuk, et al describe a device which includes one or more electrically non-conductive fluid channels made, for example, from glass. Electrically conductive terminals closely positioned at each end of the channels so as to be in direct communication when fluid is within the channel(s) are electrically connected one to the other. When a fluid such as water is passed through the channel, electrical energy is produced. Noted as a product of the process was the ancillary formation of oxygen gas at one of the terminals and hydrogen gas at the other. Though suggesting one could recover H 2 or O 2 as desired, nothing is mentioned in the patent concerning the gas generating efficiency of the disclosed process. Additionally, in a related article, the principal researchers reported power generation efficiencies of less than 1% (Electrokinetic Power Generation by Means of Streaming Potentials: a Mobile-Ion-Drain Method to Increase the Streaming Potentials, J. Yang, F. Lu, L. W. Kostiuk and D. Y. Kwok, Journal of Nanoscience and Nanotechnology” Vol. 5, 648-652, 2005).
Heyden and Dekker et al. also explored this phenomenon as reported in Streaming Currents in a Single Nanofluidic Channel , Heyden, and Dekker, Physical Review Letters, PRL 95, 116104 (2005). Therein, the generation of electric current by flowing a pressure driven salt solution (such as KCl) through a rectangular silica nano-channel was described. In later articles Electrokinetic Energy Conversion Efficiency in Nanofluidic Channels , Heyden, Stein, and Dekker, Nano Letters, 2006, Vol. 6, No. 10, 2232-2237, and Power Generation by Pressure - Driven Transport of Ions in Nanofluidic Channels , Heyden, Stein, Meyer and Dekker, Nano Letters 2007, Vol. 7, No. 4, 1022-1025, efficiencies with a single, rectangular nanofluidic channel of up to 12% were estimated, but only about 3.2% realized using different salt solutions. In none of the Dekker articles is the generation of hydrogen gas reported.
What thus still remains is the need for an efficient electrokinetic apparatus and method for co-generating hydrogen gas, while at the same time generating larger streaming currents which may be converted into useful electrical energy.
SUMMARY OF THE INVENTION
By way of this invention a novel approach is taken to the generation of hydrogen gas, which method can also serve as a method for the generation of electrical power. By the co-generation methods and the apparatus of the invention, higher efficiencies have been achieved over those obtained in the prior art.
The methods of this invention exploit the electrokinetic charge separation phenomenon. The requisite apparatus is very simple and involves no moving parts. The input energy is a hydrostatic pressure source, and the hydrogen is produced by potential-driven reduction of water enriched in protons. Proton enriched water is obtained via the electrical charge separation effected by rapid flow of liquid water through a metal orifice. The electrokinetic charge separation process also generates electrical currents, which can be harnessed for, among other things, further electrochemical water splitting, and/or power generation.
It is believed that near the metal-water interface, selective adsorption of one type of charge carrier (hydroxide, in the case of pure water) to the metal nozzle surface creates a potential. At the shear plane, a short distance into the liquid, this potential is referred to as the zeta potential. To maintain charge neutrality, counter ions (hydrated protons in pure water) generate a diffuse layer of charge near the liquid-solid interface. The rapid flow of water through the metal nozzle sweeps away the diffuse, mobile layer, such that the emerging liquid water jet is positively charged via the unbalanced proton concentration.
In one embodiment, the diameter of the metal orifice can be on the order of about 5-20 micrometers (μm), more or less. The dimension of the orifice in the direction of fluid flow (i.e. aperture thickness) is generally between about 0.1 and 1.0 mm, but can be more. Due to the relatively short length of the orifice channel, aperture thickness is insufficient to develop either completely turbulent or laminar flow. Consequently, entrance effects dominate, engendering a “top hat” velocity profile. Thus, the fluid velocity at the water-metal interface is zero, with a laminar sub-layer near the wall. The fluid velocity increases linearly across this laminar sub layer until it reaches bulk fluid velocity.
The flow of fluid through the orifice produces an electrically charged liquid water microjet. Hydrogen may be generated when the positively charged liquid microjet strikes a downstream grounded metal target. Also produced is a streaming current.
The apparatus for the co-production of hydrogen and electric power comprises a fluid source, or reservoir, means for applying a hydrostatic pressure to the fluid source, means for transport of said fluid source to an electrically isolated microjet nozzle, wherein liquid is forced through a small (microscale) orifice under pressure to form a liquid microjet, which microjet breaks up into a droplet stream, and a downstream target spaced from said microjet nozzle a distance sufficient to insure that at the time of arrival, the liquid microjet has broken up into discreet droplets. In one embodiment, a collector vessel is provided to capture hydrogen gas produced at said target. In another embodiment the electrically isolated nozzle is electrically connected to the target, whereby when fluid flows through the apparatus, a current is generated. In one embodiment, the apparatus includes but a single microjet nozzle. In another embodiment the apparatus includes multiple microjet nozzles. In yet another embodiment, a plurality of multi jet apparati can be combined to scale up the hydrogen gas/electrical power co-generation capabilities of the system.
The method of this invention for producing hydrogen more broadly includes the steps of: a) providing a source liquid containing hydrogen cations; b) providing a velocity to the source liquid relative to a solid material to form a charged liquid stream, the solid material forming a liquid-solid interface; and c) supplying electrons to the charged liquid stream by contacting the charged liquid with an electron source to thereby form hydrogen gas.
The liquid-solid interface may in one embodiment comprise one or more metals from the group comprising platinum, and iridium, or alloys of these metals. Both metals are known to produce high zeta potentials when tested with water. Other metals, or metal alloys, such as molybdenum, copper, silver, gold, iron, aluminum, nickel, and the like, may be used. Due to the cost of platinum and iridium, these may be used as thin coatings on cheaper bulk materials, such as aluminum or steel. In the water environment, stainless steel can be a preferred bulk material, with the costly platinum or iridium vapor deposited or electroplated for contact with a stream of water, or other fluid, to cause charge separation.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the above-recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to various embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIGS. 1A and 1B illustrate preferential charge carrier adsorption to a surface, FIG. 1B also illustrating fluid flowing relative to such surface, with arrow height indicating positional velocity. The approximate position of the plane of shear is marked with a dashed line. FIG. 1C illustrates the flow of fluid through a nozzle opening.
FIG. 2A illustrates an overall system according to this invention for the electrokinetic generation of hydrogen. FIG. 2B is a rotated detail of the microjet nozzle of FIG. 2A .
FIGS. 3A , 3 B, and 3 C illustrate a portion of the system according to the instant invention for the electrokinetic generation of hydrogen by the flowing of a fluid through one or more microjet orifices.
FIGS. 4A and 4B illustrate systems according to the instant invention that use the process of electrokinetic generation of hydrogen to additionally generate usable electrical power.
FIG. 5 is an enlarged illustration of an apparatus similar to that of FIG. 4B according to the instant invention useful for the generation of electrical power.
FIGS. 6A and 6B are plots of experimental results illustrating the effect of nozzle size and jet velocity on current generation as well as power production and energy conversion efficiency.
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the invention are described herein in the context of several apparati and methods for electrokinetic hydrogen generation. Those of ordinary skill in the art will realize that the following detailed descriptions of the invention are illustrative only and are not intended to be in any way limiting. Other embodiments of the invention will readily suggest themselves to such skilled persons having the benefit of this disclosure. Reference will now be made in detail to implementations of the invention as illustrated in the accompanying drawings. The same reference indicators will be used throughout the drawings and the following detailed descriptions to refer to the same or like parts.
In the interest of clarity, not all of the routine features of the implementations described herein are shown and described. It will, of course, be appreciated that in the development of any such actual implementation, numerous implementation-specific decisions must be made in order to achieve the developer's specific goals, such as compliance with application and business-related constraints, and that these specific goals will vary from one implementation to another and from one developer to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking of engineering for those of ordinary skill in the art having the benefit of this disclosure.
Hydrogen Generation
Referring now to FIG. 1A , illustrated is a schematic of a fluid 120 interacting with a solid 100 , with the solid 100 partially shown. In FIG. 1B , fluid 120 flows over the solid 100 at the liquid-solid interface 130 . As illustrated, fluid flow is shown unconstrained. However, where solid 100 represents the one wall of an orifice 140 , the flow will be symmetrical through the orifice as illustrated in FIG. 1 C, the flow being of zero velocity at the liquid-solid interface 130 , increasing from zero velocity to the maximum fluid velocity towards the center of flow.
Referring now to FIG. 2A , a complete system for the electrokinetic generation of hydrogen is illustrated. Here, pressurized fluid 120 is directed through capillary tube/conduit 135 to the input side of nozzle 140 . Charged liquid spray stream 210 is generated as the fluid passes through and exits the nozzle. This charged liquid stream 210 contains hydrated protons of the chemical structure H + (H 2 O)n, also referred to as hydronium, the stream breaking up into a droplet spray downstream from the nozzle. Target 220 receives a flow of electrons 230 to neutralize charged liquid droplet stream 210 , evolving hydrogen gas in the process. The electron source may be either a battery, an electrical connection to the liquid-metal interface of the nozzle, or ground.
The hydrogen is collected as it diffuses to a collection system 250 , where it may be stored in storage container 260 , which in one embodiment may include a hydrogen sorbent material 270 . Alternatively, and not shown, the hydrogen gas may be pumped into a pressurized storage container.
The liquid from conduit 135 passes through orifice 145 of nozzle 140 (which may be electrically grounded), the electrically charged liquid microjet stream 210 emerging at speeds (depending upon pressure) of from 1 m/s to about 500 m/s (with speeds of about 100 meters per second (m/s) or thereabouts typical of the jet streams generated in the experimental work). The liquid microjet 210 enters a containment chamber (not shown) which may be maintained at above, below, or at atmospheric pressure, the pressure in the chamber not being particularly critical to the operation of the system.
Charging of the liquid microjet may be optimized by proper selection of orifice diameter, shape (such as circular, oval, rectangular or slit like), and jet channel length. The orifice may have a diameter of between 0.5 μm to 100 μm and in one embodiment is between 5-20 μm. The channel length may be between 0.1 mm-1.00 mm, though it can be as much as 5 mm, or more. Technically there is no real limit to how thick the channel may be. Suitable hydrostatic pressures for the microjets utilized herein range from >0 MPa and 500 MPa<, and more preferably range between 1 MPa and 50 MPa. By adjusting the pressure at which the flowing liquid contacts the orifice, both liquid jet charging and the liquid jet output length may be changed.
Further detail is illustrated in FIG. 3A for a single orifice apparatus 300 for electrokinetic hydrogen generation and electrical power generation. Here, an orifice plate 140 is provided with a single orifice 145 , where the orifice surface 130 may be coated with platinum, iridium, or other high zeta potential material. The pressurized fluid stream 120 may be passively or actively pressurized, such as by the hydrostatic head of an elevated fluid reservoir (relative to the nozzle), or a pump. If the fluid is water and the solid is a metal, the partially dissociated charged liquid steam 210 will contain hydrated protons H + (H 2 0)n. An electron source (not shown) supplies electrons to the hydrated protons H + (H 2 0)n to evolve hydrogen according to the reduction reaction: 2H 3 O + +2e − →2H 2 O+H 2 . At the nozzle, oxygen is also generated by the oxidation of hydroxyl radicals according to the reaction: 2OH − →½O 2 +H 2 O+2e − .
Referring now to FIG. 3B , an example of an orifice plate 150 is illustrated, which plate may be interchangeable with plate 140 , plate 150 comprising a plurality of individual orifices 155 , each orifice of similar design to the single orifice 145 of plate 140 . Orifice plate 150 may also be formed from a mesh, or a grid structure, the critical requirement being that a charged liquid is produced after passage through the orifice. As illustrated in FIGS. 2A and 2B , the nozzle may be dish shaped (available commercially), or comprise a small borehole drilled through or otherwise formed in a disk of the type illustrated in FIG. 3 . Attached to the end of conduit 135 , in the case of the dish shaped nozzle, the dished face may be positioned either facing upstream, as shown in FIG. 2A , or downstream as shown in FIG. 2B , the orientation not of particular criticality.
The liquid, directed from conduit 135 A to the plurality of orifices 155 of metal plate 150 creates multiple liquid microjets 210 . By way of an illustrative embodiment, where the liquid is pressurized to about 4 MPa or greater, the microjet stream as it emerges from the nozzle will have a velocity of about 50 meters per second (m/s), more or less. Though FIG. 3B depicts a simple plurality of microjet orifices, the number of orifices is not intended to be limiting, such that nozzles having a far greater numbers of orifices may be used herein, and multiple bundles of such multi orifice nozzles may be employed in the construction of a hydrogen/current generation device according to this invention, such that the total number of orifices in a given system may approach 10 6 or more.
As shown in FIGS. 3A and 3C , the orifice plate may be bolted via plate 160 to or otherwise fastened to conduit 135 , and can be electrically isolated by interposition of a non-conductive material such as a Teflon washer, etc. The conduit itself can be of any internal diameter (two such possible variations illustrated as items 135 A and 135 B in FIGS. 3A and 3C ), so long as it has sufficient capacity to allow for an adequate flow of fluid, and should present a suitable mounting surface for securing the nozzle plate.
The plate used for the nozzles may be made of any metal or a combination of metals with high electrokinetic potential (or zeta potential) for water, such as platinum and iridium, or a combination of these two metals. Such materials yield high values for a set of electric potentials that accompany relative motion between the solid and liquids.
The magnitude of the zeta potential is important for determining the degree of electrical charging of the microjets. In general, any contact between two materials with different chemical potentials (i.e. work functions) will produce charge transfer from one to the other until equilibrium is reached and the chemical potentials become equal. Exemplary metals, in addition to platinum or iridium, which can be used for the nozzle, or at least to form the inside wall of the nozzle include molybdenum, copper, silver, gold, iron, aluminum, and nickel, as well as possibly silicon and germanium.
The electrically charged liquid jet output(s) 210 enter a chamber (not shown) where hydrogen production is effected by interaction of the charged microjet(s) with the metal target electrode 220 , which target is held at electrical ground, or in contact with the nozzle or other electron source, wherein production may be optimized by, among other things, utilizing the proper orifice diameters and liquid jet channel lengths. The target 220 is formed from copper in one embodiment, but may be formed from other conductors such as molybdenum, silver, gold, iron, aluminum, nickel, platinum, iridium, etc, and possibly such semiconductors as silicon and germanium.
The target is positioned a distance from the exit of the nozzle sufficient such that the jet stream brakes up into a discontinuous stream, that is, into discrete droplets before impinging upon the target. In the case of hydrogen generation, where in one embodiment the process was run in vacuum, the target was placed about a meter from the microjet orifice. In the experiment described below in connection with electrical power generation, the target was positioned about 5 cm from the microjet orifice. It has been observed that the jet stream begins to break up soon after it leaves the nozzle, and most commonly breaks up within about 1-5 cm from the nozzle exit. Thus, in the case of power generation, the target can be positioned but a few to ten centimeters from the nozzle. Generally, the target can be positioned at any distance beyond which the jet stream becomes discontinuous; although the closer the target is placed to the jet nozzle, the smaller the overall size of the device.
The target electrode at which hydrogen gas is produced can be provided with a liquid trap to collect excess liquids. Once the liquid exits orifice 145 , the trap may collect any water and/or condensable electrokinetic produced products. The trap may be a cryotrap, such as a liquid nitrogen trap.
Typically, the microjet assembly can be contained within a housing, not shown, which is used to contain the liquid flow as it reaches and then moves off the target. The vessel 250 for collecting the hydrogen gas is contained within the housing, the housing itself maintained at a pressure of from anywhere between >0 Torr and 1500 Torr, with the pressure preferably maintained within the more narrow range of 0.1 Torr and 760 Torr. Notably, for electrical power generation, the pressure within the housing in one embodiment can be maintained at one atmosphere.
The orientation of the microjet assembly is likewise not critical. That is, it may be set up in a horizontal alignment, such as illustrated in FIGS. 2 , and 5 , or in a vertical alignment, with the microjet nozzle above, and the target positioned a distance below, as illustrated in FIGS. 4A and 4B . In experimental work conducted so far, the microjet assembly has been set up in both alignments. Notably, when positioned vertically, no significant defection of the jet stream was observed, even when the target was positioned a meter away (for a system at vacuum). In atmospheric pressure experiments for power generation, when the target was placed several centimeters distant, the spray neither significantly deflected nor dissipated as a mist before striking the target.
Electrical Power Generation
As previously noted, the method and apparatus of this invention concurrently produces a streaming current which may be converted into useful electrical energy, Various arrangements for harvesting this energy are shown in FIGS. 4A , 4 B, and FIG. 5 . In FIG. 4A , with the nozzle 140 deployed vertically, face down, the presence of a current I s generated at the nozzle is measured by ammeter 410 , the nozzle being connected to ground through the ammeter. The current generated at target 220 , connected to ground via variable resistor 415 is designated as I L , and likewise can be measured using a similar ammeter.
When there is no added resistance in the target circuit, the current measured at the target is always equal in magnitude and opposite in sign to the current at the nozzle. That is, when R L =0, I s =I L . For a given aperture and flow rate, the nozzle current or the current at the target at zero resistance represents the maximum amount of charge available for energy conversion. As the resistance between the target and the electrical ground increases, the target current decreases and the voltage at the target increases.
FIG. 4B shows another circuit arrangement whereby nozzle 140 is electrically connected via wire 420 to target 220 through load resistor 430 , the nozzle serving as a source of target electrons. Also illustrated is the dissipation path in terms of a system resistance, R sys , and current, I sys . Here, I L and R L are the current and resistance through the load resistor used to calculate conversion power and efficiency, while I sys and R sys are the current and resistance associated with system losses, represented in FIG. 4B as another resistor in parallel with the load resistor. To maintain charge neutrality, the system current I sys and load current, I L , must sum to the nozzle current, I L +I sys =I s .
Using the apparatus of FIG. 4A , a series of experiments were conducted to determine what factors most affect power generation efficiencies. The components are labeled with the same numbering conventions as used in FIGS. 1 and 3 . Results are shown in FIGS. 6A and 6B .
Liquid water microjets were created by pressurizing water behind a thin metal orifice. The jet orifice was a Pt-Ir electron microscope aperture (Ted Pella Inc.) pressed between two stainless steel plates. Clean water (18.2 M Ohm cm, Millipore Milli-Q filtered) was nitrogen-purged and vacuum degassed prior to being pressurized and forced through the aperture with a Jasco PU-2089 HPLC (High Performance Liquid Chromatography) pump. Jet velocity was controlled by changing the volumetric flow rate at the pump.
Streaming currents were measured at both the jet nozzle and the downstream (approximately 5 cm) copper plate that served as the jet target. At the nozzle, the current I s was fed into a Keithley 428 current amplifier and the resulting signals recorded by a computer. Current at the target I L was recorded in the same manner, with the addition of a variable resistor 415 , R L (0-200 G ohms) before the amplifier. Both the nozzle and target were insulated from all other electrical contacts with protective Teflon sheets. For efficiency calculations, the backing pressure and volumetric flow rate from the pump were also recorded as the resistance was stepped from 0 to 200 Gohms in steps of 10 Gohms. The process was repeated at a variety of flow rates and for three different aperture diameters, the orifice thickness being held constant. After a series of measurements, the apertures were sized using a light microscope and a calibration curve created from measuring capillary tubing of known internal diameter. The apertures used in the experiments measured 4±1 μm, 7±1 μm, and 14±1 μm, with the uncertainty matching the diameter tolerances from the manufacture. FIG. 6A plots the streaming current data measured at the nozzle for each aperture size.
Demonstrated is a clear increase in magnitude of the streaming current as a function of jet nozzle orifice diameter. This increase is proportional to the increase in the metal-water interfacial surface area, i.e. aperture circumference as all the apertures are of the same thickness. The solid lines in FIG. 6A are the best fits of the data to the below developed equation, predictive of streaming current [the derivation of this equation discussed in the referenced draft prepublication paper cited at Paragraph 0057]:
I s = - 2 π R ɛ v _ ζ δ x
where ν is the average fluid velocity, δx is a measure of the laminar sublayer thickness (δx=116·R·R e (−7/8) ), ε is the permittivity of the medium times the permittivity of free space, and ζ is the potential at the shear plane. R e is the Reynolds number frequently used in fluid mechanics.
FIG. 6B plots both peak power and efficiency for the three jet diameters measured. Generally, the power production increased with aperture size and the highest power was realized with the 14 μm diameter jet. However, the greatest efficiency was realized with the 7 μm diameter jet and was lower for the other apertures. Interestingly, despite the fact that the peak values were found at a different velocities and load resistances, peak power shows a direct increase with jet diameter (R 2 =0.9999). Thus, it appears the maximum power obtainable for an aperture is directly related to the metal-water interfacial surface area. However, increases in channel diameter necessitate increases in flow rate that scale with the open aperture area (area∝diameter 2 ). Consequently, the larger diameter apertures require inordinately larger flow rates to maintain the same velocity. This leads to a decrease in efficiency, as a larger fraction of the hydrodynamic driving power is “wasted”. Accordingly, peak efficiency increases with peak power when going from the 4 μm jet to the 7 μm jet, but decreases upon moving to the 14 μm jet.
For the limited number of jet diameters measured, a maximum efficiency of 10.7% was obtained for the 7 μm diameter. However, the power at the target represents only half of the available energy. The metal nozzle yields a current that is always equal in magnitude and opposite in sign to the current at the downstream target. Thus, the efficiency can be doubled to over 21% by utilizing both the upstream and downstream currents. In addition, further increases in efficiency may be realized by maximizing surface area at the expense of cross sectional area, i.e. by using rectangular jets. Moreover, the liquid jet retains considerable kinetic energy with jet velocities at ˜30 to 400 m/s. This kinetic energy could be converted to electricity using a small scale but conventional turbine generator.
Finally, to increase output the liquid source can be fed to a number of microjet bundles which can be directed to one or more targets. The number of microjet bundles which can be combined into a single generating apparatus is limited primarily by size constraints in the case of systems intended for portability. Otherwise, there is no theoretical limit to the number of microjets or microjet channel bundles that can be combined to produce hydrogen and electric power.
Notwithstanding calculations predicting efficiencies as high as 12%-15% [van der Heyden, F. H. J.; Bonthuis, D. J.; Stein, D.; Meyer, C.; Dekker, C. Nano Letters 2006, 6, 2232-2237; Daiguji, H.; Yang, P. D.; Szeri, A. J.; Majumdar, A. Nano Letters 2004, 4, 2315-2321; and Min, J. Y.; Hasselbrink, E. F.; Kim, S. J. Sensors and Actuators B - Chemical 2004, 98, 368-377] experiments by van der Heyden, et. al. have thus far only achieved efficiencies of but 3.2% for a single nano-channel [van der Heyden, F. H. J.; Bonthuis, D. J.; Stein, D.; Meyer, C.; Dekker, C. Nano Letters 2007, 7, 1022-10250], and Yang et al [Yang, J.; Lu, F. Z.; Kostiuk, L. W.; Kwok, D. Y. Journal of Nanoscience and Nanotechnology 2005, 5, 648-652] achieved efficiencies of only 0.80% for a porous glass plug.
Without intending to be bound by the following theory, it is believed that back conduction of charge through the bulk liquid and along the surface existing in the reported approaches of the above cited prior art provide additional routes for dissipating of charges with an attendant reduction in conversion efficiency. Electrokinetic power generation using the liquid water microjets of this invention overcomes this by eliminating surface and bulk back-conduction via creation of a jet of water that breaks up into a discontinuous droplet spay before reaching the receiving reservoir, thereby terminating such undesired paths for loss of charge. Under these conditions, accumulated charge can only dissipate through the load resistor and efficiency is dramatically increased. In addition, the thin metal jet orifice creates flow conditions wherein it is believed entrance effects dominate and, consequently, the streaming current increases nearly quadratically with flow rate.
INCORPORATION BY REFERENCE
The papers entitled Electrokinetic Hydrogen Generation from Liquid Water Microjets , Duffin and Saykally, Journal Phys. Chem. C 2007, 111, 12031-12037 (Jul. 20, 2007), and the prepublication draft of the paper entitled Electrokinetic Power Generation from Liquid Water Microjets , Duffin and Saykally, 10 pages, [now published in J. Phys. Chem. C 2008, 112, 17018-17020] are attached hereto and are incorporated herein by reference as if fully set out in their entirety
It is to be appreciated that various modifications and additions to the invention as described may be made without departing from the spirit thereof. For example, the materials of the nozzle and the target could be changed such that hydrogen is generated at the nozzle and oxygen at the target. By way of a second example, should the housing be maintained at a vacuum, the target could be equipped with a heater so as to prevent the formation of ice during system operation. Still further, the diameter of the nozzle openings is not critical and in one embodiment could be nano-sized, that is, well less than one micron in diameter, thus producing a liquid nanojet.
While embodiments and applications of this invention have been shown and described, it would be apparent to those skilled in the art having the benefit of this disclosure that many more modifications than mentioned above are possible without departing from the inventive concepts herein. The invention, therefore, is not to be restricted except in the spirit of the appended claims.
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A method and apparatus for producing both a gas and electrical power from a flowing liquid, the method comprising: a) providing a source liquid containing ions that when neutralized form a gas; b) providing a velocity to the source liquid relative to a solid material to form a charged liquid microjet, which subsequently breaks up into a droplet spay, the solid material forming a liquid-solid interface; and c) supplying electrons to the charged liquid by contacting a spray stream of the charged liquid with an electron source. In one embodiment, where the liquid is water, hydrogen gas is formed and a streaming current is generated.
The apparatus comprises a source of pressurized liquid, a microjet nozzle, a conduit for delivering said liquid to said microjet nozzle, and a conductive metal target sufficiently spaced from said nozzle such that the jet stream produced by said microjet is discontinuous at said target. In one arrangement, with the metal nozzle and target electrically connected to ground, both hydrogen gas and a streaming current are generated at the target as it is impinged by the streaming, liquid spray microjet.
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BACKGROUND
[0001] Technologies associated with the communication of information have evolved rapidly over the last several decades. Television, cellular telephony, the Internet and musical electronics (such as CD players and MP3 devices), to name a few, combine to inundate consumers with available information and entertainment options. These electronic devices typically operate within a particular environment, e.g., the home of a user, however, they often function independently of one another. For example, a user will typically individually configure consumer electronic devices to enable them to perform various functions in the particular manner desired by the user.
[0002] The technological ability to provide so much information and content to end users provides both opportunities and challenges to those wishing to control media content accessibility. For example, parents may wish to restrict their children from being able to access media having certain content or from being able to access certain services altogether. Similarly, educators may wish to restrict access by students to media. As technology advances it can be expected that there will be more consumer electronic devices for delivering media to people, which further complicates this issue. For each device that is capable of displaying media, the user must manually set the device with the desired parental controls if the device supports such an ability. For example, a user may set a DVD player to not play R rated media and also set a CD player to not play media with explicit lyrics. Furthermore, if the content control is title specific, then the user must individually tell each device capable of playing the title, that it should not be played. For example, a parent may not want a particular movie to be shown and must program each movie playback device to indicate this restriction.
[0003] Another common method for allowing a parent to control content exposure in a television is through the use of a so called “V-chip”. Some televisions come with “V-chip” circuitry in the unit, which allows a parent to program what content is allowable to be viewed on that television. Content could be characterized either by the rating of the show, for example, G, PG-13 or R, or the content could be characterized by a description, such as, sexual content or violence. The “V-chip” then acts as a filter for incoming television content by comparing the content characterization of the incoming program to the rules programmed into the “V-chip”, and either passing or blocking the signal based on the results of the comparison.
[0004] Yet another specific area of concern for media control, is the content available from surfing the Internet. Currently a variety of programs can be purchased that allow a parent to set up controls for blocking content or access to a variety of web sites.
[0005] Given the increasing number of media delivery devices and the increasing amount of available content, control of access to content is becoming a difficult chore. Therefore, there is a need for a universal content control method that allows a single device or system to control the content output from all consumer electronic devices in the user's environment.
SUMMARY
[0006] Systems and methods according to exemplary embodiments address this need and others by providing techniques for universal content control to control the content output from all (or a subset of) consumer electronic devices in the user's environment.
[0007] According to one exemplary embodiment, a universal content control device for controlling media content access comprising an input for receiving input associated with media content access rules, a processor for associating media content access rules with different types of consumer electronic devices based on the capabilities of consumer electronic devices and an output for transmitting associated media content and access instructions to different types of consumer electronic devices for controlling content access at the consumer electronic devices.
[0008] According to another exemplary embodiment, a method for distributing media content access rules comprising the steps of receiving input associated with media content access rules, associating media content access rules with different types of consumer electronic devices based on the capabilities of consumer electronic devices and transmitting associated media content and access instructions to different types of consumer electronic devices for controlling content access at the consumer electronic devices.
[0009] According to another exemplary embodiment, a system for distributing media content access rules includes a universal content control device for receiving input associated with the media content access rules, a plurality of consumer electronic devices, wherein the consumer electronic devices interact with media based on media content access instructions received from the universal content control device, and communication links connecting the universal content control device to the plurality of consumer electronic devices, wherein the universal content control device further includes an input for receiving input associated with the media content access rules, a processor for associating said media content access rules with different types of consumer electronic devices based on the capabilities of the consumer electronic devices, and an output for transmitting the associated media content and access instructions to the plurality of consumer electronic devices for controlling content access at the consumer electronic devices.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The accompanying drawings illustrate exemplary embodiments of the present invention, wherein:
[0011] FIG. 1 illustrates an exemplary environment with multiple consumer electronic devices in which exemplary embodiments can be employed;
[0012] FIG. 2 illustrates an exemplary environment with a universal content control device according to exemplary embodiments;
[0013] FIG. 3 shows details of a universal content control device according to exemplary embodiments;
[0014] FIG. 4 shows an interface screen for a universal content control device according to exemplary embodiments;
[0015] FIG. 5 is a flowchart describing a method for distributing media content access rules according to exemplary embodiments;
[0016] FIG. 6 is a flowchart describing the processing of content rules by a universal content control device according to exemplary embodiments.
DETAILED DESCRIPTION
[0017] The following detailed description refers to the accompanying drawings. The same reference numbers in different drawings identify the same or similar elements. Also, the following detailed description does not limit the invention. Instead, the scope of the invention is defined by the appended claims.
[0018] In order to provide some context for this description, an exemplary environment in which exemplary embodiments can be employed will now be described with respect to FIG. 1 . FIG. 1 shows an environment 100 , such as a household or a classroom, within which there are a multitude of consumer electronic devices, such as cable box 102 , TV 1 104 , DVD player 1 106 , computer 108 , cell phone 110 , TV 2 112 , DVD player 2 114 , video game console 116 , radio/CD player 118 , phone 120 hooked up to the publicly switched telephone network (PSTN) 122 . In this environment, some of the consumer electronic devices are capable of communicating with each other, such as TV 2 112 and DVD player 2 114 , while other devices are stand alone, such as cell phone 110 . Additionally, each of these consumer electronic devices has the capability to receive external media inputs as well as commands. For example, the computer 108 can interface with the Internet (not shown) and cable box 102 receives data from the cable head-end via coax cable. According to exemplary embodiments, all of these devices (or any desired subset) may be universally programmed with controls to selectively permit or block various content.
[0019] To simplify the discussion, an exemplary home environment 200 with only two consumer electronic devices that are universally programmed with parental controls will now be described with respect to FIG. 2 . It should be appreciated, however, that the invention is not limited to implementation in a home or control by a parent. Rather, the environment of communication devices may include any environment over which control is needed, such as a classroom, prison, corporation, etc., and the control may be provided by any party seeking to control access to content by the communication devices. According to the exemplary embodiment shown in FIG. 2 , a universal control device, referred to for illustrative purposes as a universal control device 202 , contains content and access rules regarding how consumer electronic devices interact with external media. External media in this context refers to any media that can be accessed by the user of a consumer electronic device. For example, TV programs, DVD's and internet content, among other things, would all be considered external media for purposes of this specification. Note that the universal control device 202 may be physically located in the network or within the home, e.g., as part of the computer 216 or home router (not shown).
[0020] Initially, a parent can enter content and access rules from parental controls input device 204 , and communicate these rules via communication link 206 to the universal control device 202 . Parental controls input device 204 can take many different forms, an example of which is given below with respect to FIG. 4 . After various processing and/or formatting of the input, described below, universal control device 202 then communicates the relevant content and access rules to both TV 208 and computer 216 via communication links 210 and 218 , respectively. In this way, when user 1 212 or user 2 214 activate either TV 208 or computer 216 media displayed or heard will be permitted as long as the media meets the content and access rules. The parent need not individually program each device with the parental controls. It is understood that while this exemplary embodiment only illustrates an environment with two consumer electronic devices in the household environment 200 , that there could be up to n different consumer electronic devices each linked to the universal control device 202 . Additionally access rules could describe how much time per day a user was allowed to use either a single device, or all of the devices together, or any subset thereof.
[0021] According to one exemplary embodiment a single common content and access rule list (or set of characteristics) is input into the universal control device 202 . This content and access rule list is then processed using logic within the universal control device 202 to create specific instructions for each relevant consumer electronic device in the household environment 202 . These specific instructions may be generated by selection and formatting within the universal control device 202 and are then passed on to the relevant consumer electronic device(s). For example, suppose that parental input is received by the universal control device 202 that states no R rated content is to be output from those devices associated with this parental control input or device list (described below). The universal control device 202 would then send more specific instructions to TV 208 , using a format and a communication link which are compatible with TV 208 , that would not allow any media that has a content rating of R or higher to be displayed or heard. The universal control device 202 would also send more specific instructions to computer 216 that would not allow any media that has a content rating of R or higher to be displayed or heard nor allow access to internet sites with content considered R equivalent or higher.
[0022] An exemplary universal content control device, such as the universal control device 202 is shown in FIG. 3 and contains a processor 302 , memory 304 and a transmit/receive function 306 , all of which are linked together. The universal control device 202 may reside locally with respect to a single set of consumer electronic devices or may reside at a network center. The processor 302 and memory 304 are used to process and store content and access rules, as well as instructions regarding how these rules are to be implemented. Input to the universal control device 202 is received from the parental controls input 204 . The parental controls input 204 can also be part of the universal control device 202 . The communication links 206 , 210 and 218 can be any type of wire or wireless connection used for transmitting information.
[0023] As mentioned earlier, the universal control device 202 takes the inputs from parental control input device 204 and applies selection and formatting processes to generate a set of content and access control commands for that particular user's set of consumer electronic devices. For example, according to one exemplary embodiment of the present invention, the parental control input device 204 can be a web portal accessible via the parent's home computer. The web portal may provide a user interface screen such as that shown in FIG. 4 . Therein, a first list of devices which have been registered with the universal control device 202 for a particular parent (User A) are shown on the lefthand side of the screen, while a high level list of rules are shown on the righthand side of the screen. The user can select which devices to include in list # 1 via the checkboxes on the righthand side of the screen. For example, if the user is a parent of a teenager that has access to TV 1 , Computer A and car radio 1 , but not cellphone A or TV 2 , then he or she could check the boxes next to TV 1 , Computer A and car radio 1 such that rules list # 1 could be tailored to control the content which would be output by devices available to that child, without applying the same rule set to other devices. Similarly, the user can select (or deselect) rules which are applicable to this list of devices using the checkboxes on the lefthand side of the screen. Each user can have multiple device lists associated with their parental control account to enable them to control groups of devices within their environment in different ways. For additional flexibility this exemplary system could also be setup to allow controls to be input or overridden from an external communication device like a cell phone if the user had the right level of access.
[0024] According to another exemplary embodiment, the universal control device 202 can have settings that allow a device to be shared by multiple users wherein the controls for the shared device are set in accordance to the parent's rules. For example, if there are two non-parental users in the household, both users will have rules associated with them in addition to rules for the devices. This would allow, for example, a teenage child and 5 year old to share the same device with the device set to the content control rules of the person actually using the device. To manage this feature, each user can be given a login/password so that the appropriate rules set is applied to the person actually using a device.
[0025] Given this input information, the universal control device 202 can use selection techniques programmed into processor 302 and/or memory 304 to implement the selected rules list across those relevant devices in list # 1 . For example, if the parent selected no instant messaging as a rule for this device list, then the universal control device 202 would generate suitable specific instructions only to those devices in the list which have instant messaging capability, e.g., computer A and/or cellphone A, but not to those devices on the list which do not have instant messaging capability, e.g., TV 1 . This feature of exemplary embodiments saves the user time by allowing universal controls to be implemented across devices having overlapping, but not identical, capabilities and corresponding parental controls. A list of exemplary parental controls/rules which can be provided as selectable options in the user interface of FIG. 4 is provided below, but is by no means exhaustive. Some examples of exemplary parental controls are as follows: no R content, no extreme violence, no instant messaging, no explicit lyrics and no sexual content.
[0026] According to exemplary embodiments as illustrated in FIG. 5 , a method for distributing media access rules includes a number of different steps including: receiving input associated with media content access rules by a universal content control device, such as a parental control device (step 500 ); connecting the universal content control device to a plurality of consumer electronic devices with communication links (step 502 ); and interacting with media based on media content and access instructions received from the universal content control device by a plurality of consumer electronic devices (step 504 ). Again, although the steps shown in FIG. 5 refer to interactions with a parental control device, it should be appreciated that they are also applicable to any type of content control devices.
[0027] According to an exemplary embodiment the steps performed by an exemplary universal content control device are shown in the flowchart of FIG. 6 . Initially, the universal content control device receives rules for content control (step 602 ). These rules then undergo a selection and formatting process (step 604 ) is applied, e.g., based on the type(s) of consumer electronic devices to be controlled by this particular universal content control device. The output from the selection and formatting process is a set of instructions (step 606 ) for all consumer electronic devices in communication with the universal content control device. These instructions are grouped together by device (step 608 ), which may result in different consumer electronic devices receiving a different number of instructions, e.g., when certain rules do not apply to certain types of consumer electronic devices. Then the instructions are transmitted by the content control device to the consumer electronic devices (step 610 ) using, e.g., an appropriate format and communication link.
[0028] According to another exemplary embodiment the user accesses a device in, for example, the household environment through either a unique identification number or an electronic card. The system would then only allow access and content according to rules that correspond to that user. These rules would be predetermined in the content control unit. Alternatively, the rules could be embedded on the electronic card.
[0029] The above-described exemplary embodiments are intended to be illustrative in all respects, rather than restrictive, of the present invention. Thus the present invention is capable of many variations in detailed implementation that can be derived from the description contained herein by a person skilled in the art. All such variations and modifications are considered to be within the scope and spirit of the present invention as defined by the following claims. No element, act, or instruction used in the description of the present application should be construed as critical or essential to the invention unless explicitly described as such. Also, as used herein, the article “a” is intended to include one or more items.
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Systems and methods according to the present invention address this need and others by providing methods of controlling media content access through a universal control device that is linked to a plurality of consumer electronic devices in a common environment.
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CROSS-REFERENCE TO RELATED APPLICATIONS
Not Applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to roadway soundwalls and sound reducing modules for use in such soundwalls. The invention also relates to methods for constructing such soundwalls. In other aspects, the invention relates to systems and methods for reducing noise along a highway or roadway.
2. Description of the Related Art
Soundwalls are used alongside highways and other roadways to separate the roadway from residential subdivisions or communities. They serve to screen off the highway from view and provide a safety barrier between the community and the highway. Their primary purpose, however, is to significantly reduce traffic noise from the roadway within the community.
A typical roadway soundwall is from 8 to 18 feet in height and runs continuously alongside a selected section of roadway. Currently, soundwalls are constructed of wood, concrete or masonry block. Examples of such soundwalls are found in U.S. Pat. Nos. 5,713,170 and 5,537,788, both entitled "System and Method for Widening a Highway and Supporting a Sound Wall," and issued to Elmore et al. Soundwalls of this type are suitably sturdy and effective in reducing highway noise. However, they require a great deal of expensive material to construct. Further, when concrete or masonry block are used, the material is essentially a single use material and, upon destruction of the soundwall, the material cannot be recycled. It was estimated in 1995 that over 183 km (114 miles) of noise barriers or soundwalls have been constructed at a total cost of $141,000,000. R. Armstrong, "Highway Traffic Noise Barrier Construction Trends," The Wall Journal, v. 5, no. 27, pp. 6-9 (1996). In addition, soundwalls constructed of concrete, masonry block or another hard and massive material present a danger to vehicles which might leave the roadway and impact the soundwall.
Since the early 1990's, there have been attempts to incorporate greater amounts of recycled or recyclable materials into soundwall construction. These attempts have been largely unsuccessful and have not provided a soundwall with the features and advantages of the present invention. Several years ago, the Oregon Department of Transportation constructed a soundwall which used metal I-beam support columns. A number of lengths of unreinforced "boards" formed from recycled plastic were then stacked horizontally in between the support columns with the ends of the plastic boards resting within the recesses of the I-beams. A wall formed from a single layer of plastic resulted. The soundwall was tested to determine its durability to weathering. During this testing, significant warping of the boards occurred.
Recently, Carsonite International, Inc., a corporation based at 1301 Hot Springs Road, Carson City, Nev. 89706 constructed a composite soundwall which also incorporated recycled plastic. This soundwall employed steel support I-beam-type columns. Horizontally stacked between the support columns were lengths of composite members made up of recycled plastics covered with sheet metal shells.
It is noted that transparent acoustical panels are known that employ a single 1/4" thick sheet of transparent polycarbonate, such as LEXAN®. Examples of such panels are described in U.S. Pat. No. 4,214,411 issued to Pickett. Panels of this nature are useful as a window or panel element within a concrete noise barrier, or within a rapid transit sound barrier canopy, or incorporation into other small barriers. However, these panels alone do not have the structural strength necessary to be used to form a larger soundwall.
SUMMARY OF THE INVENTION
The present invention describes a soundwall and components which incorporate a significant amount of plastic materials while still retaining the strength, durability and resiliency necessary for the soundwall to resist wind loads and weathering. An exemplary soundwall is described that is composed of prefabricated sound reducing modules affixed to and anchored by support posts which are themselves constructed from a significant amount of plastics. The modules used in this exemplary wall are formed from an internal support frame which, in a preferred embodiment, is constructed from reinforced plastic lumber members. The support frame is covered by an outer sheath which, in alternative described embodiments, may be formed from reinforced plastic sheets or plastic lumber members.
A soundwall is then created by slidingly inserting the modules between the support members which are preplaced into the ground at a desired location along a roadway. The modules are affixed to the support members so that the support members are hidden from view by the modules, thus presenting an aesthetically pleasing, unbroken appearance. If desired, the soundwall modules may be textured or etched with selected designs.
Methods are also described for fabricating the individual modules, support frame and support members.
Soundwalls constructed in accordance with the present invention result in an unexpectedly great reduction in sound. The high plastic content of the soundwalls and their components permits greater amounts of recycled plastics rather than other materials to be used, thus providing environmental benefits as well.
Thus, the present invention comprises a combination of features and advantages which enable it to overcome various problems of prior devices. The various characteristics described above, as well as other features, will be readily apparent to those skilled in the art upon reading the following detailed description of the preferred embodiments of the invention, and by referring to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more detailed description of the preferred embodiment of the present invention, reference will now be made to the accompanying drawings, wherein:
FIG. 1 depicts an exemplary soundwall constructed in accordance with the present invention.
FIGS. 2A and 2B depict alternative exemplary sound reducing modules used in constructing the soundwall of FIG. 1.
FIG. 3 illustrates a supporting frame which may be used in the sound reducing modules shown in FIGS. 2A and 2B.
FIGS. 4A and 4B are cross-sectional views of alternative support members used in the soundwall of FIG. 1.
FIG. 5 is a detail cross-section showing the manner of affixing a pair of sound reducing modules to a support member.
FIG. 6 depicts aspects of constructing a portion of a soundwall.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 1, an exemplary soundwall 10 is shown which is constructed in accordance with the present invention. The soundwall 10 is typically placed alongside a roadway (not shown), most often a highway, so that the soundwall is interposed between the highway and a residential community or other area where it is desired to reduce the amount of noise generated from traffic on the roadway. The considerations involved in placement of a soundwall are well known and will, therefore, not be described here.
The soundwall 10 is made up of a number of modules 12, 14, 16, 18 and 20 and a number of vertically oriented longitudinal support members 22, 24 which serve essentially as posts to stand on either side of each module. The support members preferably have a square or rectangular cross-section, as is shown in FIGS. 4A and 4B.
Module 12 is shown as being shorter than modules 14, 16, 18 and 20 which assists in illustrating the placement of support post 24. It should be understood that there are support members similar to support members 22 and 24 which are not visible in FIG. 1. These support members are disposed between modules 14 and 16, 16 and 18, and 18 and 20.
As constructed, soundwall 10 presents a relatively smooth, unbroken surface to casual inspection. Seams 26 are shown to distinguish the edges of the modules. Support members which are located between modules, such as support member 24, will be essentially hidden from such viewing by the modules in a manner which will be described in further detail shortly.
The soundwall 10 is preferably of a height that is between 8 and 18 feet. It should be understood, however, that the soundwall and modules of the invention are not limited to any particular height or other dimensions.
The soundwall 10 rests upon the ground 28 in a selected location. The support members 22, 24 and others are disposed in the ground 28 and buried to a suitable depth. It is currently preferred that support members have at least 1/3 of their total length buried below ground. Thus, a support member having a total length of 18 feet would be buried so that 12 feet of length are disposed above ground and 6 feet of length are disposed underground. Preferably, concrete is placed around the support member to assist in firmly securing it.
Referring now to FIG. 2A, one preferred embodiment of a sound reducing module 30 is illustrated. The sound reducing module 30 is of the type used as modules 12, 14, 16, 18 and 20 in FIG. 1. The sound reducing module 30 is generally rectangular in shape and includes an internal structural support frame 32 (only partly visible in FIG. 2A) which will be described in further detail shortly. An opaque front side outer sheath or covering 34 is disposed over the front side of the frame 32. Also, an opaque rear side outer sheath or covering 36 is disposed over the rear side of the frame 32. The sheaths 34 and 36 are each comprised of a sheet of plastic. A suitable and currently preferred reinforced plastic sheet for this application is a sheet composed of high-density polyethylene (HDPE) with a small percentage of ultraviolet light inhibitors. It is preferred, but not necessary that the plastic content be mostly, or even all, recycled plastics.
FIG. 2B depicts an alternative sound reducing module which is designated as 30'. This module also has an internal support frame 32' and front and rear side outer sheaths 34' and 36'. Each of the sheaths 34' and 36', however, are formed of plastic lumber members 38 rather than a sheet. The lumber members 38 are also formed of a high-density polyethylene plastic. Alternatively, the lumber members 38 may be formed from a fiberglass-reinforced plastic having the formulation described below for use in forming the alternative support member 60'.
It is noted that each of the modules 30, 30' are constructed so that the outer sheaths 34, 36, 34', 36' are wider than the support frame 32, 32' so that a protruding flange 40 is formed. The protruding flange 40 protrudes from the frame so that the amount of the protrusion approximates just slightly less than half the width of the support member, such as support member 24, which will stand alongside the module when installed in the soundwall 10. In a currently preferred embodiment, the amount of protrusion is approximately 4.5". A longitudinal channel 41 is formed between the two protruding flanges 40. Use of the protruding flange 40 to encase the support members 22, 24 is depicted in FIG. 1 and will be described further with respect to FIG. 5.
Referring now to FIG. 3, an exemplary support frame 32 is depicted without outer sheaths 34, 36. The frame 32 is basically constructed of lengths of fiberglass-reinforced plastic lumber which are affixed to one another by suitable connectors such as nails or screws 42. Lengths of such reinforced plastic lumber are available from Enviro Specialty Products, Inc., P.O. Box 2714, Gulf Shores, Ala. 36547. Preferred nominal dimensions for the plastic lumber are 2"×9". The exemplary frame 32 is made up of upper and lower end caps 44, 46 and three vertically disposed studs 48. Supporting cross pieces 50 are affixed between the studs 48 for added strength. Voids 52 are formed between the structural members 44, 46, 48 and 50. Screws, ring-shank nails or other suitable connectors (not shown) are used to affix the front and rear outer sheaths 34, 36 or 34', 36' to the support frame 32. When the sheaths are affixed in this manner, the voids 52 become enclosed compartments.
It is believed that the enclosed compartments function to increase sound reduction by increasing the reflectivity coefficient of the soundwall. Reflectivity, one of the components of sound loss, is a measure of the intensity of the sound waves that are reflected in a direction opposite to their original direction of travel. It is surmised that the use of a pair of enclosing sheaths, such as 34 and 36, increases the reflectivity coefficient.
FIGS. 4A and 4B depict in cross-section, alternative embodiments for the support members, such as support members 22, 24 shown in FIG. 1. According to FIG. 4A, exemplary support member 60 is composed of a body 62 of a plastic, such as HDPE with four sections 64 of #8 reinforcing steel ("rebar") disposed along the length of the body 62. FIG. 4B shows alternative support member 60' which has a body 62' that is made up of a fiberglass-reinforced HDPE plastic. A preferred formulation for the fiberglass-reinforced plastic is approximately 805 HDPE and 205 loose fiberglass.
FIG. 5 shows a cutaway to view (along lines 5--5 in FIG. 1) of a portion of the soundwall 10. Specifically depicted is the support member 24 and the edges of modules 12 and 14. Spacing and dimensions in FIG. 5 are exaggerated for ease of illustration of the relationship of the components to one another. As shown, the support member 24 is received within the longitudinal channel 41 of each module 12, 14. The flanges 40 from each of the modules 12, 14 overlap and partially cover the support member 24 from view, resulting in a seam 26 which is relatively small. It may be possible to form a perfect complimentary fit between the support member 24 and the longitudinal channel 41. However, for ease of installation, small gaps are acceptable and even desirable. When assembled in this manner, then, the seam 26 becomes essentially invisible to casual inspection and the support member 24 is essentially hidden from view. As a result, the soundwall 10 presents an essentially continuous, unbroken surface.
A single connector 66 is shown which is used to affix the flanges 40 of the modules 12, 14 to the support member 24. It should be understood that multiple connectors 66 should actually be used to secure each flange 40 to the support member 24. Suitable connectors include screws and ring-shank nails. Bolts with nuts may also be used as connectors, but these are less aesthetically pleasing. The support members are enclosed by the wall panels to improve the aesthetics of the wall.
A soundwall which is constructed as described is significantly safer than soundwalls constructed from a massive material such as concrete or masonry brick. There are no massive or non-yielding surfaces present, as is the case for example with a concrete or masonry, which would cause a vehicle to be stopped cold, resulting in lethal deceleration to the vehicle occupants.
Sound tests conducted with a prototype soundwall have demonstrated that an unexpectedly great amount of sound reduction results from soundwalls and sound reducing modules constructed in accordance with the present invention. In a test conducted with the prototype wall constructed at the Riverside Campus, sound insertion loss was predicted by the Federal Highway Administration's STAMINA (Standard Method in Noise Analysis) computer program for sounds generated on one side of the prototype wall and detected by a sound meter on the other side of the wall. The insertion loss is a measurement of the sound reaching a sound meter regardless of whether the sound passes through, over, or around the wall. The STAMINA program estimated the insertion loss to be 12.2 dBA. Actual measured insertion loss, however, proved to be 17.1 dBA--an unexpectedly greater amount. It is suspected that the presence of the compartments formed by the enclosed voids 52 of the module's frame 32 are at least part of the reason for the unexpected benefit.
Construction of a soundwall, such as soundwall 10, is preferably accomplished as follows. A desired location, or site, for the soundwall is identified, and the site is then prepared by removal of trees, plants, debris, or other objects. If necessary, the site may be leveled. It is preferred that a concrete base be placed for the soundwall to be seated upon. Next, the locations for holes for the support members are identified and marked, and these holes are then excavated. The locations for the holes are based upon the width of the modules to be used in constructing the soundwall. Support members are then placed within the holes and secured in a vertical orientation. If concrete is used, the concrete is allowed to cure. Accurate measurement of the distance between the holes and support members is important.
Prefabricated sound reducing modules are then delivered to the site. As FIG. 6 illustrates a crane or other suitable lifting device 100 is used to slidingly insert the modules (such as module 12 in FIG. 6) between the support members (such as support members 22 and 24 in FIG. 6) so that the support members are essentially covered by the protruding flanges 40 of the modules. In order to slidingly insert a module between two support members, the module is lifted so that the lower end of the modules is at a height above the upper ends of the support members. The longitudinal channels 41 of the module are then aligned with the support members. The module is lowered so that the support members are slidingly disposed into the channels 41. Connectors 66 are then used to secure the flanges to the support members.
If desired, with the exception of a modest number of connectors and reinforcing members, the soundwall 10 can be made up entirely of recycled plastics. Also, if desired, designs may be etched, engraved, stamped or otherwise placed on the surface of the modules.
While preferred embodiments of this invention have been shown and described, modifications thereof can be made by one skilled in the art without departing from the spirit or teaching of this invention. The embodiments described herein are exemplary only and are not limiting. Many variations and modifications of the system and apparatus are possible and are within the scope of the invention. Accordingly, the scope of protection is not limited to the embodiments described herein, but is only limited by the claims which follow, the scope of which shall include all equivalents of the subject matter of the claims.
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A soundwall and components are described that incorporate a significant amount of plastic materials while still retaining the strength, durability and resiliency necessary for the soundwall to resist wind loads and weathering. An exemplary soundwall is described that is composed of prefabricated sound reducing modules anchored by support posts which are themselves constructed from a significant amount of plastics. The modules used in this exemplary wall are formed from an internal support frame which, in a preferred embodiment, is constructed from reinforced plastic lumber members. The support frame is covered by an outer sheath which, in alternative described embodiments, may be formed from reinforced plastic sheets or plastic lumber members. Methods are also described for fabricating the individual modules, support frame and support members as well as the soundwall itself. Soundwalls constructed in accordance with the present invention result in an unexpectedly great reduction in sound. The high plastic content of the soundwalls and their components permits greater amounts of recycled plastics rather than other materials to be used, thus providing environmental benefits as well.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims benefit of U.S. Provisional Patent Application Ser. No. 60/441,884, filed Jan. 22, 2003, which application is herein incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to automated downhole tools that are remotely movable between a primary and a secondary position. Particularly, the invention relates to computer control of automated downhole tools using an interactive computer touch-screen to facilitate use of a control system that operates the tools. More particularly, the invention relates to a means of monitoring the operation of the downhole tools using computer software to compare variables to known standards.
2. Description of the Related Art
In oil and gas wells, hydrocarbons are collected from at least one wellbore formed in the earth by drilling. In some cases, the wellbore is lined with steel pipe called casing or liner that is perforated at a given location to permit the inflow of hydrocarbons. In other instances, the wellbores are left unlined or “open” to facilitate the collection of hydrocarbons along a relatively long length of the wellbore. When hydrocarbons are collected at different locations within the well, it is useful to control the inflow of the fluid between the different points along the wellbore in order to take advantage of changing wellbore conditions. For example, inflow devices with adjustable sleeves can be placed at different, isolated locations in a tubular string. The sleeves in these devices have apertures formed therethrough that can be placed in or out of alignment with mating apertures in the body of the tool. By adjusting the relative position of the apertures, the sleeves can permit a varying amount of fluid to pass into a production stream for collection at the surface. The ability to control inflow is especially important along a wellbore where the make up of the incoming fluid can change over time. For example, if an unacceptable amount of water begins flowing into production tubing at a certain location, an inflow device at that location can be partially or completely closed, thereby preventing the water from entering the production stream.
Some prior art inflow devices require the sleeves to be set at the surface of the well based upon a prediction about the wellbore conditions. After run-in, changing the position of the devices requires them to be completely removed from the well along with the string of tubulars upon which they are installed. More recently, the inflow devices have been made to operate remotely using hydraulic fluid transported in a control line or some electrical means to shift them between positions. In the most advanced applications known as “Intelligent Completions”, the devices are computer controlled, permitting them to be operated according to a computer program.
A typical computer-controlled apparatus for the operation of downhole inflow devices includes a keyboard that is connected to a computer; solenoid-controlled valves that open to permit control fluid to travel down to the device in the wellbore; a pump; a source of control fluid; and at least two fluid lines traveling downhole to a fluid powered controller that determines which of the more than one hydraulic/mechanical inflow device is supplied with the control fluid. Typically, the controller includes some type of keyable member that can align or misalign fluid ports connected to the devices therebelow. Each such device has at least one fluid line extending from the fluid controller, but may require a multiplicity of fluid lines. The fluid lines provide fluid to the device and a path for return fluid back to the surface. In one arrangement, the computer at the surface provides a source of fluid at a relatively low pressure that can shift an internal valve mechanism in the controller in order to set up a particular alignment of ports to supply control fluid to the proper downhole device. Once the fluid controller is properly arranged, control fluid is provided at a second, higher pressure to the particular device in order to move a shiftable sleeve from its initial position to a second position. In this manner, each device can be operated and separate control lines for each device need not extend back to the surface.
While the computers have made the devices much more useful in wells, there are some realities with computer equipment at well locations that make their use difficult and prone to error. For example, personnel at a well are not typically trained to operate computer keyboards and even the most straightforward commands must be entered with the keyboard, posing opportunities for error. Even the use of a computer mouse requires precise movements that are difficult in a drilling or production environment. Additionally, environmental conditions at a well include heat, dirt, and grime that can foul computer equipment like a keyboard and shorten its life in a location where replacement parts and computer technicians are scarce.
Another issue related to computer-controlled equipment is confirming that the orders given to a downhole device via computer have actually been carried out. For example, in computer-controlled systems, a command is given for a downhole tool to move from one position to another. Ultimately, the software command is transmitted into some mechanical movement within the tool. While there might be a computer-generated confirmation that the command has been given, there is no real way of immediately knowing that the prescribed physical action has taken place. In some instances, movement within a tool is confirmed by monitoring the well production to determine if the flow has been affected by the closing of an inflow device. This type of confirmation however, is time consuming and uncertain.
There is a need therefore for a computer control system that is easier to use when operating automated downhole tools in a wellbore. There is a further need for an apparatus and method of quickly and easily ensuring the automated computer commands to downhole equipment have been carried out.
SUMMARY OF THE INVENTION
The present invention generally includes a computer-controlled apparatus for use in wellbore completions. A touch-screen is provided that facilitates commands and information that is entered by an operator ordering movement of a downhole tool. In another embodiment, real-time information about the status of the downhole tools is transmitted to the apparatus based upon operating variables within the system, like pressure, flow rate, total flow, and time.
In another aspect, the present invention provides a method of operating one or more downhole devices in a wellbore. The method includes disposing the one or more devices in the wellbore, the one or more devices having at least an open and a closed position. Also, a signal is provided to the one or more devices to move the one or more devices between the open and the closed position. Preferably, the signal is computer generated based upon an operator's interaction with a touch screen.
In another aspect, the present invention provides a method of monitoring operation of a downhole tool. The method includes providing a signal to the downhole tool, whereby the signal causes the tool to move between an initial and a second position. Additionally, the method includes monitoring variables within a fluid power system to confirm the position of the downhole tool, the variables including at least one of pressure, time, total flow, or flow rate.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIG. 1 is a section view of a wellbore showing some components making up an intelligent completion apparatus.
FIGS. 2-7 are touch screens representing various steps in the operation of the control apparatus of the present invention.
FIG. 8 is another embodiment of a touch screen for operating a control apparatus.
FIGS. 9-11 are touch screens showing the status of the controller.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention relates to automated downhole equipment and its control using a touch-screen at the surface of the well to input commands and information. The invention further relates to a quick, simple and reliable means to ensure that computer generated commands to operate downhole tools are successfully carried out.
FIGS. 2-7 referred to in this application illustrate a touch-screen. A basic touch-screen system is made up of three components: a touch sensor, controller, and software driver. The sensor is a clear panel, which when touched, registers a voltage change that is sent to the controller. The controller processes this signal and passes the touch event data to the PC through a bus interface, be it a bus-card, serial, USB, infrared, or wireless. The software driver takes this data and translates the touch events into mouse events.
Resistive LCD touch screen monitors, such as the ones intended by the inventors, rely on a touch overlay, which is composed of a flexible top layer and a rigid bottom layer separated by insulating dots, attached to a touch-screen controller. The inside surface of each of the two layers is coated with a transparent metal oxide coating (ITO) that facilitates a gradient across each layer when voltage is applied. Pressing the flexible top sheet creates electrical contact between the resistive layers, producing a switch closing in the circuit. The control electronics alternate voltage between the layers and pass the resulting X and Y touch coordinates to the touch-screen controller. The touch-screen controller data is then passed on to the computer operating system for processing.
Resistive touch-screen technology possesses many advantages over other alternative touch-screen technologies (acoustic wave, capacitive, Near Field Imaging, infrared). Highly durable, resistive touch-screens are less susceptible to contaminants that easily infect acoustic wave touch-screens. In addition, resistive touch-screens are less sensitive to the effects of severe scratches that would incapacitate capacitive touch-screens. For industrial applications like well production, resistive touch-screens are more cost-effective solutions than near field imaging touch-screens. Because of its versatility and cost-effectiveness, resistive touch-screen technology is the touch technology of choice for many markets and applications.
FIG. 1 is a partial section view of a wellbore 5 showing the components that might be typically used with the present invention. The components (described from the upper wellbore to the lower end thereof) include hydraulic control lines 11 that carry fluid to and from components. A production packer 15 seals an annular area 20 between production tubing 25 and the wall of casing 30 therearound. Below the production packer 15 is the downhole controller 100 referred to as a “hydraulically controlled addressing unit” that is used to control one of various downhole, inflow devices 110 , 120 , 130 . Below the controller 100 and above a zonal isolation packer 115 , is an inflow device 110 referred to in FIG. 1 as a remotely operated sliding sleeve (ROSS). The sleeve 110 is of the type described herein with a sliding member that determines the inflow of fluid into the production tubing 25 . In this embodiment, two additional inflow devices 120 , 130 are disposed in the wellbore 5 . Each of the sleeves 110 , 120 , 130 is located in its own isolated section of the wellbore 5 , and each includes a set of sleeve control cables 111 , 121 , 131 extending back upwards to the controller 100 . Casing perforations 70 are shown that form a fluid path from the formation around the wellbore 5 into the inflow devices 110 , 120 , 130 . It is understood that the inflow devices 110 , 120 , 130 may also be operated to regulate the outflow of fluids from the production tubing 25 .
In the preferred embodiment, the controller 100 is adapted to control all of the inflow devices 110 , 120 , 130 . As shown, the controller 100 is designed to control all three inflow devices. Particularly, information or instructions from the touch screen may initially be transmitted to the controller 100 . In turn, the information or instruction causes an actuating member in the controller 100 to move relative to a park position. As will be discussed below, the actuating member will position itself such that the control lines 11 will align with the sleeve control lines of the selected inflow sleeve 110 , 120 , 130 for operation thereof. According to aspects of the present invention, the control cables 111 , 121 , 131 of the inflow devices 110 , 120 , 130 need only connect to the controller 100 , which is also located in the wellbore 5 . In this respect, it is not necessary to run control lines for each inflow device all the way to the surface, thereby reducing the number of control lines to the surface. In addition to hydraulic control lines, the inventors also contemplate using electric lines, fiber optics, cable, wireless, mechanical or other means known to a person of ordinary skill in the art to communicate or transmit information or instruction between the touch screen, controller 100 , and the inflow devices 110 , 120 , 130 . For example, after election is made on the touch screen, a fiber optics signal may be transmitted to the controller 100 via a fiber optics cable.
FIG. 2 shows the touch-screen 200 that is located at the surface of the well and is used to control the position of the inflow devices 110 , 120 , 130 as well as to monitor operating characteristics and input information. As shown in FIG. 2 , the touch-screen 200 includes an icon 210 , 220 , 230 representing each downhole device 110 , 120 , 130 that is controlled from the surface. In the example of FIG. 2 , there are three downhole inflow devices, each having an adjustable sliding sleeve that is manipulatable from the surface of the well via commands given at the touch-screen 200 . The devices 110 , 120 , 130 are labeled “ROSS 1,” “ROSS 2,” and “ROSS 3,” respectively. In FIG. 2 , the touch screen system is in “stand-by mode” waiting for instructions. Additionally, the status of the inflow devices is “closed.”
In operation, an operator may initially touch a decision screen, e.g., FIG. 2 , to indicate a desire to operate the inflow devices. For example, the operator may touch the icon 210 for the first device (“ROSS 1”) 110 to indicate a desire to send a command to the first device 110 . In another embodiment, the screen 200 could be operated through a wireless remote device utilizing an infrared light source or any other means well known in the art to send commands to a receiver located at a computer.
After the initial selection, another screen 300 , shown in FIG. 3 , prompts the operator to confirm his decision to operate the first inflow device 110 . To confirm, the operator may touch the screen 300 where indicated.
After a response is received, the touch screen 400 , as shown in FIG. 4 , will illustrate the corresponding operation of the fluid controller 100 to align the control lines 11 to the sleeve control lines 111 of the first inflow device 110 . In this respect, a pump at the surface provides a first, low pressure to rotate the actuating member of the controller 110 . In this manner, the actuating member is rotated to align the control line 11 with the sleeve control lines 111 , thereby placing the fluid ports of the pump in fluid communication with the inflow device 110 . As indicated on the screen 400 , the “Selected HCAU Operation” is to “Open ROSS 1” 110 . Additionally, the screen 400 also indicates that the “Current HCAU State” is “Operating Secondary,” which refers to moving the actuating member of the controller 100 into position to align the control line 11 with the sleeve control line 111 . Operational variables shown on this information screen 400 include outlet flow rate 405 in cc/sec, return flow rate 410 , time elapsed during the operation 415 , and fluid pressure 420 . As will be discussed later, the successful alignment of the ports to the inflow device 110 is assured based upon changing conditions in the fluid control system. For example, pressure increases and flow rate decreases in the outlet flow line when the movable member in the controller 100 has moved to its proper position and stopped.
After the control line 11 is aligned with the sleeve control line 111 , the system is ready to open the first inflow device 110 . However, the next screen 500 , shown in FIG. 5 , asks the operator to confirm his desire to operate the first inflow device 110 . Alternatively, the screen 500 also allows the operator to return the controller to the “Stand-by mode.”
After confirmation by touching the screen 500 , the pump at the surface of the well provides fluid at a second, higher pressure. The next screen 600 , shown in FIG. 6 , is another information screen showing an increase in fluid pressure as the pump provides fluid at the higher pressure to manipulate a sliding sleeve in the first inflow device 110 . As indicated on the screen 600 , the “Current HCAU State” has changed to “Operating ROSS 1,” which refers to the opening of the first inflow device 110 . In one embodiment, the pressure needed to operate the controller 100 , i.e., move the actuating member, is between 200-1000 psi. Pressure exceeding 1000 psi is then required to operate the first inflow device 110 . Real-time display shows the increasing, operating and decreasing pressures and flow rates associated with the operation of the first inflow device 110 between an initial and a secondary position. In this example, the first inflow device 110 is moved from a closed to an open position. Although separately operating the controller and the inflow device is disclosed herein, it is also contemplated that the inflow device may be operated by supplying only one pressure to the controller.
After the first inflow device 110 is opened, another screen 700 , shown in FIG. 7 , shows that the icon 210 of the first inflow device 110 now indicates that the first inflow device 110 is open. Additionally, the screen 700 also indicates that the system has returned to a standby mode for commencement of another operation that opens or closes inflow devices 110 , 120 , 130 .
Throughout the automated operations described above, the conditions within the fluid power system can be constantly monitored and compared to standards in order to spot malfunctions or operational characteristics that are outside of a preprogrammed value. For example, if the pressure or flow rate of the fluid operating the controller or an inflow device should drop unexpectedly during an operation, the operator can be alerted of the condition via a warning screen. The condition can mean a fluid leak at either a line or a device and action can be quickly taken to address the problem. Similarly, if an operation is not completed during a preprogrammed time limit necessary for that operation, an operator can be alerted of the condition and take appropriate action. These and other warnings are possible based upon the ability to constantly monitor pressure, flow rate and other variables within the automated system.
FIG. 8 shows another embodiment of a touch screen 800 according to aspects of the present invention. In this embodiment, the wellbore 5 is provided with three inflow devices 110 , 120 , 130 located in three different zones of the wellbore 5 . Each of the inflow devices 110 , 120 , 130 is represented by a respective icon 810 , 820 , 830 on the screen 800 . As shown, the screen 800 is in stand-by mode. The inflow device icons 810 , 820 , 830 may be selected to operate the desired inflow device. If necessary, the controller 100 may be returned to the park position by selecting the tell-tale icon 840 . The screen 800 also includes a controller icon 850 . The controller icon 850 may be selected to view the status of the controller 100 .
FIG. 9 represents an information screen 900 that is provided when the controller icon 850 is selected. As shown, the controller 100 is in the park position 905 or the “Tell-Tale” position. The modes of operation of the controller 100 is arranged to represent the position of the actuating member.
FIG. 10 represents an information screen 1000 that shows the second inflow device 820 as being open. Specifically, the indicator bar 915 extends from the “tell-tale” position to the open position of the second inflow device 820 . This represents that the actuating member of the controller 100 has moved to a position that aligns the control 11 with the sleeve control line 121 of the second inflow device 820 .
FIG. 11 represents an information screen 1100 that shows the third inflow device 830 is closed. From the open position of the second inflow device 820 , an operator may elect to open the closed third inflow device 830 . Specifically, the operator may return to the previous touch screen and select the third inflow device icon. Thereafter, the operator may press the controller icon 850 to return to the controller information screen 1100 to view the status of the controller 100 . Once selected, a second indicator bar 925 will extend from the previous position to the “close” position of the third inflow device 830 . The second indicator bar 925 represents that a second operation was performed, i.e., closing the third inflow device 830 . In this manner, the controller 100 may be operated to control the inflow and outflow of the various inflow devices.
It must be noted that aspects of the present invention may be applied to operate one or more inflow devices. The inflow devices may include any suitable inflow or outflow device known to a person of ordinary skill in the art. Additionally, the one or more inflow devices may be adapted to control the flow of fluid in one or more isolated zones in a wellbore. The wellbore may include a deviated or non-deviated wellbore, a single or multilateral wellbore, or any other types of wellbore known to a person of ordinary skill in the art.
While the foregoing is directed to embodiments 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 that follow. For example, while the invention has been described for use with inflow devices having slidable sleeves, it will be understood that the invention can be used with any downhole tool that might benefit from computer control and/or real time monitoring.
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A method and apparatus for a computer controlled apparatus for use in wellbore completions. A touch-screen is provided that facilitates commands and information that is entered by an operator ordering movement of a downhole tool. In another embodiment, real-time information about the status of the downhole tools is transmitted to the apparatus based upon operating variables within the system, like pressure, flow rate, total flow, and time.
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BACKGROUND OF THE INVENTION
This invention relates to mountings for cranes, and more particularly, to a retainer which limits the separation of the upper works of a crane from its base during the occurrence of an abnormal condition. This retainer may find particular application in use on marine crane mountings.
With the development in recent years of offshore oil drilling platforms anchored at sea, specialized luffing cranes have been installed on such platforms for handling loads both on the platforms and between the platforms and ships brought alongside. Such cranes are commonly called marine cranes and the revolving upper works of a conventional marine crane is supported on a swing circle mounted atop a pedestal fixed to the platform. Instances have recently occurred where such cranes while lifting and transferring cargo between a ship and a platform have been subjected to unusually large, dynamic loads peculiar to the nature of their use. For example, if cargo aboard a ship is hooked to a crane while the ship is in a turbulent or heavy sea, a dynamic load may be imposed on the crane by the action of the ship falling away from the platform, or by a vertical rise and fall of the ship in response to passing crests and troughs of the waves. The roll and pitch of the ship may also impose extreme dynamic load variations, particularly when the crane hoist line is caused to slacken and tighten in response to ship movement while the load is not fully airborne or free of the ship. The cargo then presents a rapidly varying load on the crane that may impose unusually large peak stresses. Severe and unpredictable load stresses can also develop from cargo catching on ship rails, hatches or other protrusions of a ship superstructure.
These various dynamic load variations can be accentuated when crane operators and other personnel use the equipment under conditions which require greater caution than that exercised. An operator may, for example, lower the boom tip to stay over a load moving outward from the crane as a ship falls away, and thus increase the boom radial distance beyond the rated capability of the equipment for the particular load, or conversely, he may allow the load to become improperly positioned with a shift of the ship, and then commence lifting under improper conditions. In the exigencies of such situations, these maneuvers of an operator may be carried out without properly checking the relation of the load to the crane rating, and parts may be stressed beyond limits for which the crane is designed. It also appears that at times an operator may simply overload his crane beyond its designed capacity to load or unload a cargo as quickly as possible.
The unpredictable, dynamic loads that lead to overloading of marine cranes, as contrasted to the basically static and pure lifting loads of land cranes, makes it desirable to have an arrangement that reduces the possibility of total separation of a crane upper works from its pedestal. This would minimize possible injury to personnel, loss of the crane and other property damage.
The prior art has disclosed a crane modification to counteract the effects of excessive loading of marine cranes in U.S. Pat. No. 4,011,955 issued Mar. 15, 1977, to Morrow Sr. et al for a "Sea Crane Tiedown." There, an annular collar is attached to a pedestal, and a ring-like device positioned beneath the collar is suspended by tension links depending from the frame of the crane upper works. This ring-like device is out of contact with both the collar and pedestal, and the entire structure is referred to as a "sea crane tiedown." Such structure is bulky and complex, and difficult to install. British Pat. No. 1,470,019 for an "Offshore Counterbalancing Crane" discloses hook rollers that are mounted on a bracket for rotating along the underside of a flange of a combination bull gear and roller path. This, however, is not for the purpose of providing retention of the upper works in case of an overload that could topple the upper works from the crane base.
Arrangements that limit the separation of an upper works from its supporting structure have also been provided for other types of material handling machines. One such device is disclosed in U.S. Pat. No. 1,929,397 issued Oct. 3, 1933, to Davidson for an "Excavating Apparatus." Davidson discloses radial lugs that extend under a projection along the circumference of an annular track. Another device is disclosed in U.S. Pat. No. 2,408,378 issued Oct. 1, 1946, to Davenport for a "Stabilizer Attachment For Cranes." Davenport shows a plurality of roller-carrying hangers that ride along an annular track during operation of the crane. None of these arrangements are entirely satisfactory, however, and the present arrangement has been developed to provide an improved means for limiting the separation of the upper works of a crane from its supporting structure during the occurrence of an abnormal condition.
SUMMARY OF THE INVENTION
The present invention relates to a crane mounting that reduces the possibility of a separation of a crane upper works from its base, and it more specifically resides in a hook-like member carried by the rotatable upper works that extends beneath and out of contact with a stationary circumferential member on the base together with a series of buttresses secured to the hook-like member. These buttresses provide additional support for the hook-like member when such members strike the stationary member to resist separation of the upper works from the base, as may occur under an abnormal load condition tending to separate the upper works from its base.
Marine cranes are usually mounted upon pedestals of relatively small diameter as compared to the reach of the crane boom. A swing circle is mounted at the top of the pedestal, and the crane upper works rides on and revolves around such circle. Thus, the moments of large loads at great reaches must be counteracted and resisted within the restricted confines of the relatively small diameter of the swing circle. Repeated crane overloading or repeated dynamic loading may cause abnormal, momentary peak stresses of such magnitudes that failure may ultimately occur in the swing circle. The present invention seeks to solve this problem by providing a retainer as a part of the swing circle mounting that is passive during normal operation, but which functions to restrain a separation of the crane upper works upon occurrence of an abnormal condition. In its preferred form, there is an arcuate structure fastened on the upper works, at a position opposite the boom, which extends from the rear 90° quadrant of the swing circle. This arcuate structure has a projecting lip that extends beneath and out of contact with an overhanging surface that is a part of the stationary crane base. Secured to the arcuate structure are a plurality of vertical buttresses that extend radially outwardly and upwardly to approach, but not contact, the underside of the crane deck. Thus, if the crane upper works loses its normal stability, such that the upper works beings to separate from the base, the lip of the arcuate structure will engage the overhanging surface to maintain the upper works in place. The buttresses will function to strengthen the arcuate structure, so that resistance to separation is accomplished by a structure that can be confined to within a relatively small space. The height or diameter of the pedestal type base commonly used for marine cranes need not be enlarged to accommodate the invention.
It is an object of the invention to provide a means of limiting the extent of separation of the upper works of a pedestal mounted marine crane from its pedestal during the occurrence of an abnormal condition.
It is another object of the invention to povide an arrangement that does not interfere or affect in any way the normal operations of a marine crane.
It is still another object of the invention to provide an arrangement that can extend around a sufficient portion of a swing circle to limit the separation of the upper works from its pedestal without regard to whether the separation results in forward, rearward, or sideward movement of the upper works in relation to the pedestal.
It is yet another object of the invention to provide an arrangement that is reliable, easy to install and maintain, and which does not add appreciable bulk to the crane structure.
The foregoing and other objects and advantages of the invention will appear from the following description. In the description, reference is made to the accompanying drawings which form a part hereof, and in which there is shown by way of illustration and not of limitation a preferred embodiment of the invention. Such embodiment does not represent the full scope of the invention, but rather the invention may be employed in different embodiments, and reference is made to the claims herein for interpreting the breadth of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view in elevation of a marine crane with parts cut away that incorporates the present invention;
FIG. 2 is a partial bottom view, with parts cut away, taken through the plane 2--2 indicated in FIG. 1; and
FIG. 3 is a fragmentary view in cross-section taken through the plane 3--3 indicated in FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, there is shown a marine crane 1 mounted on a fixed pedestal 2 that may be part of a sea platform, such as used in oil exploration or drilling. The crane 1 has a stationary base in the form of a pedestal adapter 3. The lower end of the adapter 3 is of a circular, cylindrical configuration matching the pedestal 2, and the two parts are welded together to firmly anchor the crane 1 in place. Supported above the pedestal adapter 3 is a crane upper works 4 having a deck 5. A machinery housing 6 covers most of the deck 5 and an operator's cab 7 projects forward from the housing 6. The deck 5 also supports a boom 8 and an A-frame assembly 9 rises from the top of the housing 6.
FIGS. 2 and 3 show the mounting of the upper works deck 5 upon the pedestal adapter 3, the present invention being a part of such mounting. The upper end of the adapter 3 has an overhanging circumferential flange 10 that mounts a stationary inner bearing race 11 of a swing circle assembly. A plurality of vertical gussets 12 are equally spaced from one another circumferentially around the upper end of the pedestal adapter 3 to brace the underside of the flange 10, so that the flange 10 can support the load imposed by the crane upper works 4. To secure the inner race 11 atop the flange 10, a number of closely spaced fastening bolts 13 are inserted upwardly through the race 11, and as seen in FIG. 2 the heads 14 of the bolts 13 present a succession of downwardly facing surface areas that are on the underside of the flange 10.
The inner wall of the stationary race 11 is toothed to present the usual gear track of a swing circle assembly, and as shown in FIG. 2 there are two engine driven pinions 15 depending from the upper works 4 which work against the swing circle teeth to propel the upper works 4 in its circular motion around the swing circle axis 16. In addition to the inner race 11, the swing circle assembly includes a two part outer bearing race 17 and three sets of roller bearings 18 inserted between the races 11 and 17 to complete the swing circle. A large annular ring 19 is welded to the bottom surface of the deck 5 and engages the top surface of the outer race 17.
The upper works 4 is mounted on the swing circle, and a plurality of fastening bolts 20 (the heads of which are shown in FIG. 2) firmly secure the two part outer bearing race 17 and the upper works deck 5 together. The outer race 17 thus rotates with the upper works 4 around the pivot axis 16.
As a means for limiting the extent to which the upper works 4 can be separated from the pedestal adapter 3, in the event of an abnormal condition, a retainer 21 is provided that extends arcuately around a portion of the swing circle assembly. As shown best in FIGS. 2 and 3, the retainer 21 includes a pair of curved segments 22 that are fastened by a plurality of long bolts 23 to a portion of the underside of the outer race 17. The bolts 23 are similar to the bolts 20, except for their longer length to accommodate the retainer segments 22. They are circumferentially spaced similarly as the bolts 20, to continue the bolting together of the outer bearing race 17 and the ring 19 to the deck 5 around the circumference of the swing circle assembly.
The segments 22 form an arc in their longitudinal direction that conforms to the circular shape of the outer race 17, and as seen in cross section in FIG. 3 a lip-like projecting portion 24 of each segment 22 extends radially inward into a position beneath and out of contact with the heads 14 of the fastening bolts 13. These projecting lip portions 24 are normally spaced from the lower surfaces of the bolt heads 14, but are adapted to catch upon the bolt heads 14 to limit separation of the upper works 4 from the crane base, comprising the pedestal adapter 3, in a manner as will hereinafter be described. The distance between the inwardly projecting lip portions 24 of the retainer segments 22 and the bolt heads 14 can be controlled by shims 25 that are inserted between the tops of the segments 22 and the lower face of the outer race 17. This gap can be from about 0.0625 to 0.1875 inches.
As seen in FIG. 3, the retainer segments 22 have a hook-like appearance in cross section, and in the preferred form shown, this hook-like configuration circumferentially encompasses the rear 90° quadrant of the swing circle assembly that is diametrically opposite the boom 8. Each of the two segments 22 encompasses an arc of 45°, and together they provide sufficient circumferential extent to limit the separation of the upper works 4 from the pedestal adapter 3 whenever the upper works 4 begins to tilt forwardly in the direction of the boom 8. However, it should be noted that the retainer segments 22 may encompasss the entire circumference of the swing circle, or some other portion thereof. Also, the hook-like, inwardly projecting lips 24 may be divided into circumferentially spaced segments extending around all or a part of the swing circle assembly.
Welded to the radially outer surface of the hook-like retainer segments 22 are a plurality of vertical plates that form buttresses 26. As seen in FIG. 2, each buttress 26 is positioned in a vertical plane extending radially from the axis of machine rotation 16. The radial extent of the buttresses 26 varies, as space limitations have required, and the general configuration for the buttresses 26 is shown in FIG. 3. From the line of welded attachment to the retainer segments 22, each buttress 26 extend radially outward, and then turns upwardly to terminate in an abutment end 27 that faces the underside of the upper works deck 5.
The buttresses 26 function to brace and resist dislocation of the hook-like retainer segments 22 whenever the segments 22 strike the heads 14 of the fastening bolts 13. In normal operation, the buttresses 26 do not play any function in the machine operation, and it is desirable to have a slight clearance of about 0.02 to 0.03 inches between the buttress abutment ends 27 and the underside of the deck 5, so as not to interfere with flexing of the deck 5 that takes place during normal operation of the crane 1.
The retainer 21 made up of the segments 22 of the buttresses 26 may be assembled as a subassembly by first welding the buttresses 26 to the hook-like segments 22. The retainer 21 is then secured loosely to the bottom of the outer race 17 by the bolts 23. A gap of about 0.0625 to 0.1875 inches is then provided between the projecting lip portions 24 of the hook-like segments 22 and the heads 14 of the fastening bolts 13 by placing shims 25, as needed, between the segments 22 and outer race 17. The completed retainer structure is then tightly secured to the deck 5 and outer race 17 by the bolts 23, and after tightening the bolts 23, the buttresses 26 should also have a clearance of about 0.02 to 0.03 inches between their abutment ends 27 and the underside of the deck 5.
In the event loading of the crane 1 results in an abnormal condition, such as breakage within the swing circle assembly, that may allow the upper works 4 to tip forward and separate from the pedestal adapter 3, the retainer 21 will come into play to effectively limit this separation, as long as the retainer 21 itself is not subjected to such an extreme overload that its segments 22 or the bolts 23 fail. Upon a forward tilting of the upper works 4, there will be an upward movement of the rear of the deck 5. Such a movement of the deck 5 causes the projecting lip portions 24 of the hook-like segments 22 to engage and catch on the heads 14 of the fastening bolts 13. This engagement prevents any further upward movement of deck 5 to arrest tilting of the upper works 4, as long as the strain is within the load limits of the retainer 21 itself. Thus, the upper works 4 is effectively retained on the pedestal adapter 3, upon the occurrence of an abnormal condition.
When the retainer 21 engages the bolt heads 14, the hook-like segments 22 may tend to rotate clockwise, as seen in FIG. 3, by pivoting at their outermost point of contact 28 with the outer race 17. Such rotation tends to bend the heads and shanks of the through bolts 23 clockwise, so that the bolts 23 fail to retain the retainer segments 22 tightly in place against the underside of the outer bearing race 17. If this should occur, then the buttresses 26 come into play to prevent the bolts 23 from being distorted or the segments 22 from rotating clockwise. The abutment ends 27 of the buttresses 26 will engage the underside of the deck 5 as the bolts 23 tend to give or distort. They then resist clockwise rotation (as viewed in FIG. 3) of the segments 22 to maintain the retainer assembly 21 in place, so that the upper works 4 is restrained from tilting. The region of contact between the abutment end 27 of a buttress 26 and the underside of the deck 5 is radially outside the point 28 around which displacement of a segment 22 may occur. The radial distance between the point 28 and this region of contact provides a lever arm, so that the reaction force at the abutment end 27 is effectively multiplied to enhance the resistance to any dislocation of the retainer segment 22. The outward, radial extension of the buttresses 26 thus enhance the strength of the retainer assembly 21. Thus, the greater the lever arm that may be provided between buttresses 26 and the hook-like segments 22, the more effectively the buttresses 26 will resist the rotation of the segments 22.
A retainer 21 has been shown and described that limits the separation of the upper works 4 of a crane 1 from its base. In this structure, the crane base has an overhanging surface which in the drawings comprises the circumferentially arranged bolt heads 14 that extend in a circle around the axis of rotation. Thus, to whatever position the upper works 4 may be rotated, there is an overhanging surface against which the retainer 21 may strike to resist separation of the upper works 4. The retainer 21, in turn, is provided with a substantial arcuate surface that can contact the overhang so that a restraining force can be spread over a substantial area. In addition, radially extending buttresses 26 are provided to give greater strength and stability to the retainer structure. It is apparent, however, that various modifications may be made from the specific structure described. As previously indicated, the retainer 21 may extend completely around the circumference of the crane's swing circle assembly, rather than merely its rear 90° quadrant. Although it is preferred that the hook-like segments 22 be fastened to the rotatable deck 5 of the upper works 4 beneath the outer race 17, they may also be fastened in other positions such as the radially outer surface of the outer rotatable race 17, as well as directly to the deck 5 itself. Also, the overhanging surface areas provided by the bolt heads 14 can take some other form, such as a supplementary flange built around the pedestal adapter 3 or the inner bearing race 11.
It should be noted that under normal operation of the crane 1, the projecting lip portions 24 of the hook-like retainer segments 22 do not engage or rub on the pedestal adapter 3 or any part thereof. Therefore, the retainer 21 does not hinder or interfere in any manner with the normal operation of the crane 1. Also, the retainer 21 may be designed for and used on any size or type of base mounted crane, and may also be adapted for use with other material handling machines.
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A marine crane having an upper works rotatably mounted on a pedestal adapter, includes a retainer for limiting the extent to which the upper works can be tilted, such retainer having an arcuate member secured to the upper works that extends partially around the pedestal adapter and presents a lip beneath and out of contact with a stationary circumferential member forming a part of the pedestal adapter. The arcuate member has a series of vertical, plate-like buttresses spaced along its circumferential length that have outer ends facing a machinery deck of the upper works to brace the arcuate member, so as to retain the arcuate member in place in the event of abnormal forces being applied thereto.
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This is a continuation of application Ser. No. 07/705,627, filed on May 24, 1991, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to a catheter for the simultaneous or near-simultaneous recording of monophasic action potentials (MAPs) and ablating arrhythmia-causing tissue by coupling radiofrequency energy to tissue surrounding the catheter tip, and more particularly to a method and apparatus for simultaneously recording MAPs and ablating by contacting heart tissue with a small dual MAP/ablating electrode under positive pressure.
The electrical charge of the outer membrane of an individual heart muscle cell is known as the "membrane potential". During each heart beat, the membrane potential discharges (depolarizes) and then slowly recharges (repolarizes). The waveform of this periodic depolarization and repolarization is called the "transmembrane action potential." Mechanistically, the action potential is produced by a well-organized array of ionic currents across the cell membrane.
At the turn of the century, it had already been recognized that a potential similar in shape to the later-discovered transmembrane potential could be recorded if one brought into contact a first electrode with an injured spot of the heart and a second reference electrode with an intact spot. Those signals became known as "injury potentials" or "monophasic action potentials" (MAPs) because of the waveform shape.
The further development of the science of MAPs may be found in U.S. Pat. No. 4,955,382, the disclosure of which is hereby incorporated by reference. It has been recognized that local heart muscle injury is not a prerequisite for the generation of MAPs, and that application of slight pressure with the tip against the inner wall of the heart will result in the generation of monophasic action potential signals. These signals can be recorded reliably (i.e., without distortion) by using direct current (DC) coupled amplification.
One problem to overcome in MAP recordation is the slow DC drift caused by electrode polarization in conventional electrical material used in the recording of intracardiac electrical signals, such as silver or platinum. These materials are polarizable and cause offset and drift-which is not a problem in conventional intracardiac recordings, because those signals are AC coupled, which eliminates offset and drift. The MAPs, however, are to be recorded in DC fashion, and therefore are susceptible to electrode polarization. The use of a silver-silver chloride electrode material yields surprisingly good results in terms of both long-term stability of the signal and extremely low noise levels.
Another important discovery has been that the tip electrode of the catheter should be held against the inner surface of the heart with slight and relatively constant pressure. In order to accomplish this in a vigorously beating heart, a spring-steel stylet is inserted into a lumen of the catheter to act as an elastic spring, keeping the tip electrode in stable contact pressure with the endocardium throughout the cardiac cycle. This leads to major improvements in signal stability.
Another design objective for a good MAP catheter is to ensure a relatively perpendicular position of the electrode tip with the endocardial wall. Again, the spring electrode is useful in this respect. Conventional catheters are usually brought into contact with the heart wall in a substantially tangential manner. Such conventional catheters are designed simply to record intercardiac electrograms, not MAPs. For the monophasic action potential catheter, direct contact between the tip electrode and the endocardium is made. This also keeps the reference electrode, which is located along the catheter shaft, away from the heart muscle.
To facilitate the maneuverability of the catheter during a procedure in the human heart, the distal end of the catheter should be relatively flexible during the time of insertion, and the spring-loading feature preferably comes into action only after a stable position of the catheter tip has been obtained. Thus, in a preferred embodiment the catheter is constructed in such a way that the spring wire situated in the lumen of the catheter is retractable. During catheter insertion, the spring wire or stylet is withdrawn from its distal position by approximately 5 cm, making the tip relatively soft. Once the catheter is positioned, the spring wire is again advanced all the way into the catheter in order to stiffen it and to give it the elastic properties that are important for the described properties. Improved stylets and wires that position the tip electrode perpendicularly to the heart surface with the proper amount of constant pressure are described in U.S. Pat. No. 4,955,382.
Thus, a main feature of a good catheter is the ability to bring into close and steady contact with the inner surface of the myocardial wall a nonpolarizable electrode which both produces and records MAPs. To achieve this property, the electrodes are formed from nonpolarizable material such as silver-silver chloride, and the tip electrode should be maintained at a relatively constant pressure against the myocardial wall, preferably with some type of spring loading.
The catheter of the present invention preferably contains a spring-steel guide wire which provides a high degree of elasticity or resilience, allowing the catheter tip to follow the myocardial wall throughout the heartbeat without losing its contacting force and without being dislodged. The inner surface of the heart is lined with crevices and ridges (called the trabeculae carneae) that are helpful in keeping the spring-loaded catheter tip in its desired location. The contact pressure exerted by the tip electrode against the endocardial wall is strong enough to produce the amount of local myocardial depolarization required to produce the MAP. The contact pressure is, on the other hand, soft and gentle enough to avoid damaging the endocardium or the myocardium or cause other complications. In particular, no cardiac arrhythmias are observed during the application of the catheter. Usually a single extra beat is observed during the initial contact of the catheter tip against the wall.
The tip electrode is responsible for the generation and the recording of the MAP itself. A reference electrode, or "indifferent" electrode, required to close the electrical circuit, is located approximately 3 to 5 mm from the tip electrode in the catheter shaft and is embedded in the wall so that it is flush with or slightly recessed in the catheter shaft. In this position, the electrode makes contact only with the surrounding blood and not with the heart wall itself.
This reference electrode is brought into close proximity with the tip electrode, since the heart as a whole is a forceful electrical potential generator and these potentials are everywhere in the cardiac cavities. If the reference electrode were in a remote location, then the amplifier circuit would pick up the QRS complex.
Another feature of this invention relates to thermal destruction, or ablation. Ablation of abnormal myocardial tissue (such as arrhythmia-causing tissue) is a therapeutic procedure used with increasing frequency for treatment of cardiac arrhythmias such as, for example, ventricular tachycardia. The medical technique of ablation is discussed in G. Fontaine et al., Ablation in Cardiac Arrhythmias (New York: Futura Publishing Co., 1987), and D Newman et al., "Catheter Ablation of Cardiac Arrhythmias", in Current Problems in Cardiology, Year Book Medical Publishers, 1989.
Catheter ablation of ventricular tachycardia was first described in 1983 as a method for destroying arrhythmia-causing tissue. Typically, a pacing catheter is introduced into the left ventricle of the heart, and manipulated until the site of earliest activation during ventricular tachycardia is found, indicating the location of the problem tissue. Electrical energy, often high voltage DC pulses are then applied between a catheter-mounted electrode and an external chest wall electrode. In this way, arrhythmia-causing cardiac tissue is destroyed.
More recently, less drastic methods than high voltage pulses have been developed, which are painful (requiring general anaesthesia), and dangerous due to arcing and explosive gas formation at the catheter tip. The use of electromagnetic energy, more particularly radiofrequency (RF) or microwave energy, is currently in popular use. RF and microwave energy, unless otherwise noted, refers to energy in the electromagnetic spectrum from about 10 kHz to 100 GHz. RF ablation, usually in the range of 300-1200 kHz, is a safer alternative to high voltage DC pulsing in which RF energy is applied to the endocardium via an catheter electrode. Tissue destruction, or ablative injury, is effected by heating generated by the RF electric field. RF ablation results in a more controllable lesion size, with no gas or shock wave formation. Ablation may also be effected with energy having microwave frequencies, from about 700 MHz to 100 GHz.
Currently, no reliable on-line method exists to quickly and accurately determine whether radiofrequency (RF) energy application has resulted in lesions of a size sufficient to destroy the injured myocardial tissue. That is primarily because previously, no provision has been made for accurately measuring the electrophysiological activity of the heart in the immediate vicinity of heart tissue which is being ablated by an ablating catheter. Moreover, if it is desired to pace the heart at the same time as measuring MAPs in the heart, two entrance sites to the patient must be created and two catheters must be utilized, which is highly undesirable.
Because of the complexity of electrical cardiac activity, when a pacing or ablating electrode is inserted into the heart, and it is desired to measure the resulting monophasic action potentials of the heart, it would be of extreme usefulness to be able to measure such potentials in the vicinity of the ablation, rather than at a more remote location.
Important applications of the present invention are in the areas of studying and treating myocardial ischemia and cardiac arrhythmias. In particular, the present invention permits (1) precisely locating areas of myocardial ischemia by studying localized MAPs and directly treating them; and (2) diagnosing the nature and locality of arrhythmias originating from after-depolarizations and treating those arrhythmias. These after-depolarizations have heretofore been detected only in isolated animal tissue preparations where microelectrodes can be applied. The MAP/ablation catheter is a tool that can allow the clinical investigator to detect and remedy such abnormal potentials in the human heart and thereby significantly broaden the ability to diagnose this group of arrhythmias.
SUMMARY OF THE INVENTION
The present invention overcomes the drawbacks in the prior art by permitting ablation both in the same region where MAPs are being recorded, and at the same or nearly the same time as they are being recorded. The system uses an electronic filter system to eliminate radiofrequency interference that would otherwise prevent simultaneous ablation and recordation. Although simultaneous ablation and EKG reading has previously been possible, simultaneous ablation and MAP recordation offers more information to the user, as the MAP signal is a more sensitive indicator of tissue viability.
Previously, simultaneous ablation and MAP recording was possible using two catheters. However, this method was more invasive and more uncertain, as situating the two catheters at precisely the same location was difficult or impossible. Therefore, the present invention provides a heretofore unavailable single ablating catheter capable of being a precise instantaneous indicator of thrombus conditions or tissue death.
By permitting ablation and MAP recordation at approximately the same time and same location in the heart, the present invention also potentially minimizes the necessary lesion size, as ablation may be stopped immediately upon recognition of tissue death.
Therefore, it is an object of the present invention to provide an apparatus for measuring monophasic action potentials and, at about the same time, ablating surface myocardial tissue with electromagnetic energy.
It is another object of the present invention to provide an apparatus for measuring monophasic action potentials and, at about the same time, ablating surface myocardial tissue with radiofrequency energy.
A further object of the present invention is to provide a MAP measuring apparatus which can accurately record action potentials and ablate surface myocardial tissue over sustained periods of time.
Another object of the present invention is to provide a MAP measuring apparatus which can ablate surface myocardial tissue and measure action potentials in a vigorously beating in-situ heart.
Another object of the present invention is to provide a method of using the apparatus for recording MAPs while simultaneously ablating surface myocardial tissue, or immediately before or after ablating surface myocardial tissue.
A further object of the present invention is to provide a method of detecting and correcting ischemia by sensing MAPs and, at approximately the same time and location in the heart, ablating surface myocardial tissue.
In accordance with the above objects, the present invention includes an apparatus for both detecting monophasic action potentials and ablating surface tissue in an in vivo heart of a patient. The apparatus comprises a catheter probe having a terminal tip portion and a first electrode carried on the tip such that a portion of the first electrode is exposed to ambient. A second electrode is spaced along the tip from the first electrode for supplying a reference potential signal. A third electrode is located adjacent to the first electrode but electrically insulated from both the first and second electrodes for providing electromagnetic energy, preferably radiofrequency or microwave energy.
The electrodes are electrically connected to the proximal end of the catheter through individual conductors or wires that run through an insulated cable. In one embodiment of the invention, coaxial cable may be used as the conductors and cable together. The connection of one conductor to the third electrode (the ablation electrode) will include an antenna for receiving electromagnetic energy. The antenna may be formed by the conductor itself, or may be a separate component, such as a conductor wound in the form of a helix. Helical antennas, and their connection in an ablating catheter system, are described in U.S. Pat. No. 4,945,912, the disclosure of which is hereby incorporated by reference.
The system of this invention may also include a steering mechanism for positioning the catheter in various locations in the heart. The mechanism permits the distal end of the catheter to be bent into varying shapes, and will include proximally located controls, a flexible steering shaft, and a distal apparatus for bending the distal end. Suitable steering mechanisms are disclosed in commonly-owned, copending U.S. application Ser. No. 07/473,667, the disclosure of which is hereby incorporated by reference.
In accordance with further aspects of the invention, an electronic filter is provided to permit the recording of MAPs during ablation without radiofrequency interference. The probe may also be provided with a structure for holding the first electrode in contact with heart tissue with a positive pressure without causing significant macroscopic damage to the heart tissue and for orienting the probe such that the second electrode is spaced from the heart tissue and the third electrode remains near the heart tissue.
The first and second electrodes of this invention are non-polarizable, preferably formed of silver-silver chloride, to avoid direct current drift during the course of investigation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of the tip portion of the apparatus of the invention.
FIG. 2 is a sectional view of the tip portion shown in FIG. 1.
FIG. 3 is another sectional view of an alternate embodiment of the tip portion of the apparatus of the invention.
FIG. 4 is a schematic view of the tip portion of an alternate embodiment of the invention.
FIG. 5 is a sectional view of a variable tip assembly, an alternate embodiment of the invention.
FIG. 6 is another sectional view of an alternate embodiment of the tip portion of the apparatus of the invention.
FIG. 7 is an electrical schematic of the electronic filter system of the invention.
FIG. 8 is a schematic view of a combination MAP/ablation/pacing catheter tip of the invention.
FIG. 9 is an overall schematic view of the catheter system of the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 and 2 show the tip portion 10 of a probe according to the present invention. Tip 10 comprises an exposed tip electrode 20 for detecting monophasic action potentials. Electrode 20 is a sintered depolarizing electrode, preferably formed of silver-silver chloride. Adjacent to, but electrically insulated from the tip electrode is the ablating electrode 30. Electrode 30 is preferably formed of stainless steel or platinum, and is insulated from electrode 20 by skirt 40. 40. Skirt 40 may be made of Teflon tubing, for example, or any other insulating material. Skirt 40 has a thickness of 0.001-0.200 inches, most preferably 0.002-0.020 inches.
In this manner, the ablating electrode 30 is located in close proximity to the MAP recording tip electrode 20, and the catheter tip will effectively be recording MAP signals at the same location where ablation is taking place. The two electrodes may be as close as possible, limited only by the finite thickness of insulating skirt 40. If the two electrodes are separated by much more than 0.200 inches, however, the ablating electrode may no longer be effectively ablating the area where the MAP signals are recorded, or it may be ablating a different area.
Located proximally from electrode 30 is a side electrode 50, which serves as the "indifferent" electrode for tip electrode 20. Side electrode 50 is electrically insulated from the tip and ablation electrodes by an insulating insert 60. Insert 60 is preferably formed from an insulating material such as plastics or rubbers, more preferably Delrin.
The tip and side electrodes 20 and 50 are preferably formed from a sintered silver-silver chloride material. An alternative structure for the electrodes 20 and 50 is provided by utilizing silver-silver chloride flakes bound together by cyanoacrylate adhesive. It has been found that it is desirable to place side electrode 50 proximally from the tip electrode 20 by a suitable distance as, for example, 3-10 mm, preferably 3-5 mm.
As seen in FIG. 2, electrodes 20, 30 and 50 are electrically connected to the proximal end of the catheter via electrical conductors 22, 32 and 52, respectively. The electrical conductors are formed of a suitable material such as insulated copper and serve as signal wires. Tip electrode 20 is soldered to center conductor 22, which is covered with a teflon sleeve for electrical insulation. Electrical conductor 22 may also act as an antenna for receiving transmitted electromagnetic energy.
FIGS. 1 and 2 also show an ablating skirt 70, which is in fact an optional component of the present invention. Skirt 70 forms a ring on the probe surface at the proximal end of electrode 30. The thickness of skirt 70 varies based on its axial distance from the junction of electrode 30 and insert 60. The thickness of skirt 70 tapers to zero at the distal rim and monotonically increases to about 0.010-0.040 inches at the proximal rim. The skirt is formed from a partially conductive material, preferably a partially conductive epoxy such as a silver epoxy. Proximally located to skirt 70 on the probe surface is insert 60, although electrode 30 may have a tapered base, thereby extending proximally beyond skirt 70 in the probe interior as seen in FIG. 2.
Skirt 70 is formed so that the electrical properties at the electrode-insert junction are tempered. Without the skirt, the junction forms a hot spot and an undesirable charring focus. The presence of a partially conductive skirt with resistive or capacitive properties changes the surface impedance, equalizes the external electric fields and improves radial penetration of the field. By vastly reducing or eliminating the aberrational electrical fields, the skirt eliminates the charring problem.
FIG. 3 shows an alternate embodiment of the housing for the tip and ablating electrodes. Socket 35 is designed to receive electrode 30 (as shown in FIG. 6), which tapers at its base to about 0.058 inches in diameter. When inserted, electrode 30 is thereby fitted in teflon skirt 45 with an inner diameter of about 0.058 inches and an outer diameter of 0.080 inches. Electrode 30 extends about 0.046 inches down the probe and sits on the thin bottom of the teflon skirt.
FIG. 4 shows an alternate embodiment of the catheter of the invention which, in addition to performing simultaneous MAP recordation and radiofrequency ablation, is able to simultaneously perform standard mapping through a number of standard mapping electrodes. The process of mapping through mapping electrodes is well known as described in Zipes et al., Cardiac Electrophysiology (Saunders Pub. Co.). The probe shown in FIG. 4 consists of a distal end identical to that shown in FIG. 1, but utilizes a series of proximally located standard mapping electrodes 80 separated by a series of insulating inserts 90. Although the drawing depicts three mapping electrodes, as few as 1 and as many as 16 or more could actually be used.
FIG. 5 shows an alternate embodiment of the tip of the current invention. In this embodiment, a variable tip assembly is utilized so that alternate tip shape or configuration may be easily substituted. Tip shapes including "peanut", "hourglass" or bulbous geometries are contemplated. The tip electrode and ablating electrode are contained on removable head 100, which varies in size from 3-10 mm and attaches to probe 110 through threaded plug 120. Plug 120 is a watchmaker's thread screw and screws into threaded hole 130 to sit on teflon skirt 140. Electrical conductors to the electrodes extend through plug 120 and attach to conductors located centrally in probe 110 through hole 130. Loctite is used to fix head 100 in proper position.
The variable tip assembly configuration of FIG. 5 can be used to provide nonsterilized tips, which can be easily sterilized by conventional methods prior to use, permitting ease of manufacture and use.
FIG. 6 shows yet another alternative embodiment of the catheter of the current invention in which the tip and ablating electrodes have been inserted into socket 35 of the device of FIG. 3. In particular, this figure shows a central bore 140 running from the proximal end of the probe to the tip electrode at the distal tip. Bore 140 contains the electrical conductors that electrically connect the distal electrodes to the proximal end, and may also contain steering wires for controlling catheter steering.
FIG. 7 is a schematic diagram of the electronic filter system of the invention. The filter is a DC-accurate 5 kHz low pass filter that receives the MAP signal from electrode 20 via conductor 22 as shown in FIG. 1. The filter permits passage of frequencies only below 5 kHz. Accordingly, all ablating frequencies (RF and microwave) do not pass, and only MAP signals will pass. The outputs 202 and 203 pass the filtered signal to a display device such as an oscilloscope or strip chart recorder.
The filter in FIG. 7 uses two inputs 200 and 201. These two inputs may be connected to either the distal tip electrode 20, proximal side electrode 50, as shown in FIG. 1, or directly to the skin of the patient. When the inputs are connected to the two electrodes, the system is called a "distal bipolar" system. A distal or proximal "unipolar" system occurs when input 200 is connected to one electrode and input 201 is connected to the patient's skin.
FIG. 8 shows an alternative embodiment of the invention, depicting a catheter 10 which is a combination pacing, ablation and MAP catheter. FIG. 8 is similar to FIG. 1, the difference lying in the presence of a pair of pacing electrodes 75. The function and method of use of pacing electrodes such as electrodes 75 for activating is well known in the art in standard configurations of pacing electrode catheters; that is, the same types of electrical signals which are provided to pacing electrodes in standard pacing catheters may also be provided to the electrodes 75 in the present invention.
The two pacing electrodes 75 are 0.035" platinum dot electrodes, and are positioned substantially diametrically opposite each other on the exterior surface of the catheter. Side electrode 50 is radially positioned halfway between said two pacing electrodes, but may be located axially toward or away from the catheter tip.
FIG. 9 is a schematic overview of a combination MAP, ablation, and pacing catheter 200, in which pacing electrodes 210 and 220 are mounted at the distal end 230 of the catheter 200. In addition, a tip electrode 240 a side electrode 250, and an ablation electrode 255 are provided, as in the configuration of FIG. 1, and are electrically connected to connections such as plugs 260 and 270.
The pacing electrodes 210 and 220 are similarly connected to plugs 280 and 290, respectively. Plugs 280 and 290 are standard plugs. It will be understood that contained within FIG. 9 are the necessary electrical leads to the electrodes 210, 220, 240, 250 and 255, and in addition stylets and other features as described herein with respect to other embodiments may be included. The electrical lead to electrode 255 may be connected to an electromagnetic energy source, such as a radiofrequency source or microwave source, for providing ablating energy to the catheter tip. The electrical leads to electrodes 240 and 250 may provide input to the RF filter of FIG. 7, as described above.
A coupling 300 for the plugs 260-290 is provided, insuring a reliable connection between the plugs to the electrical leads contained within the catheter 200. This coupling 300 is preferably of a hard material such as polycarbonate, and has an enlarged diameter relative to the catheter 200. This provides greater torque control for the user of the catheter when manipulating the catheter into the heart and positioning the tip electrode 240 against the endocardium.
In addition to the coupling 300, a knurled knob 310 may be attached at the proximal end 320 of the catheter 200. The knob 310 is preferably connected to the catheter 200 in a nonrotatable fashion, such that axial rotation of the knob 310 causes similar axial rotation of the catheter 200. As shown in FIG. 8, the knob 310 may be generally cylindrical in configuration, or may be of some other convenient shape for twisting by hand.
METHODS OF USE
The general principle of identifying ischemic, infarction, and arrhythmia-causing sites using MAPs is described fully in U.S. Pat. No. 4,955,382. That procedure is basically followed in the current invention with the following additions.
To localize and treat myocardial ischemia or ventricular tachycardia, the catheter of the present invention is inserted endocardially, and as the catheter is consecutively placed at multiple endocardial locations, MAP signals are detected until an abnormal condition is discovered. This abnormal condition may be the late arrival of the action potential, or the wrong potential. When the abnormal MAP is detected, RF energy is passed to the ablation electrode to ablate the abnormal tissue. While the ablating RF energy is being dissipated to the tissue, the MAP signal is simultaneously being read and recorded. When the MAP signal has disappeared for a certain period of time, the tissue is presumed dead and ablation may cease.
After the procedure has been performed, the success of the procedure may be determined by conventional methods. For example, the heart may be paced to induce the arrhythmia or tachycardia using pacing electrodes both before and after the procedure.
The ability to simultaneously record MAPs and ablate cardiac tissue with a combination MAP/ablation catheter has been examined in dogs. In one study on 22 left ventricular sites in six closed-chest dogs, RF ablation at 25 watts was applied for 60 seconds or until a rise in impedance occurred. Simultaneous MAP recording throughout each RF application took place using the lowpass filter system described above. Before RF ablation, stable MAP signals of 22±7 mV amplitude were obtained at each site. In 13 RF applications, MAP signal amplitude decreased to less than 20% of baseline within only 3-5 sec of RF ablation. In these cases, power was shut off at 6-8 sec (group A). In 5 RF applications, MAP amplitude decreased more slowly, falling below 20% within 40-60 seconds. In these cases, power was shut off at 60 sec (group B). In the 4 remaining applications, MAP amplitude decreased by only 35-65%, and upon cessation of RF ablation (at 60 sec) recovered to 60- 85% of baseline (group C). Post-mortem analysis showed similar lesion volumes in group A and B (135±24 mm 3 vs 88±36 mm 3 , NS) but smaller lesion volumes in group C (52±32 mm 3 ; p<0.05 vs. group A).
In another set of experiments, application of RF energy of low power and short duration were delivered to the canine heart through the combination MAP/ablation catheter of the current invention to observe the relationship between RF power and duration on one hand and lesions size and change in MAP signal morphology on the other hand. MAP signals were recorded using the low-pass filter and distal bipolar signals, proximal unipolar signals, and distal unipolar signals were all recorded before, during and after RF ablations.
In total four lesions were made in the left ventricle and two in the right ventricle. RF power varied from 5-10 watts and duration varied from 10-60 seconds or until an impedance rise occurred. Changes in MAP signal morphology during and after RF ablation were recorded. These morphology changes can later be correlated to lesion depth, volume and location. The animal is then sacrificed to determine lesion depth, volume and location.
These experiments demonstrate that simultaneous MAP monitoring during RF ablation provides instantaneous feedback about the magnitude and permanence of myocardial tissue destruction, even during very brief RF pulses.
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A combination catheter for both detecting monophasic action potentials and ablating surface tissue in an in vivo heart of a patient is provided. The apparatus includes a catheter probe having a terminal tip portion and an electrode carried on the tip such that a portion of the tip electrode is exposed to ambient. A reference electrode is spaced along the tip from the first electrode for supplying a reference potential signal. An ablating electrode is located adjacent to but electrically insulated from both the tip and reference electrodes for providing electromagnetic energy to the tip. The electrodes are electrically connected to the proximal end of the catheter through individual conductors or wires that run through an insulated cable. An electronic filter is provided to permit the recording of MAPs during ablation without radiofrequency interference. The catheter may also include standard mapping and/or pacing electrodes. The catheter may further include a steering mechanism for positioning the catheter at various treatment sites in the heart, and a structure for holding the tip electrode in substantially perpendicular contact with heart tissue with a positive pressure, and for spacing the reference electrode from the heart tissue.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to the structure of sorting conveyors. More specifically, the invention relates to an improved structure of conveyors having laterally deflectable article transporting pallets.
2. Description of the Prior Art
The use and design of sorting conveyors of the type consisting of deflectable article carrying sliders mounted on slide rods fixed at each end to an advancing chain is well known. Typical conveyors of this type are disclosed in U.S. Pat. Nos. 3,731,782; 3,500,983; 3,190,432; 3,167,171; 3,129,803; 3,093,245; and 3,009,572. Various advances in the conveyor art have been made which have improved the reliability of these devices and which have enabled the increase of number of articles per minute capable of being handled by the devices. However, one substantial limitation of the prior art devices has remained until the advancement of the present invention.
State-of-the-art conveyors of the type having deflectable article carrying sliders mounted on slide rods are disadvantaged by the fact that they are incapable of operating faultlessly when they are required to convey and sort heavy articles, especially at higher throughputs. It is believed that the major cause of this disability is that the increased weight of the conveyed articles causes the slide rods to bow, thereby making deflection of the sliders along the slide rods more difficult. This difficulty is aggravated by the increase of friction between the slider and the slide rod which results from the increased weight of the conveyed articles and which further impedes the deflection of the slider. Finally, in those conveyors exemplified by U.S. Pat. Nos. 3,731,782 and 3,167,171 in which a magnetic device is utilized to cause switching of magnetically attractable sliders as well as to cause the sliders to follow a given path, the resistance effects of additional momentum of the heavier articles as well as the previously discussed effects of increased friction and slide rod bowing tend to contribute to a condition which frequently exceeds the ability of the magnetic devices to attract and hold the magnetically attractable slider. In this event, either the switching operation is not effectively completed or the slider breaks away from the desired path prematurely so that the sorting conveyor is ineffectual for accomplishing its sorting function.
SUMMARY OF THE INVENTION
Thus is posed the problem of providing a flow deflecting conveyor and especially a magnetically operated flow deflecting conveyor which is not subject to the difficulties of the prior art devices and which is capable of handling articles of increased weight at increased speeds without fault. These and other objects are realized by the present invention through the fact that carriage type articles carrying pallets are provided which are mounted on rollers rather than slideably engaging slide rods as was done in the prior art. The pallet rollers are captured in and roll along the inner surfaces of pairs of mutually facing support channels. The support channels are mounted at either end and are carried by the side roller chains of the conveyor. The support channels, due to their shape and construction, are better able to resist the bending moments placed on them than were the prior art slide rods. Additionally, the design of the present invention substantially reduces the frictional resistances encountered during the lateral deflection of the pallet in comparison to the prior art devices with the elimination of sliding friction by the substitution of dramatically decreased rolling friction.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention may be better understood and its numerous objects and advantages will become apparent to those skilled in the art by reference to the accompanying drawings wherein like reference numerals refer to like elements in the several figures and in which:
FIG. 1 is a plan view of a magnetic flow director conveyor embodying the present invention;
FIG. 2 is an elevation of FIG. 1 taken along line 2--2;
FIG. 3 is a detailed elevation of the structure of one end of the apparatus as shown in FIG. 2;
FIG. 4 is a cross-sectional view taken along the line 4--4 of FIG. 3; and
FIG. 5 is a cross-sectional view of the apparatus taken along the line 5--5 of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention relates to an improved design of an endless conveyor which is provided for the purpose of moving an article or articles selectively along one or more predetermined paths in a given direction. Accordingly, the conveyor of the type hereinafter disclosed is useful for sorting articles into two or more discharge lines. This sorting capability may be used in association with a checkweigher with one of the discharge lines carrying away articles having weights falling within a certain allowable range and the other discharge line carrying away articles whose weight falls outside of the allowable range.
A typical conveyor of the type disclosed herein is described in detail in U.S. Pat. No. 3,731,782 entitled MAGNETIC FLOW DEFLECTOR by Victor Del Rosso issued May 8, 1973: the disclosure of which is herein incorporated by reference. Briefly then, the Magnetic Flow Deflector conveyor 10 is disposed between an infeed line 11 and a multiplicity of discharge lines 13 and is operated in a manner that causes the articles to move from infeed line 11 onto the conveyor 10 and subsequently to be separated into one of a multiplicity of lines for eventual discharge to discharge conveyors 13.
The Magnetic Flow Deflector itself consists of a pair of supporting side rails 12 which support roller chains 14 by chain rails 34 and other suitable support structure generally indicated by numeral 33. Spanning the distance between chains 14 are a plurality of transversely mounted laterally extending support members 20. Support members 20 are fixed at either end to roller chains 14 and are carried along with chains 14 as chains 14 are advanced by commonly driven chain sprockets 18. Transversely mounted support members 20 in turn carry article carriers 36 which are each independently mounted for independent movement tranvsversely of the direction of the movement of the drive chains 14 and of the support members 20. As taught by the above cited U.S. patent, pallets 36 are deflected along predetermined paths by means of the interaction of magnetically attractable rollers 42 fixed thereon with magnetic switch means 72 and magnetic guide means 62.
As best shown in FIGS. 3 and 4, the present invention provides an improved design for the transversely mounted support members 20 and for the means for mounting the deflectable pallets 36 on the support members 20. In general, support membes 20 include both an upwardly facing first tread surface 52 and a downwardly facing second tread surface 54 as well as a vertically disposed stiffening member or web 56 connected to each of said first and second tread surfaces. Each pallet 36 has a downwardly extending leg 38 which carries rollers 40 mounted on axle pins 46 with generally horizontally disposed axes of rotation. Rollers 40 engage and receive support from one of said first and second tread surfaces 52 and 54.
In the preferred embodiment whown in FIGS. 3 and 4, the support member 20 consists of a pair of mutually facing channels having cross-sections resembling a squared off C. The lower leg of the C-channel provides the upwardly facing first tread surface 52, and the upper leg of the C-channel provides the downwardly facing second tread surface 54. Connecting these two portions is a vertically extending web means 56 which provides the support member 20 with vertical stiffness. As best seen in FIG. 5, the two mutually facing support channels 20 are linked together and are held separated by a predetermined distance by a rectangular spacer member 26. Channels 20 are fastened to the spacer members 26 by bolts 30 and by positioning pins 58. Each of the spacer members 26 has a pair of holes therethrough for receiving extended chain pins 16 of the roller chain 14. As can be seen in FIG. 3, the roller chains 14 both consist of overlapping links 22 and 24 with each extended chain pin 16 carrying a roller element 28 which engages and rolls along the supporting surface of chain rail 34.
As best seen in FIG. 4, the pallet or article carrier 36 includes a downwardly extending leg 38 which receives therethrough axle member 46 disposed substantially horizontally. Axle pin 46 has a retaining head 48 at one end and at the other end a retaining ring 50 between which are captured a pair of rollers 40 on opposite sides of the downwardly extending leg 38. Rollers 40 are positioned within the mutually facing support C-channels 20 and are sized so that in an upright position the rollers 40 engage and roll along the upwardly facing tread surface 52 without interference with the downwardly facing tread surface 54. It can be readily seen that on the return or lower flight of the conveyor 10 the entire assemblage depicted in FIG. 4 (with the exception of rail 34 and supporting structure 33) is inverted so that rollers 40 engage and roll along tread surfaces 54 which have now become the upwardly facing surfaces.
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A conveyor with laterally deflectable article transporting pallets is disclosed in which the pallets are mounted on a carriage-like structure having wheels which run in and are guided by heavy duty channels.
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FIELD OF THE INVENTION
[0001] The invention relates to a device for bridging a difference in height between two floor surfaces, with said device comprising a profiled cover that is provided with a covering flange which covers the edge of each of the two floor surfaces and at least one clamping extension that protrudes downward from the covering flange, extends longitudinally with respect to the profiled cover, and clamps into and engages with a fixture. The said device also comprises a compensating strip located between the covering flange of the profiled cover and the lower of the two floor surfaces.
DESCRIPTION OF THE PRIOR ART
[0002] A known method for bridging steps or joints in floor coverings is disclosed in WO 99/01628 A1, wherein profiled covers for steps and joints are invisibly attached by means of fixtures. For this purpose, the fixtures consist of a profiled section with a flat horizontal fastening element on the floor side. Extending upward from this flat horizontal element are vertical retaining legs, between which the downwardly protruding clamping extension of the profiled cover is inserted and held in place. In order to bridge height differences between adjacent floor coverings, a hollow cavity is formed adjacent to and along the length of the clamping extension of the metallic profiled cover, allowing the flange of the profiled cover that extends from the clamping extension to bend in such a way that the angle of flex of the profiled cover can adjust to the height difference between the floor coverings to be bridged in each case. Such an adjustment for height differences with respect to the floor coverings being bridged requires the profiled covers to have the requisite flexural properties, which for instance timber building materials do not possess. In order to facilitate a height adjustment between two floor coverings using timber materials accordingly, without the necessity of using various profiled covers, WO 03/04092 A1 discloses a profiled cover with a compensating strip arranged on the low floor side. This compensating strip is provided with an undercut groove for attachment to the underside of the covering flange of the profiled cover. The purpose of the groove is to accommodate a projection on the underside of the covering flange parallel to the clamping extension of the profiled cover in a form-fitting manner. The primary disadvantage of this known device for bridging a difference in height between two floor surfaces is that the projection on the underside of the covering flange hinders the manufacture of the profiled cover and that it is virtually impossible to achieve a form-fitting joint between the profiled cover and the compensating strip due to the unavoidable manufacturing tolerances resulting from the separate production of the profiled cover and the compensating strip. Moreover, the profiled cover can only be used without a compensating strip as a cover for an expansion joint between two level floor coverings if the projection on the underside of the covering flange is removed beforehand.
SUMMARY OF THE INVENTION
[0003] Consequently, the object of the invention is to develop a device for bridging a difference in height between two floor surfaces of the aforementioned type that is able to fulfill the requirements for the exact fit of a profiled cover and compensating strip, while still being simple to manufacture.
[0004] The invention fulfills this object by means of the fixture forming a clamping seat for the compensating strip. Consequently, as the resultant fixture for accommodating the clamping extension of the profiled cover also creates a clamping seat for the compensating strip there is no need for a form-fitting joint between the profiled cover and the compensating strip. This not only facilitates the manufacture of the profiled cover, but also of the compensating strip as there is no provision of a projection on the underside of the covering flange of the profiled cover nor the provision of a longitudinal groove in the covering strip. The absence of a projection on the underside of the cover flange of the profiled cover also means that the profiled cover can be used to bridge expansion joints between level sections of floor, without having to perform additional work on the profiled cover.
[0005] The fixture for the profiled cover and also for the compensating strip can be designed differently as the only important thing is to have corresponding clamping joints to ensure the reciprocal spatial correspondence of the profiled cover and the compensating strip. However, construction is particularly simple if the fixture consists of a known profiled section with resilient retaining legs protruding upwardly from a mounting plate for clamping the clamping extension of the profiled cover. The mounting plate on the low floor side extends past the retaining leg and bears the clamping seat for the compensating strip, which only needs to be pushed onto the clamping seat before the profiled cover with the clamping extension is clamped firmly between the retaining legs and the covering flange rests on the compensating strip. It is advantageous if the clamping seat for the compensating strip can be developed as a retaining leg engaging with a longitudinal channel in the compensating strip, with said leg firmly holding the profiled cover clamped in the profiled section of the fixture transversely to its longitudinal axis. In addition, the covering flange of the profiled cover for the compensating strip can form an abutment on the clamping extension side so that the local clamping extension forms an abutment such that the profiled cover and the compensating strip are not only held in position by the fixture, but also directly by the abutment.
[0006] With the retaining leg serving as a clamping seat there is the advantage that the compensating strip lies against the abutment of the covering flange due to the resilient pretensioning of the retaining leg, facilitating compensation of manufacturing tolerances. If the profiled cover is employed without the compensating strip, for instance to bridge an expansion joint, the widened part of the mounting plate of the fixture can hinder its placement inside the expansion joint. For this reason the section of the mounting plate extending beyond the retaining leg can be removed from the remaining mounting plate by means of a predetermined breaking point.
[0007] The underside of the covering flange without the projection is an essential requirement for a simple manufacturing process with respect to the profiled cover and the compensating strip. This manufacturing process is characterized in that initially a common profiled section is produced, the cross-section of which is formed from the cross-section of the profiled cover and at least one adjoining compensating strip, including machining allowances for kerfing on the underside of the covering flange on the one hand and on the lateral surface of the clamping extension on the other. Then the compensating strip is separated from the profiled cover by cutting along the underside of the covering flange and the lateral surface of the clamping extension. By manufacturing the profiled cover and the compensating strip from a common profiled section with separating cuts along the underside of the covering flange on the one hand and along the lateral surface of the clamping extension on the other, not only can the material for the profiled cover and the compensating strip be utilised advantageously, but also the precision of fit increased enormously as the deviations from the specified cutting plane for the profiled cover and the compensating strip correspond to each other when the profiled cover and the compensating strip are mated, allowing the profiled cover and the compensating strip to be joined without any play.
[0008] Although the profiled section can be limited to the simultaneous production of the profiled cover and a single compensating strip, it can be advantageous to cut two differently shaped compensating strips from one common profiled section with one profiled cover. This can be done if a common profiled section is initially manufactured for one profiled cover and one compensating strip for each side of the clamping extension, before the two compensating strips are separated from the profiled cover by means of a cut along the underside of the covering flange and along each side of the clamping extension. This provides two compensating strips for one covering strip, to be employed as required.
[0009] Manufacturing the profiled cover and the compensating strip or strips at the same time provides additional advantages for coated profiled covers and compensating strips as the structure and appearance of the coating of the profiled cover and the compensating strips are identical if the common profiled section is initially coated on what will become the visible side of the profiled cover and the compensating strip or strips, before then being separated into the profiled cover and compensating strip or strips. The difference between the abutting coatings of the abutting profiled cover and compensating strips can at the most involve changes at the kerfs, changes that are visually negligible owing to the minimal kerf widths.
[0010] If the profiled covers and the compensating strips are coated using droplets, as for instance with spray coating, vacuum deposition or vaporisation, the common profiled section can first be cut along the underside of the covering flange and then be coated before the profiled cover and the compensating strip or strips are completely separated by cutting along each lateral surface of the clamping extension. This partial cut prior to coating has for instance the advantage that the partial coating of the cut between the covering flange and the compensating strip coats the longitudinal edges of the profiled cover and the compensating strip, an outcome that is not achieved if cutting is performed afterwards. In order to prevent the creation of a gap between the covering flange and the floor covering under the covering flange when covering the higher of the two floor surfaces, the cut along the underside of the covering flange of the profiled cover can run at an acute angle, requiring the covering flange to be undercut. This undercutting also causes the compensating strip to be centred due to the wedging effect when the profiled cover is subject to load, pressing the compensating strip against the abutment.
[0011] If the kerfs of the cuts along the underside of the covering flange and the lateral surfaces of the clamping extension only overlap in part of the kerf width, a step is created in the section of kerf overlap that advantageously serves as an abutment for the compensating strip that is pressed against it by the fixture, achieving exact positioning of the compensating strip with respect to the profiled cover.
BRIEF DESCRIPTION OF THE DRAWING
[0012] The drawing illustrates examples of embodiments of the invention. In the drawing
[0013] FIG. 1 shows a device in accordance with the invention for bridging a difference in height between two floor surfaces in a simplified cross-section,
[0014] FIG. 2 shows a frontal view of a common profiled section for producing a profiled cover and two compensating strips,
[0015] FIG. 3 shows a cross-sectional view of the profiled section in accordance with FIG. 2 after a separating cut along the underside of the covering flange of the subsequent profiled cover in cross-section, and
[0016] FIG. 4 shows a cross-sectional view of the covering strip produced from the profiled section in accordance with the FIG. 2 by cutting along the lateral surface of the clamping extension, with the two compensating strips in an arrangement corresponding with the profiled section.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] In accordance with the embodiment in FIG. 1 , a difference in height between a floor surface 1 , for instance a floor covering 2 , and a floor surface 3 requires bridging, with the latter floor surface 3 in accordance with the embodiment being formed by the substrate for the floor covering 2 . The floor surface 3 can of course also be formed by another floor covering. A profiled cover 4 is employed to bridge the difference in height between the floor surfaces 1 and 3 , said profiled cover 4 consisting of a covering flange 5 and a clamping extension 6 protruding downwards from the covering flange 5 , said clamping extension being held and gripped in a fixture 7 . This fixture 7 is developed as a profiled section, having resilient retaining legs 9 protruding upward from a mounting plate 8 , with the clamping extension 6 of the profiled cover 4 being engaged by said legs.
[0018] As the profiled cover 4 is developed symmetrically with respect to a longitudinal middle plane, the profiled cover cannot bridge the difference in height between the floor surfaces 1 and 3 . Accordingly, to bridge this difference in height, provision is made for a compensating strip 10 , which attaches to the underside of the covering flange 5 of the profiled cover 4 on the side with the lower floor surface 3 and rests on this floor surface 3 . To ensure a flush connection between the compensating strip 10 and the covering flange 5 , without provision having to be made for a form-fitting connection between these structural components, the fixture 7 forms a clamping seat 11 for the compensating strip 10 . To this end, the mounting plate 8 extends past the retaining legs 9 and bears a retaining leg 12 at the longitudinal edge of the extension, said retaining leg 12 being inserted into a longitudinal groove 13 in the compensating strip 10 . The covering flange 5 of the profiled cover 4 forms an abutment 14 in the vicinity of the clamping extension 6 for the compensating strip 10 , which is pressed against this abutment by the resilient pretensioning of the retaining leg 12 of the clamping seat 11 , such that the compensating strip 10 is positioned precisely with respect to the profiled cover 4 .
[0019] Accordingly, the difference in height between two floor surfaces 1 and 3 is bridged in an advantageous manner with the assistance of the compensating strip 10 in conjunction with a profiled cover 4 that is symmetrical with respect to a longitudinal middle plane, without impinging upon the use of the profiled cover as a cover for an expansion joint in the vicinity of a floor covering that does not differ in height around the expansion joint. This is achieved by fastening the compensating strip 10 by means of the clamping seat 11 of the fixture 7 as in this case a form-fitting connection between the covering flange 5 and the compensating strip 10 is not required. However, the clamping seat 11 of the fixture 7 for the compensating strip 10 does not preclude an adhesive joint between the compensating strip 10 and the adjacent section of the covering flange 5 , which to this end can be provided with an adhesive strip, which is not represented for reasons of maintaining clarity. If the profiled cover 4 is used without the compensating strip 10 , the widened section of the mounting plate 8 with the retaining leg 12 generally hinders positioning of the fixture 7 . Therefore, the widened section of the mounting plate 8 with the retaining leg 12 is provided with a predetermined breaking point immediately adjacent to the profiled section of the fixture 7 , as indicated in FIG. 1 . Consequently, if required, the retaining leg 12 can be separated from the rest of the profiled section, together with the widened section of the mounting plate 8 .
[0020] Simply positioning the compensating strip 10 on the corresponding section of the covering flange 5 constitutes an advantageous condition for simple manufacturing of the compensating strip 10 and the profiled cover 4 , as the profiled cover 4 and the compensating strip 10 can be manufactured from a common profiled section in accordance with FIGS. 2 to 4 . In accordance with FIGS. 2 to 4 the common profiled section 15 encompasses not only one compensating strip 10 , but also two compensating strips 10 of differing form, something that further expands the application options of the profiled cover 4 thanks to the optional use of either of the two compensating strips 10 .
[0021] As can be seen in FIG. 2 , the cross-section of the common profiled section 15 is comprised of cross-sections of the profiled cover 4 on the one hand and the compensating strips 10 on the other, with provision being made accordingly for machining allowances 16 for kerfs between the covering flange 5 and the clamping extension 6 of the cross-section of the profiled cover 4 as indicated by the dash-dotted line and the abutting compensating strips 10 , the outline of which is also indicated by means of dash-dotted lines. FIG. 3 shows the compensating strips 10 partially separated from the subsequent profiled cover 4 by kerfs 17 along the underside of the covering flange 5 . Complete separation is achieved by cutting along the lateral surfaces of the clamping extension 6 , as indicated by the dash-dotted kerfs 18 . The compensating strips 10 that are completely separated from the profiled cover 4 are visible in FIG. 4 , specifically in a bilateral arrangement corresponding to the profiled section 15 , on which the device is based. It is demonstrated that the profiled cover 4 and the compensating strips 10 can be produced from the same profiled section 15 by simple, straight cuts corresponding to kerfs 17 and 18 , and in fact with the advantage that unavoidable cutting inaccuracies are compensated when the profiled cover 4 and the compensating strips are placed together.
[0022] In accordance with FIG. 3 , the kerfs 17 and 18 only overlap for a section of the kerf width along the underside of the covering flange 5 and along the lateral surfaces of the clamping extension 6 such that a step is produced in the vicinity of the clamping extension 6 of the profiled cover 4 , said step able to serve as an abutment 14 for the corresponding compensating strip 10 .
[0023] In order to avoid gaps at the edges between the covering flange 5 extending over the floor surface 1 and the floor covering 2 , the covering flange 5 must form an undercut so that the longitudinal edge of the covering flange 5 is reliably supported on the floor covering 2 , as shown in FIG. 1 . In order to achieve such an undercut during manufacture of the profiled cover 4 , the kerfs 17 only need to run at an acute angle ‘α’ with respect to the covering flange 5 , as shown in FIG. 3 . The corresponding inclination of the upper side of the compensating strips 10 formed by the kerfs 17 provides the advantage that the section of the covering flange 5 in the vicinity of the compensating strip 10 is supported across the full surface of the compensating strip 10 .
[0024] Manufacturing the profiled cover 4 and the compensating strips 10 from a common profiled section 15 also ensures advantageous conditions for coating the visible surfaces of the profiled cover 4 and the compensating strips 10 in a similar manner as the profiled cover 4 and compensating strips 10 can be coated at the same time as part of the profiled section 15 . Differences regarding the surface structure and the appearance of the coating can only occur as a result of changes near the kerfs 17 when the compensating strips 10 are separated from the profiled cover 4 after the common profiled section 15 has been coated. This separation by means of the kerfs 17 can be performed prior to or after coating, depending on the type of coating. Cutting along the kerfs 17 is recommended after coating with a foil for instance in order to achieve the smoothest transition possible between the coating structure and the appearance of the coating between the compensating strips 10 and the profiled cover 4 . On the other hand, in the case of spray coating, for instance varnishing, it is best to cut along the underside of the covering flange of the common profiled section 15 before coating in order to coat the edges producing by the kerfs 17 as indicated by the dot-dashed lines in FIG. 3 , which indicate the spray coating 19 that extends over the edges and into the kerfed areas.
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A device for bridging a difference in height between two floor surfaces ( 1, 3 ) is described, with said device comprising a profiled cover ( 4 ) that is provided with a covering flange ( 5 ) which covers the edge of each of the two floor surfaces ( 1,3 ), with at least one clamping extension ( 6 ) that protrudes downward from the covering flange ( 5 ), extends longitudinally with respect to the profiled cover ( 4 ), and clamps into and engages with a fixture ( 7 ), with said device also comprising a compensating strip ( 10 ) located between the covering flange ( 5 ) of the profiled cover ( 4 ) and the lower of the two floor surfaces ( 1, 3 ). In order to create advantageous construction conditions it is proposed that the fixture ( 7 ) forms a clamping seat ( 11 ) for the compensating strip ( 10 ).
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of my prior patent application Ser. No. 469,819, filed May 14, 1974 as a continuation-in-part of my prior patent application Ser. No. 290,223, filed Sept. 18, 1972 and both now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to scrubbing of chlorine. More particularly, it relates to catalytic decomposition of hypochlorite formed by scrubbing of chlorine-containing gas.
2. Description of the Prior Art
Scrubbing of chlorine-containing gases with alkali or alkaline earth metal hydroxide solution eliminates discharge to the atmosphere of most of the chlorine. However, the principal product of such scrubbing, hypochlorite, is often present in sufficiently high concentration to contaminate or pollute and create an objectionable odor in the streams or ponds of water receiving it.
It has previously been proposed to decompose such hypochlorites by exposing them to metal oxides such as the oxides of cobalt, copper, nickel or the like.
Kriegsheim U.S. Pat. No. 1,153,502 suggests, however, that the speed and completeness of the action depends very materially on the physical form of the oxide and upon the circumstances such as upon the way in which the reaction mixture and the catalyst are brought together. Kriegsheim, therefore, suggested that the salts of cobalt and other metals should be reacted with a zeolite, apparently to form a compound catalyst. Whether this compound catalyst included the metal as a salt or in oxide form is unclear.
Vasilev and Mikhaylova in KINETICS OF CATALYTIC DECOMPOSITION OF SODIUM HYPOCHLORITE (Kum vuprosa za kinetikata na katalitichnoto razlagane na natriev khipokhlorit.) Godishnik na Khimiko- Tekhologicheskiya Institut, Vol. 10, No. 2, pp. 25-32, 1963, discussed the use of copper, cobalt and nickel catalysts using chloride salts of these metals. They concluded that cobalt was the most effective catalyst. However, conversion of the amount of catalyst used (1 gram-mole per liter) to ppm indicates that a huge amount of catalyst (over 56,000 ppm) was used which would, of course, be economically unattractive. The recital of the amount of other ingredients indicated that Vasilev et al were operating in a pH range of about 13.2. SUMMARY OF THE INVENTION
After extended investigation, I have found that the problems outlined above can be substantially eliminated by catalytic decomposition of the hypochlorite into basically non-polluting products, chloride of the alkali metal or alkaline earth metal and oxygen. To do this, I employ, as catalyst a material containing one or more of the elements cobalt, nickel, copper and calcium, while operating in a pH range of 7-13. The catalyst concentration is at least 9 ppm and most advantageously is between 9-1000 ppm. Representative materials for supplying the catalyst, which appears to be converted to the oxide form in the course of the decomposition of the hypochlorite, include (1) salts (nonoxides) such as the nitrates and chlorides, for example, the hydrated form Co(NO 3 ) 2 .6H 2 O for cobalt (the most effective catalyst according to the invention), (2) the fused metal, and (3) the metal powder, although decomposition rates are generally slower for the catalyst in elemental form.
BRIEF DESCRIPTION OF THE DRAWING
The sole drawing comprises a diagrammatic outline of the process of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
For a better understanding of the invention reference will now be made to the drawing which forms a part hereof.
In the drawing, chlorine-containing gas enters scrubber 10 via line 12 and is scrubbed by sodium hydroxide solution, which enters at line 14. Effluent from scrubber 10 containing sodium hydroxide, sodium carbonate and sodium hypochlorite is conducted at a pH of 8.5 via line 16 to baffled decomposition tank 18, which is maintained at a temperature of 60°C. Catalytic cobaltous nitrate hexahydrate supplied from source 20 enters the scrubber effluent via line 22. Steam enters tank 18 at line 24. During about 6 hours of residence time in decomposition tank 18, the sodium hypochlorite, with the aid of the cobalt catalyst, is broken down into oxygen, which exits at line 26 and is discharged to stack 28, and sodium chloride, which exits at line 30 in an effluent also containing sodium carbonate, the excess sodium hydroxide from the scrubbing operation and insoluble cobalt oxide (CoO).
The hypochlorite treated according to my invention is formed by scrubbing of chlorine-containing gas with a base, for example, alkali or alkaline earth metal compound such as hydroxide or carbonate. When I refer to chlorine-containing gas, I include phosgene and any other gas containing chlorine alone or combined which produces hypochlorite upon alkaline treatment. There may also be some alkali or alkaline earth metal carbonate-which comes from the carbon dioxide in the chlorine-containing gas being scrubbed-in the scrubbing product containing the hypochlorite to be decomposed according to the invention. Such carbonate is usually substantially unaffected by the catalytic treatment of the hypochlorite. Thus, the principal or primary reaction taking place during the decomposition procedure employed according to my invention may be represented by the net overall equation,
2NaOCl → 2NaCl + O.sub.2 ↑,
the resulting products being substantially non-polluting.
I have determined that the rate of decomposition of the hypochlorite when a cobalt catalyst is used may be calculated from the equations,
log r = 0.0324T + 1.3703 log Z - 0.16699 pH--4.6162
and
r = log N.sub.o - log N.sub.F,/t
wherein r is the rate constant of decomposition, T the temperature in degrees Centigrade (°C), Z the cobalt catalyst concentration (expressed as the element) in parts per million by weight (ppm), N o the initial NaOCl concentration in grams per liter (g/1), N F the final NaOCl concentration in g/1 and t the time of residence in the tank in minutes. Preferred catalyst concentration is at least about 9 ppm, most advantageously between 9 and 1000 ppm. Representative materials for supplying the catalyst, which appears to be converted to the oxide form in the course of the decomposition of the hypochlorite, include salts such as the nitrates and chlorides, for example, the hydrated form Co(NO 3 ) 2 .6H 2 O for cobalt (the most effective catalyst according to the invention), the fused metal and the metal powder, although decomposition rates are generally slower for the catalyst in elemental form. Thus, the use of the term "salts" as well as the terms "fused metal" and "metal powder" are intended to exclude metal oxides.
The pH may be adjusted for optimum decomposition and is preferably held at 7-13, since at a pH below 7 the hypochlorite may decompose spontaneously and release free chlorine gas, and at a pH above 13 the hypochlorite becomes stabilized, requiring unduly high amounts of catalyst. The optimum temperature range for conducting the hypochlorite decomposition according to the invention is 20°-80°C, 45°-75°C being preferred, although the solution to be treated may reach its boiling point without any adverse effect.
While the process of the invention may be conducted batchwise, I prefer to decompose the hypochlorite by passing it substantially continuously through a baffled vessel in the presence of the catalyst via a circuitous route.
The following examples are illustrative of the invention.
EXAMPLE 1
A solution containing sodium hypochlorite was prepared by scrubbing chlorine with sodium hydroxide, the solution also containing Na 2 CO 3 from the reaction of CO 2 with the NaOH, and a small excess of NaOH. The pH of the solution was controlled to be between 8 and 9. The relative rates of decomposition of such solution with various cobalt-supplying catalysts are shown in Table I, using for comparison a rate of (1) for a single piece of cobalt. In the run employing the cobalt nitrate hexahydrate catalyst, a finely divided cobalt oxide (CoO) precipitated
Table I______________________________________Relative Rates of Decomposition of NaOCl 27°C 50°CCo Additions 600 ppm Co 50 ppm Co______________________________________Co(NO.sub.3).sub.2.6H.sub.2 O (crystals) 2.9 3.6Co Powder < 325 mesh 2.0 2.0Co (single spherical piece) 1.0 1.0______________________________________
EXAMPLE 2
Waste sodium hypochlorite from alkaline scrubbing of chlorine was decomposed into NaCl and O 2 in a series of runs, varying the conditions of operation as they appear in the following table.
Table II______________________________________Inlet Outlet ResidenceNaOCl, NaOCl, Temp., Time Co,g/l g/l °C pH min. ppm______________________________________ 3.3 0.08 43 7.3 900 18-2193.4 0.7 90 11.6 450 980.0 2.0 80 11.6 500 12______________________________________
EXAMPLE 3
A system for decomposing hypochlorite to chloride and oxygen similar to that of the drawing was operated continuously for several days, decomposing approximately 10 gallons per minute of an 85 g/l sodium hypochlorite solution resulting from scrubbing chlorine with sodium hydroxide.
EXAMPLE 4
The addition of 45 ppm cobalt from cobaltous nitrate hexahydrate, [Co(NO 3 ) 2 .6H 2 O] to a solution coming from a scrubber in which chlorine-containing gas was scrubbed with sodium hydroxide, the solution containing 85 g/l sodium hypochlorite and being at a pH of 8.5 and a temperature of 47°C, resulted in catalytic decomposition of the hypochlorite to sodium chloride and oxygen in 6 hours. The initial hypochlorite concentration was determined by iodometric titration. The rate of sodium hypochlorite decomposition was determined by measuring gas evolution as a function of time in a water displacement apparatus. Displacement was recorded periodically from burette readings and temperature read with a thermometer suspended in the solution. The solution was stirred continuously with a magnetic stirrer. The volume of gas displaced was the difference between the initial and final burette reading, each milliliter of the burette reading being equivalent to 0.2 g NaOCl per liter. The volume of oxygen evolved was determined, assuming ideal behavior for the gas. After calculation of moles of oxygen released, the amount of sodium hypochlorite which should remain after decomposition was determined from the equation NaOCl → NaCl + 1/2 O 2 . This value was then subtracted from the initial hypochlorite concentration and found to be substantially the same as the comparative value obtained by iodometric titration of the final solution. The volume of collected gas also agreed quantitatively with the measured titration value. Mass spectrographic analysis showed that the collected gas formed by the catalytic decomposition of the hypochlorite was oxygen.
EXAMPLE 5
A comparison was made of the relative activities of cobalt, nickel, copper and calcium catalysts in decomposing sodium hypochlorite obtained by alkaline scrubbing of chlorine into sodium chloride and oxygen. Relative activities were found to be 115, 40, 10 and 1 respectively, using the 1 for the reference or comparison point.
EXAMPLE 6
To further compare the process of the invention to the use of compound catalysts using zeolite supports as suggested by the prior art several runs were made using, in each instance 70 ppm cobalt. A standard NaOCl solution was prepared by adding 40 grams of NaOH to 1000 cc of H 2 O and mixing until dissolved. Cl 2 was then bubbled through the solution while monitoring the pH. The Cl 2 was then shut off and N 2 bubbled through the solution for 1/2 hour. The final pH reading was 10.
For run A (corresponding to the process of the invention) 0.011 grams of Co(NO 3 ) 2 .6H 2 O was added to 30 cc of the above NaOCl solution at 58°C. The evolved gas (O 2 ) was measured every 5 minutes using an inverted burette until evolution stopped.
For run B, 0.046 grams of an impregnated zeolite containing 70 ppm cobalt was substituted for the cobaltous nitrate of run A. The impregnated zeolite was prepared by adding 100 grams of cobaltous nitrate [Co(NO 3 ) 2 .6H 2 O] to 200 cc of H 2 O. After the cobaltous nitrate had dissolved, 10 grams of a zeolite mixture CS-207-V (Fisher Scientific) was added and the mixture stirred for 1 hour to saturate the zeolite with the cobaltous nitrate solution. The mixture was then filtered and the impregnated zeolite was placed in an oven to dry overnight at 110°C.
From previous experimentation, it has been determined that Co(NO 3 ) 2 .6H 2 O, when heated to 250°F (about 120°C) converts to Co(NO 3 ) 2 .3H 2 O. Using this computation, 0.046 grams of the impregnated zeolite (including the tare weight of the zeolite) was calculated to provide 70 ppm cobalt as in run A. This amount of impregnated zeolite was then placed in 30 cc of the above NaOCl solution at 58°C and the evolution of gas again measured as in run A.
In run C, 0.031 grams of a zeolite impregnated as described above was used. This zeolite, however, was previously heated to 1500°F to convert the impregnated Co(NO 3 ) 2 .6H 2 O to CoO. The 0.031 gram amount was calculated to provide 70 ppm cobalt as in runs A and B (including the tare weight of the zeolite).
This impregnated zeolite was added to 30 cc of the above 58°C NaCl solution and the evolution of gas again measured.
The results for runs A, B, and C are all tabulated below.
Table III______________________________________Time in minutes Evolved Gas in ml. Run A Run B Run C______________________________________5 60 5010 116 9315 158 12720 188 15025 200 16430 202 17635 203 18440 204 18645 204*505560 19185 195135 204145 73180 204*190 92225 103265 108300 114330 117380 125395 125*______________________________________ *Test Stopped
The results clearly indicate that there is no benefit and actually some detriment in using the compound catalyst utilizing zeolite carriers as taught in the prior art. Furthermore, as seen in run C, introduction of the cobalt initially in oxide form provides inferior results compared to the introduction of the cobalt as a salt, as that term has been defined hereinabove.
While I do not wish to be bound by any theory, it seems that possibly the introduction of the cobalt catalyst into the NaOCl solution as a salt or in elemental form results in a precipitate of cobalt oxide with enhanced catalytic properties compared to the use of cobalt already oxidized. This may be due to a more finely divided cobalt oxide being precipitated from the NaOCl solution.
In any event, it can be clearly seen that the use of an unsupported catalyst in accordance with the invention in run A resulted in complete reaction in less than 1 hour while the use of supported catalysts in salt or oxide form as in runs B and C respectively resulted in longer reaction times which--in the oxide case--was over 6 hours with incomplete reaction.
While the invention has been described in terms of preferred embodiments, the claims appended hereto are intended to encompass all embodiments which fall within the spirit of the invention.
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Use of Co, Ni, Cu or Ca catalyst to decompose hypochlorite contained in the product resulting from scrubbing of chlorine-containing gas.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of my prior U.S. patent application Ser. No. 06/817,708, filed Jan. 10, 1986, now abandoned.
FIELD OF THE INVENTION
The invention is concerned with improvements in or relating to ammeters for attachment to A.C. electric power lines for measurement of the current passing through the power lines, and particularly to such an ammeter which will permit on-line recording of the current passing through the line over a period of time.
REVIEW OF THE PRIOR ART
There is a continuing need in power systems practice to provide accurate information as to the distribution of line loading in various power lines, since such information is required for decisions regarding distribution, new installations and load transfer. This information normally is obtained by the use of portable or permanently installed recording ammeters consisting of at least one insulated current transformer which is clipped onto the line under investigation and is connected to a recorder. Such apparatus involves significant operational, reliability and safety problems, especially with higher power lines e.g. 27.6 kV and 44 kV, owing to the difficulty of ensuring safety in installation and removal and maintenance of adequate insulation during use.
Ammeters of the so-called snap-on type are well known consisting of a hinged core, the jaws of which are opened to provide a gap wide enough for it to be snapped onto the power line whose current flow is to be measured, the jaws being held closed by a spring to ensure that it constitutes a substantially continuous magnetic loop permitting the current to be measured without substantial error irrespective of the position of the ammeter on the power line. The use of such ammeters becomes extremely difficult with high power lines owing to their weight and the mechanical difficulty of manipulating the movable jaws while installing the device and removing it from the line, and also the problems inherent with the high voltages involved. Examples of such split core transformer ammeters are disclosed in U.S. Pat. Nos. 2,295,959, 3,102,988 and 3,984,798.
Current transformer measuring apparatus which avoids the need for such a split core is disclosed in U.S. Pat. No. 2,375,591 to E. O. Schweitzer, Jr., his apparatus typically employing two C-shaped core members which are clamped together with joining sections between them to form a single core having a single gap; a single winding is mounted on the core for connection to external measuring apparatus. In one embodiment the core has a special configuration that permits the device to be mounted on the line by lifting it vertically until the core extends on opposite sides of the line, and then rotating the device about the vertical axis through 90 degrees. Schweitzer, Jr. is concerned to minimize the effect of this very large single gap on the reluctance of the core.
DEFINITION OF THE INVENTION
It is therefore a principal object of the invention to provide a new ammeter particularly adapted for attachment to an A.C. electric power line for measurement of the current passing in the power line.
It is a more specific object to provide a recording ammeter which can readily be attached to an A.C. power line and will record the current passing in the line for a substantial period of time.
In accordance with the present invention there is provided an ammeter for mounting on an A.C. electric power line for measurement of the current passing in the power line, the apparatus comprising:
(a) a support member;
(b) two at least approximately C-shaped flux-concentrating magnetic cores each comprising a base portion and two arm portions mounted oppositely to one another on the support member, the cores being separated at all times from one another to provide a power line receiving air gap between them with corresponding arm portions thereof disposed opposite to one another to define between the said oppositely disposed arm portions two respective opposed separate permanent non-magnetic gaps through one of which the power line passes while mounting the ammeter on and dismounting the ammeter from the power line;
(c) at least two opposed multi-turn inductive coils wound respectively on the cores and connected in series with one another;
(d) measuring means connected to the said coils for measuring directly the current flowing therein, thereby obtaining a measurement representative of the current passing in the power line; and
(e) means for locating the line within the power line receiving space at least approximately centrally between the two cores.
For a recording ammeter intended to be left in position for an extended period of time, the said means for locating the line comprise clamp means on the support member adapted to engage the power line and to clamp to the power line with the power line in position passing through the power line receiving space between the two cores.
Preferably the clamp means is clamped to and unclamped from the power line by movement of an operating member having a loop for engagement by a live-line hook stick for an operator to effect the said movement.
For an ammeter intended for spot measurements, the said means for locating the line comprise a closed-end slot within the support member and into which the line is passed to mount the ammeter on the line, the closed end of the slot being disposed at least approximately centrally between the two cores.
The apparatus may include current measuring and recording means mounted on the support member and electrically connected to the coils.
The apparatus may also include means for powering up the current measuring means for successive measuring periods spaced from one another by respective predetermined non-measuring intervals, and for powering down the current measuring means during the said non-measuring intervals, and for powering up the recording means during both the said non-measuring intervals and the said measuring periods.
DESCRIPTION OF THE DRAWINGS
Electronic recording ammeters which are particular preferred embodiments of the invention will now be described, by way of example, with reference to the accompanying diagrammatic drawings, wherein:
FIG. 1 is a perspective view of a first embodiment of the apparatus intended for mounting on an A.C. power line for extended periods, and showing it mounted on a power line;
FIG. 2 is a side elevation view of the apparatus of FIG. 1;
FIGS. 3a and 3b are together a circuit diagram of the electronic circuit of the recording ammeter;
FIGS. 4a and 4b are together a circuit diagram of the electronic circuit of a display module for use with the recording ammeter;
FIGS. 5a and 5b illustrate the preferred manner in which the coils of the ammeter are oriented relative to the power line conductor;
FIG. 6 is a flow chart showing the mode of operation of the recording portion of the ammeter;
FIG. 7 is a side elevation view of a second embodiment of the apparatus, intended for manual mounting on the A.C. power line; and
FIG. 8 is a side elevation of a third embodiment of the apparatus, intended for mounting on a large diameter power line.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 1 and 2, the ammeter comprises a support member consisting of a plate 10 of non-magnetic material, such as aluminum, to which is fastened two opposed C-shaped cores 12 of high permeability material, a clamp 14 and a non-magnetic, weather-proof container 16 for the electronic circuit. In the embodiment illustrated each core 12 has a longer base side 18 and two shorter arm sides 20 and 22. The cores are securely attached to the support member 10 oppositely to one another, so that two of the shorter opposed arm sides 20 together define a substantial permanent gap 24 large enough to permit the passage therethrough of the largest diameter power line 28 with which the ammeter is intended to be used. The other shorter arm sides 22 together define a similar permanent gap 26 directly opposite to the gap 24. The two base sides 18 each has mounted thereon a multi-turn inductive coil 30, the two coils being connected in series with one another and oppositely wound. In a specific embodiment each of these coils consists of approximately 10,000 turns of AWG 36 wire. In a commercial embodiment at least the cores and coils are enclosed by a protective coating, which is omitted in the attached drawings in the interest of clarity of illustration. The coils are connected to the electronic circuit as will be described below.
The clamp 14 of this embodiment consists of a fixed portion 32 which is rigidly secured by bolts 33 to the enclosure 16, and thus to the support member 10, and comprises the fixed jaw of the clamp. The movable jaw of the clamp consists of a movable member 34 guided for movement to and away from the fixed jaw member by a guideway 36 and moved towards and away from the fixed jaw member by a screw-threaded rod 38 which is rotatable about its longitudinal axis while anchored in the movable member against longitudinal movement by a pin 40, the rod being screw-threaded into a suitable screw-threaded recess in the fixed portion 32. The rotatable rod has at its free end a loop 42 which can readily be engaged by the standard live-line hooked stick used, for example, by line servicemen for fuse manipulation, the engagement permitting the device to be picked up and hoisted into position on the line, and thereafter the rod rotated to close the clamp on the line. The clamp member and the magnetic cores 12 are so mounted relative to each other by the support member that, with the clamp firmly clamped onto the power line 28, the line passes at least approximately through the magnetic and geometric centers of the two cores. Thus, the current measured by the device is least sensitive to variations in the position of the conductor when the conductor is placed at the center of the rectangle defined by the two cores. Since it is desired to be able to use each device with power lines of a range of different diameters, and a fixed jaw clamp is used in this embodiment, exact concentricity will only be obtained for a power line of one specific diameter. However, any small displacements of the centre of the conductor involved in its use with power lines of different diameters does not cause any unacceptable error. In a specific embodiment the clamp has been positioned such that the center of a clamped conductor having a diameter of 15.8 mm (0.625 inches) is approximately at the center of the rectangle.
In operation, the device is picked up using the live-line stick and positioned on the power line to be investigated by maneuvering until the fixed portion of the clamp rests on the line. The line stick is now rotated, thereby rotating the screw member until the clamp has been clamped onto the power line, the device also being rotated about the longitudinal axis of the line until the core and its windings is in the desired relationship to the line and to adjacent parallel lines, as will be discussed below. The clamp is then finally tightened onto the line and will hold the ammeter securely in place for as long as is required, while the associated circuitry to be described below measures the current passing in the line and stores the information in the memory provided therein.
It is also possible to provide the ammeter with measuring means constituted by a display device, consisting of, for example, a relatively large size LCD display 44, shown in broken lines in FIG. 1, that will display the current value measured by the device in a manner that it can be read from the ground. Such an arrangement permits spot checks to be made of the current flow, but usually is not more generally used, since the battery consumption of the display is relatively high compared to the remainder of the circuitry and it cannot therefore be left in position for as long periods as when the device is storing the information in the manner to be described.
It is further possible to provide the ammeter with measuring means comprising a low-power transmitter that will transmit signals representative of the measured values to a nearby receiver for storage, or more usually for transmission by telephone line to a central monitoring station. The use of such a transmitter/receiver link has the advantage of providing isolation of the line-mounted ammeter from the telephone system used to transmit the information.
As described above, most of the prior art devices proposed hitherto require the magnetic ore or cores to have the parts thereof fitted tightly together with the minimum possible gap or gaps, U.S. Pat. No. 2,375,591 of Schweitzer, Jr. disclosing a device with a single permanent gap that is relatively large, and Schweitzer is concerned to minimize the effect of this large air gap. In a current transformer it is necessary to provide a low reluctance path around the core for the magnetic flux and therefore no gap, or at most only the very narrow gap produced by the cores touching is preferred, to avoid saturation and ensure a sufficient flow of flux to induce enough current in the secondary winding. In the unsaturated condition the current induced in the secondary winding is a good replica of the primary current, with its value directly related to that in the primary current line by the turn ratio between them, as is conventional. The secondary winding and its shunt (i.e. the meter) are designed to have as low an input resistance as possible, so as not to unduly load the secondary winding and ensure accuracy.
The devices of the present invention are more accurately regarded as current transducers. The cores in the special configuration characteristic of the invention, namely two C-shaped cores permanently mounted with fixed air gaps to allow a conductor to enter readily between the cores, have the cores acting as "flux concentrators". Thus, the device is permeated by the flux generated by the power line current flowing in the power line on which it is mounted and, owing to the low permeability of the air gaps between the cores, the flux that would be incident on the gaps flows preferably through the nearest core to be concentrated therein. This is to be contrasted with the prior art split core devices where the gap must be made virtually zero to enable the flux to circulate in the core across the gap. It is found that once substantial gaps are present between the core ends there is relatively little effect on the accuracy of the device in varying the size of the gaps over quite a wide range. This line current flux induces a relatively small amount of flux in the cores, but this induces a satisfactorily measurable current in the multi-turn coils that are wound around the cores. As will be described below, care is taken with the devices of the invention to avoid errors due to unequal flows of flux in the two flux concentrators, and to this end the two gaps 24 and 26 are preferably of equal width, even though only the gap 24 through which the line 28 passes needs to be physically wide enough for the line to pass easily therethrough.
FIG. 7 shows in side elevation a second embodiment that will permit rapid measurement of the current passing through a line 28 when "spot" measurements of this kind are required, without the need to clamp the ammeter to the line. The same references are used for similar parts whenever possible. The support 10 has a container 16 fastened thereto which may contain a recorder and/or transmitter and/or may incorporate a visual display 44 of a size to be read from the ground. The support also has a protruding arm 46 to which is fastened by a pivot joint 48 an insulated stick 50 by which the ammeter is lifted and placed on the line whose current is to be measured. The joint 48 allows for adjustment of the inclination of the device to the stick to minimize errors, and ensure that the visual display device, when provided, can easily be read from below. The aluminum support 10 is provided with a front-opening, closed-rear-end slot 52 having convex, converging, leading edges 54, the part of the slot between the core arms 20 being of the same height as the gap 24. The length of the slot 54 is such that when the line 28 is pressed firmly against its closed end 56 it is positioned accurately centered between the two cores 12. The center portion 10A of the support 10 in which the slot is formed is made removable from the remainder of the support, so that the same instrument can be used with different diameters of line 28 by providing respective center portions 10A with respective slots of the required height and length for the corresponding line diameter.
FIG. 8 shows in side elevation a third embodiment intended primarily for use with large diameter power lines which would result in gaps 24 that are larger than is desirable. To this end the lower part 58 of the base plate 10 is pivoted at 60 to the remainder of the plate and urged to the closed position of minimum size shown in FIG. 8 by a coil spring 62 around the pivot 60 with its end engaging a stop 64. Thus, as the device is pressed against the power line the jaws 54 of the slot can open to pass the line 28 through the smaller part of the slot adjacent to the enlarged end 56 until it reaches the enlarged closed slot end 56 when the jaws are again closed by the spring while the power line is positioned accurately centrally, as with the two previously described embodiments. The jaw again opens when the device is withdrawn from the line.
Although these embodiments are intended primarily for spot measurements, and consequently employ a visual display, they will also with advantage include means for recording the values measured together with time, date, etc., so that a permanent record is also provided.
Referring now particularly to FIGS. 3a and 3b, a preferred electronic circuit for the ammeter of FIGS. 1 and 2, and usable also with the ammeter of FIGS. 7 and 8, consists of a microcomputer U1 connected to an external RAM module U2; in a typical application, a RAM of 2K bytes capacity is ample for approximately 20 days operation. The microcomputer requires a relatively large operating current (typically about 60 mA) and in order to conserve battery life it is turned on only briefly and only when required which, in this embodiment, is about 2 ms every 16 seconds when recording, or else 2 ms every 3 seconds if the visual display is connected, this being sufficient time to maintain the display. Thus, the microcomputer is normally only switched on every 16 seconds for a period of 2-5 ms and the respective power supplies thereto are therefore designated as +5 V (SW) to indicate that they are intermittent. The RAM unit U2 is constantly powered to maintain the information stored therein. Power for the microcomputer and the related circuitry is taken from capacitor C3 which is charged through a resistor R1 from a high capacity 9 V battery 66 when the microcomputer is switched off. Voltage regulation is provided by module U6 and is set at 5.1 V as determined by the voltage divider chain R3 and R4. The supply to the microcomputer and to an analog/digital converter U3 is switched by means of transistors Q2 and Q3, these transistors being turned on either by the flip-flop U6 or by a NAND gate U5-A whose input is tied to pin B of the external connector where the external power is applied. The NAND gate has a one second delay to allow time for good connection to the connector.
The circuit also contains a real time clock consisting of a 32,768 Hz crystal oscillator Y1 whose output is divided down by divider U4 to provide in a negative-going transition every 16 seconds at pin 11 thereof. This transition sets a flip-flop consisting of the two NAND gates U5-C and U5-D which turns on the microcomputer. The microcomputer increments a seconds counter by 16 seconds units and updates a minute-of-day counter and a day-of-year counter, these counter values being stored in the RAM during power down.
The clock consists of three counters, one of which keeps track of the day of the year, one counts the minutes of the day and the third keeps track of seconds. The first two are programable and the seconds counter is reset to zero whenever the time is reprogrammed. The minute of the day and day of the year counters can be programmed.
Alternatively, the flip-flop U5-C and U5-D can be set by an externally applied pulse provided at pin F for remote start up of the device. The flip-flop will be reset by a negative-going transition transmitted at pin 19 of the microcomputer. If not reset in this manner, it will reset unconditionally after a period of 10 ms, the time delay provided by the combination of resistor R14 and capacitor C10.
The microcomputer is turned on in one of three ways, each determining a particular mode of operation, namely:
(1) A pulse is sent every 16 seconds from the real time clock signalling an "update time mode" operation.
(2) A pulse on pin F is sent every 3 seconds from the external display module if connected to the ammeter resulting in "display mode" operation.
(3) When a suitable external voltage is applied to pin B of the outside connector resulting in an "output mode" operation.
In the "update time mode", which is the normal program of operation of the device, the microcomputer updates the date and time and takes a current measurement every 16 seconds. Over a 15 minute period, either 56 or 57 samples are taken and totalled. At the end of each 15 minute period, at 0, 15, 30 or 45 minutes after the hour, the average is calculated and stored in memory with the newest data overwriting the oldest data. The normal time required to update the clock and take a current measurement is about 2 ms, while the time required every 15 minutes to calculate the average and store it in memory is about 5 ms.
Current transducer T1 consisting of the coils 30 produces an A.C. signal that is applied to a diode bridge CR9, which rectifies the signal and generates a corresponding D.C. voltage. The current range in which the ammeter operates is selected by a switch 68 (FIG. 3b), which either connects with resistor R26 and R27 for a 250 amp scale, or else connects resistors R28 and R29 across the resistors R26 and R27 to obtain a 500 amp scale. The microcomputer determines which setting is operative via an input port comprising pin 6 of unit U1. To prevent excessive input voltages due to an incorrectly selected current range, or fault level currents, a Diac Q7 conducts when the input signal is greater than 20 V to fire a Triac Q6, thereby shorting the current sensor. After being rectified, the signal is filtered by a resistor R25 and capacitor C15 and is limited to a maximum of 6 V by a zener diode Z3. The resultant voltage is then fed to the input of the analog/digital converter U3, producing a signal corresponding to the voltage level detected. Since the A/D unit U3 is powered down most of the time, an FET switch Q5 prevents the capacitor C15 from discharging into the device. The timing for the A/D converter U3 is determined by resistor R23 and capacitor C14, the converter beginning a sample when a write pulse is received from the microcomputer. After a conversion from analog to digital is completed, the digital code is read by the microcomputer and stored in the RAM unit together with the information corresponding to the minute-of-day and day-of-year.
After sufficient information has accumulated, the device is removed from the power line and may then be connected to a computer via port AE. With the device powered externally, determined by pin 38 of microcomputer U1, it will output the contents of the memory on serial output port pin 23. The resistor R13 and transistor Q4 are used to generate the required zero and +5 V signals, while a transzorb Z2 provides transient protection. Input to the microcomputer occurs at test port T1 (pin 39) with resistor R11 providing current limiting and a zener diode Z1 providing transient protection.
When the display module 44 is to be used with the embodiments of FIGS. 7 and 8, or when it is connected to the ammeter of FIGS. 1 and 2, the display circuitry shown in FIGS. 4a and 4b takes control of the microcomputer in between normal current samples taken every 16 seconds. The display information is sent to the display via the transmit port using pulse width modulation for each bit. When the display is first connected to the ammeter, the logic is reset. The display logic waits until the ammeter takes a normal 16 second current sample. The display shows 8's while waiting. When the transmit port goes HI (terminal E of the connector) indicating that the ammeter is powered up and a current sample is being taken, monostable flip-flop U1-B is set, thus starting oscillator U6-A. The monostable has such a long time delay that it acts as a latch. The oscillator produces four 300 μs pulses on the output of U6-C, which are 3.2 seconds apart. These pulses are output on terminal F setting the latch in the ammeter thereby powering up the microcomputer. The receive port, terminal A, is shorted during these four pulses by transistor Q1 to indicate to the microcomputer that the display initiated the power up and a display update is required. The pulses are also fed to counter U2(B) which resets latch U1(B) and the counter after four pulses.
When the microcomputer in the ammeter is powered up by the display, it takes a sample and outputs the display code on the transmit port (terminal E). The display code consists of twelve bits, 4 per digit, each bit being 100 μs long. A "zero" bit is LO for 33.3 μs and HI for 66.7 μs, whereas a "one" bit is LO for 66.7 μs and HI for 33.3 μs. A 50 μs one-shot U1(A), fires every time the transmit signal goes LO. After the one-shot times out, the transmit signal is clocked into the shift register. After four shifts, Q1 of counter U2(A) will go LO, writing the code for one digit into the display driver's memory, as addressed by Q2 and Q3. The other two digits are stored in the display driver's memory in the same manner. The counter, U2(A), is reset by a pulse generated by capacitor C14 when the transmit line goes HI, just before the display code is sent.
The apparatus should be mounted on a relatively straight section of the conductor, keeping it away from the nearby conductors where possible, especially ones carrying high current, since one of the main sources of possible error is the presence of magnetic fields produced by these nearby current carrying conductors. In most cases, these errors are negligible as long as the conductors are at least 1.5 m (5 feet) away, regardless of how the device is mounted. If the coils of the transducer are perpendicular to the magnetic lines of force as shown in FIG. 5a, the effect of the field of the external conductor on the two legs will approximately cancel. In the configuration of FIG. 5b, since the cores are wound in opposite directions, there would be no effect in a uniform field. However, in this case one leg is closer to the external conductor than the other, and therefore the induced currents are not equal, resulting in a net error. These errors are minimized by keeping the apparatus at least 45 cm (1.5 feet) away from the conductors carrying currents comparable to the one being measured, and by avoiding placing the device within 1.5 m (5 feet) of conductors carrying higher current. If this is not possible, the arrangement of FIG. 5a should be followed to keep errors as low as possible. In this industry errors of ±5% are acceptable and the coil/core arrangement of the invention has been made to have errors in the range ±1-2%, with additional errors occuring in the electronic circuit.
With the embodiments of FIGS. 7 and 8 the attitude of the support 10 on the stick 50 is adjusted as necessary, depending for example on whether the different lines are spaced from one another horizontally or vertically.
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The invention provides an ammeter specially suited for measuring the currents passing in high voltage, high power A.C. lines and, when required, storage of the resultant information, together with time of day and date over an extended period of time. The ammeter employs two C-shaped cores defining between two of the core arms a relatively large permanent gap that can pass the power line to facilitate mounting on the line using a live-line stick. One embodiment intended for mounting for an extended period of time also employs a clamp that can be manipulated using the stick to clamp it to the line and unclamp it, the clamp and core being related so that the power line passes through the center of the space between the cores. An embodiment intended for "spot" measurements has a locating member that performs the same function. A third device has the locating member in two parts that pivot to enable a large power conductor to pass through the slot in the locating member to the closed locating end thereof. The devices may be characterized as "current transducers" and the two cores carry respective coils that are oppositely wound on the core arms opposite to one another. The A.C. signal from the coils is converted to a digital signal and is fed to an external display and/or is recorded in a non-volatile memory together with the time and date data using a microcomputer that is powered only during the short interval required for measuring, thus conserving battery power.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a division of application Ser. No. 401,524 filed Sept. 27, 1973 and now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the field of printer devices. In particular, the invention relates to the field of printers utilized as the output of the computer as well as to the field of print registration for such a printer.
2. Description of the Prior Art.
Record is made of a known automatic print gap adjusting mechanism utilized with the IBM 3211 printer. Known prior art patents made of record in this application are U.S. Pat. Nos. 2,993,437, 3,049,990 and 3,183,830. These patents are cited as being of interest since they relate to the art of print registration.
Previously known designs of printer gap adjusting mechanisms utilized with conventional impact printers have required operator intervention. Accordingly, it has been the practice in these known printer arrangements to require manual adjustments to compensate for varying forms and ribbon thicknesses. Manual adjusting of the print gap has not been entirely satisfactory for the fact that it is a time consuming operation and further for the fact that the operator may forget to make such necessary manual adjustments after inserting new forms or ribbon. When there is a failure to obtain a proper print gap clearance, the possibility of paper jams, character edge clipping and improper print registration becomes proximate. Therefore, it is with these shortcomings in mind that the instant automatic adjustment technique has been designed.
SUMMARY OF THE INVENTION
The invention discloses an "on the fly" printer which utilizes a closed loop servo mechanism which provides an automatic adjustment of the print band with respect to the print hammer. The technique comprises initially making a measurement of both the ribbon and the form thickness which are variable. The above measurement is made from a sub-carriage assembly which includes the print band and further includes a probe which is extended against the forms pack under spring pressure. The shape of the end of the probe and spring are formed to simulate the actual printing operation. Upon completion of the above mentioned measurement, the sub-carriage is repositioned with respect to the fixed print head until a desired position is obtained. The desired separation between the print hammer and print band is achieved when a null position is developed by the servomechanism. The null position varies in accordance with the thickness of the forms and ribbon.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 depicts a mechanical arrangement for developing automatic gap positioning for the printer mechanism utilized in this invention.
FIG. 2 shows the logical circuitry utilized in conjunction with the mechanical arrangement in FIG. 1 for developing the automatic print gap adjustment.
FIG. 3 is a schematic of the probe and eccentric drive motor control circuit.
FIGS. 4 (a) and 4 (b) illustrates the probe device utilized in the print hammer simulation cycle.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 discloses a printer device assembly which is utilized as the output of a digital computer. The printer assembly disclosed operates in accordance with well-known "on the fly" printing principles. With this type of operation, a plurality of uniformly spaced engraved type members (not shown) are attached to a continuous belt 18. Suitable drive means such as a constant speed electric motor (not shown) including drive gears are provided to advance the print band in a continuous horizontal path and along a print line. A plurality of hammers such as 11 associated with an assembly known as a print head 10 are arranged in a horizontal fashion and opposite the print band. Each print hammer is associated with a solenoid which when energized causes the print hammer to strike the appropriate letter on the print band 18. Interposed between the print hammer 11 and the print band 18 is the forms pack 12, the ribbon shield 14 and the ribbon 16. The forms pack 12 comprises the paper forms upon which printing is to be performed. It should be noted hereat that the forms pack 12 and the ribbon 16 may have a varying thickness depending upon the type of paper and ribbon used or the number of carbon copies required. Therefore, as can be readily appreciated, when the hammer 11 is actuated by the solenoid against the print band 18 a character will be printed on the forms of the pack 12 in view of the interposed ribbon 16.
The print band 18 and its associated assembly is attached to the sub-carrier 28. Also the probe assembly 20 is permanently attached to the sub-carriage 28 via the L shaped bracket 25. The probe assembly 20 comprises essentially a linear variable differential transformer (LVDT). As is well known in the art, an LVDT is a transformer arrangement having both secondary and primary windings wherein the core 15 is moveable in a linear fashion between the primary and the secondary winding. The windings of the LVDT are permanently positioned in the probe assembly housing 20 which is in turn permanently positioned to the sub-carriage 28 via the L shaped bracket 25. Attached to the LVDT core 15 is a probe 21. The probe via the core 15 of the LVDT can be extended by means of a motor (not shown) which is connected to the coupling 29 by means of a linkage 88 (FIG. 4). As depicted in FIGS. 1 and 4, the probe 21 is extended against the ribbon 16 and through the ribbon shield 14 until it touches and presses against the forms pack 12 via the coupling 29 and the compression spring 31. When the paper pack 12 is contacted by the probe, the latter stops but the motor continues to compress the spring 31 until correct spring pressure is obtained. In other words, the motor will compress the spring 31 until it contacts an adjustable limit switch 90 and this action will constitute the correct spring pressure. The shape at the end of the probe 21 is formed together with the spring 31 to simulate the actual printing operation as will be discussed in greater detail in FIG. 4.
Positioned below the sub-carriage 28 is the main carriage 24. An eccentric 22 is located upon the main carriage 24 such that its periphery is contiguous to the eccentric follower 30. The follower 30 is connected to the sub-carriage 28 and slides horizontally on the sub-carriage guide shafts 32. The sub-carriage 28 is fixed at its outermost points to the extremities of the guide shafts 32, which are arranged to slide within the self-aligning spherical bearings 34. The bearings 34 which are positioned at the outer most points of the main carriage 24, have sleeves which are adapted to receive the guide shafts 32.
Summarizing the operation, the probe 21 is made to extend towards the forms pack 12 from the fully retracted position. After the probe 21 is extended, the eccentric 22 is then revolved in such a manner that it causes the sub-carriage 28 via the eccentric follower 30 to move towards the print head 10. This action of the eccentric 22 further causes the windings of the LVTD assembly 20 to also advance toward the print head 10. The windings are advanced until they align with the core 15 of the LVTD. When alignment is achieved, a null condition in the LVDT is developed and the eccentric motion is stopped. The correct distance between the print head 10 and the print head 13 is thereby produced. The probe 21 is then retracted and the automatic gap adjust cycle is completed.
Whenever the sub-carriage 28 and the main carriage 24 are opened (i.e., pivoted away from the print head) for any reason, the assumption is made that the forms pack 12 or the ribbon 16 has been changed. Accordingly, when the carriage is opened, the eccentric 22 rotates in the reverse direction so that the main carriage 24 and the sub-carriage including the probe 28 are translated to the furtherest distance from the print head 10. The motion of the eccentric is then stopped and the cycle above described begins again when the carriage is closed. This cycle is also performed when the carriage power is initially applied to the machine.
Referring now to FIG. 2, the logical circuitry for developing the cycles of operation discussed above is shown. For the sake of discussion, let us assume that the sequence of operation begins with an initial power-up sequence. A positive power-up (PWR-UP) signal is first generated in the printer which is applied directly to the AND GATE 46 as well as to the inverter 44. The second positive signal applied to the AND GATE 46 originates from the GAPLIMF (gap limit) signal. This signal is generated by a switch that is activated when the print gap is increased to its maximum (i.e., the eccentric is driven fully in the reverse direction). This signal is presumed to be low (L) since it is assumed that the carriage is not driven to its fully reverse direction. Accordingly the output of the inverter 52 is high (H) and since both inputs to the AND GATE 46 are now H its output will be L. This L signal is applied to the set (S) terminal of the flip-flop 50 so that the GAPINCR (gap increase) is H. The GAPINCR signal is applied to the eccentric drive motor control terminal causing the motor winding to rotate in a direction which causes the gap between the print head 10 and the print band 18 to increase until terminated.
FIG. 3 depicts the eccentric drive motor and its associated control circuitry. The motor is essentially a split phase motor and the control circuitry comprises a triac element, a reed switch and a T 2 L circuit. When a positive GAPINCR signal is applied to the base element of the T 2 L logic circuit, a current is conducted from the +5 volts source, through the coil of the reed switch and through the collector-emitter junction of the T 2 L circuit to ground. This current causes the contacts of the reed switch to close so that current is allowed to flow through the gate element of the triac. The current through the gate element causes the triac to conduct and, therefore, the AC circuit is completed so that the appropriate winding of the split phase motor is energized and the eccentric is driven in the reverse direction to increase the gap between the print head 10 and the print band 13.
The GAPINCR signal is terminated when the gap is made as large as possible and the eccentric is driven fully in the reverse direction. This occurs when the maximum gap limit switch 26 is activated by the stop 27 and the GAPLIMF signal is produced thereby. The GAPLIMF signal when activated by the limit switch 26 is applied to the inverter 52 and its negative output is applied to the AND GATE 46 as well as to the reset (R) terminal of the flip-flop 50. Since one of the inputs of the AND GATE 46 is now negative its output will be positive and will be applied as such to the S side of the flip-flop 50. In similar manner, the output of AND GATE 48 is positive and the CARROPF (carriage open) signal is negative. The CARROPF signal is positive only when the main carriage 24 on the sub-carriage 28 is opened. Therefore, since both inputs to the S terminal of flip-flop 50 are positive and its R terminal has a negative signal applied thereto the flip-flip will revert to the reset condition and the GAPINCR singal will become negative. The negative GAPINCR signal is applied to the base of the eccentric motor control T 2 L circuit causing it to stop conducting. The non-conduction of the transistor causes the reed switch and the triac gate circuit to open which in turn causes the triac to open and the AC circuit to no longer conduct through the eccentric motor reverse winding. Therefore, the eccentric motor stops running.
After the eccentric drive control has caused the eccentric to move the sub-carriage 28 so that the gap between the print head 10 and the print band 18 is as large as possible, the next sequence of operation is to cause the probe 21, which is coupled to the LVDT, to be driven unitl it is fully extended. This is accomplished in the following manner. The GAPLIMF signal which is positive when the carriage is driven fully in a reverse direction is also applied as such to the AND GATE 54. The second positive pulse applied to the AND GATE 54 is derived from the CARROPF signal. As stated previously, the CARROPF signal is H when the sub-carriage is open, but in the cycle under discussion (i.e., the sub-carriage is closed) the CARROPF signal will be L as applied to the input of the inverter 66. Since the input of the inverter 66 is L its output will be H as applied to the OR GATE 67. The second input to the OR GATE 67 is initiated by the PWR-UP signal. The PWR-UP signal is generated only when the machine power is first turned on after which it reverts to the L state. Therefore, the L output applied to the inverter 44 becomes H so that either input to the OR GATE 67 is H and its output is L. This L signal is applied to the inverter 68 so that its output is H as applied to the second input of the AND GATE 54. The third H input to the AND GATE 54 originates from the L PRBSOUTF (probe fully retracted) signal, which is applied to the input of the inverter 80. When the probe 21 is fully retracted, the PRBSOUTF signal is L.
Since all three inputs to AND GATE 54 are now H its output goes L as applied to the S terminal of the flip-flop 58. At this time, the two inputs shown to the R terminal of the flip-flop 58 are both H. One input is H in view of the PRBSINF (probe fully in position) signal, which is L, being applied to the inverter 56. The PRBSINF signal is generated by a switch 90 that is activated to the H voltage level when the probe is fully extended. Since the probe is not extended at this point in time, it may be appreciated that the PRBSINF signal is L and, therefore, the output of the inverter 56 is H. The second input to the R terminal of flip-flop 58 is H for the reason that the second input to the AND GATE 54 is H as previously discussed.
The L input signal applied to the S terminal and the two H signals applied to the R terminal of flip-flop 58 cause the latter to be set so that its output is H. This H signal is applied as an input to the AND GATE 62. The second input to the AND GATE 62 results from the LATCHOPF (latch open) signal, which is applied to the inverter 60. The LATCHOPF signal is L if the carriage latch is not open, which is assumed in the instant discussion. Accordingly, the output of the inverter 60 will be H so that both inputs to the AND GATE 63 are H. Accordingly, the output of the AND GATE 62 is L and is applied to the inverter 64 so that the PRBIN (probe to be driven) signal is H. The PRBIN signal activates the probe drive motor control causing the probe to be driven until it is fully extended against the forms pack 12.
When the probe 21 is in position or fully extended the PRBSINF signal will be generated. The PRBSINF signal is generated by a switch 90 that is activated when the probe is fully extended and under this condition the PRBSINF signal is H. The inverter 56 changes the H voltage to a L voltage and is applied as an input to the R terminal of the flip-flop 58 so that the latter is reset. The output of the flip-flop 58 is therefore L when applied to the AND GATE 62. Since one of the inputs of the AND GATE 62 is now L its output will revert to a H state and will be altered by the inverter 64 to a L signal. This L signal causes the probe motor control to inactivate the probe drive motor.
In summary, the sequence of the logic circuitry has provided that the sub-carriage 28 has been fully retracted so as to provide a maximum distance between the print head 10 and the print band 18, and the probe 21 has been fully extended towards the forms pack 12.
As will be recalled the GAPLIMF signal is H when the print gap between the print head 10 and the print band 18 is increased to its maximum. The GAPLIMF signal is, therefore, applied as one of the three H inputs to the AND GATE 70. Another H signal to the AND GATE 70 results from the PRBSINF signal, which is produced when the probe is being fully extended. The third H input to the AND GATE 70 emanates at the output of the inverter 68. It will be recalled that the CARROPF signal is L at this point in the cycle since it is assumed that the carriage is not open. Therefore the output of the inverter 66 is H as applied to the OR GATE 67. Since the second input to the OR GATE is H because the PWR-UP signal is now L the output of the OR GATE 67 will be L and accordingly the output of the inverter 68 is H.
The three H inputs to the AND GATE 70 causes its output to be L and cause the eccentric motion forward flip-flop 72 to be set. This H output signal is applied as one of the two inputs to the AND GATE 74. The second H input signal to the AND GATE 74 originates with the LATCH OPF signal to the inverter 60. It will be recalled that the LATCH OPF signal is L since it is assumed that the carriage latch is not opened. Therefore, the output of the inverter 60 is H. Since both inputs to the AND GATE 74 are H its output is L and this is inverted to a H signal identified as GAPDECR (gap decrease). The GAPDECR singal is applied to the eccentric drive motor control circuitry of FIG. 3 so as to cause the eccentric motor to rotate to begin to decrease the distance between the print head 10 and the print band 18. In other words, the sub-carriage 28 is caused to move in a leftward direction by means of the rotation of the eccentric.
Referring again to FIG. 1 it can be seen that as the eccentric 22 begins to rotate counterclockwise it causes the eccentric saddle follower 30 to move in a leftward direction so as to cause the sub-carriage 28 to likewise move in this direction. As the sub-carriage 28 is moved towards the left by the eccentric, the LVDT transformer body of the LVDT 20 containing the primary and secondary windings, which are mounted within the probe assembly, is similarly moved forward. When the core of the LVDT lines up with the center of the transformer body then alignment or a null condition is achieved and the eccentric motion is stopped. The eccentric stops the sub-carriage at the desired separation between the print head 10 and the print band 18. The stopping action occurs as follows.
A 9 volt AC, 60 HERTZ signal is applied to the primary winding of the LVDT 20. When a non-null condition is present in the LVDT, (i.e., the core 15 is not aligned within the windings) a sine wave output having a period of 16.7 milliseconds is produced and is applied to one of the inputs of the operational amplifier 36. The second input to the amplifier 36 is grounded. The output of the amplifier 36 is essentially a sine wave output, which has been amplified by a factor of ten, and is coupled by a capacitor into the input terminal of the amplifier 38. The amplified sine wave produced at the output of amplifier 36 is further amplified and clipped by the operational amplifier 38 to form a square wave output. The comparator 40 is a T 2 L circuit utilized for detecting and coupling the analog signals produced by circuits 36 and 38 to the digital circuit 41 and 42. In the instant embodiment the voltage reference applied to one of the comparator 40 inputs is approximately 0.7 volts. Consequently, when the second input to the comparator 40 is equal to or less than 0.7 volts its output will be 0. In other words, a signal will not be present at the output of comparator 40 as applied to the input of the AND GATE 41 when the LVDT is at a null position. When the input to the comparator 40 exceeds 0.7 volts a square wave output will be produced that extends from 0 to 3.2 volts with a period of 16.7 milliseconds.
Accordingly, when the LVDT is not at a null position a positive voltage pull will be applied to the AND GATE 41. In other words, the comparator 40 will produce a signal of sufficient amplitude to activate the digital circuit 41 when the LVDT is not nulled. A second input to the AND GATE is produced by the ground connection which is applied after inversion and gating by the OR GATE 39. Therefore, when the L inputs to the AND GATE 41 are positive it triggers the retriggerable delay flop 42. The pulse width of the delay flop is 18 microseconds. The output of the retriggerable delay flop 42 is applied to the R terminal of the flip-flop 72. This H signal will have no effect on the flip-flop 72 and, therefore, the GAPDECR signal applied to the eccentric drive motor control will continue to cause the eccentric to move in a direction to decrease the distance between the print head 10 and the print band 18.
Let us now assume that the automatic adjust mechanism has reached the proper gap distance. Since the output of the comparator 40 will now be L as applied to the AND GATE 41 the delay flop 42 will not be retriggered and its output will go L. This L output is applied to the R terminal of the flip-flop 72 so that the latter is reset. The output of the flip-flop 72 being reset will cause the second input to the AND GATE 74 to go L and its output to go H. After inversion by the inverter 76 the GAPDECR signal will be L as applied to the eccentric drive motor control. Consequently, the eccentric forward motion will stop and the distance between the print head 10 and the print band 18 will be at the desired separation.
When the flip-flop 72 is reset, its L output becomes H and is fed to the single-shot multivibrator 78. This H input signal applied to the multivibrator 78 causes its output to go L and sets the flip-flop 84. At this point in time, the PRBSOUTF signal is H since the probe is fully extended. Therefore, after inversion by the inverter 82 the signal applied to the R terminal or flip-flop 84 will be H. Accordingly, the L output of the single shot multivibrator 78 will cause the flip-flop 84 to be set so that the PRBOUT signal is H. This H signal activates the probe drive motor control causing the probe to be driven until it is fully retracted. When the probe is fully retracted the PRBSOUTF signal is produced by a switch 87 (FIG. 4a) that is activated when the probe is fully in its retracted position. This L signal remains L after a double inversion by the inverters 80 and 82 causing the flip-flop 84 to be reset and the PRBOUT signal to become L.
Referring now to FIG. 4 a in greater detail, the probe 21 assembly is shown in the rest position before the simulation cycle begins. In the rest position, the forms load spring 31 is not compressed and the probe is retracted. While the probe is retracted the retraction spring 86 is loaded to insure positive retraction. When the PRBIN signal is applied to the probe motor control circuit (FIG. 3), the motor (not shown) through the motor shaft 84 and the probe arm 82 causes the probe 21 to extend until the probe limit switch 90 is contacted as shown in FIG. 4 b. The activation of limit switch 90 causes the motor to stop and the retraction spring 86 will be unloaded and the forms spring 31 will be loaded.
The load on the forms load spring 31 will vary depending on the compressibility and thickness of the forms 12 and ribbon 16. The forms 12 may be a single or a multi-part form. If a multi-part form is being used it should be understood that the probe 21 will not be allowed to extend as far as if a single part form were being used. A multi-part form has a thickness of 0.020 inches and a single-part form a thickness of 0.003 inches. The ribbon thickness may vary between 0.003 to 0.005 inches. The variation that is sensed by the probe 21 is 0.019 inches. Therefore, the difference in the spring load 31 is proportionate to the difference in the forms thicknesses. In other words, the spring load is greater for a multi-part form than for a single part form since the spring 31 is compressed a greater distance in the former than in the second case. Accordingly, a larger spring force is used to compensate for the air spaces that exist between the sheets of a multi-part form.
The size and shape of the end of the probe are chosen so that the compression of the forms under spring load by the probe is like the compression of the form under actual printing process. Therefore, the gap between the print hammer and print band provided automatically by this invention is made in accordance with a print hammer simultion or what the print hammer sees.
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The mechanism herein relates to the automatic positioning of the print mechanism with respect to the forms and ribbon in a printer assembly. The automatic adjustment takes place for varying thicknesses of the forms, which is a function of the number of copies being printed and the type of form, as well as the variations in the thickness of the ribbon. The abovementioned adjustment takes place after there has been a simulation of the print hammer striking the paper which may be a single-part or multi-part form. Simulation is obtained by extending a probe to deform the forms in the same manner as a print hammer deforms the forms in the actual printing operation.
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RELATED APPLICATIONS
The present application is a Continuation-in-Part of U.S. application Ser. No. 13/713,723 filed on Dec. 13, 2012, whose contents are expressly incorporated by reference.
FIELD OF THE INVENTION
The current invention pertains to new and useful improvements to a door assembly process utilizing mortises, tenons and dowels as well as use of dowels for locking door stiles and rails.
BACKGROUND OF THE INVENTION
Millions of doors are assembled, installed and renovated every year. The process of manufacturing and assembling door is long and complicated; usually it takes several hours to assemble and install a door. Generally, the door is supplied as fully assembled with or without a frame. If the door is supplied without a frame, then prior to installation, the hinges and locks have to be drilled, cut and attached to the door and the frame. Generally, most of the doors have to be prepped for hardware prior to installations; this procedure requires a manipulation of a heavy door.
The manufacturing process requires that the door assembly be glued to keep the parts together, and during the gluing process the door has to be locked in special clamps to keep its integrity. The glue requires an extensive curing time before the rest of the door assembly can be completed. Following the gluing process, the door stiles have to be beveled in order to allow smooth closure of the door. The beveling process is known in the art and involves a removal of some layer(s) of material from the stiles on the hinge and/or lock side, thus creating a vertical plane with a slope of approximately 2-3 Degrees. Only after beveling can the whole door be sanded, prepped and painted or covered by protective layers known in the art.
This lengthy and involved door manufacturing process allows delivery of fully assembled doors. Delivery of doors in a disassembled state is not possible as the gluing and beveling process can only be performed on the manufacturing site. Furthermore, in the current process if a part or parts of the door are damaged during transportation, the entire door is considered broken and must be replaced.
In the case of a modular door, only the damaged part needs to be replaced.
The delivery of disassembled doors has the following benefits: they take less space, the risk of breakage is reduced, and if there are broken parts, they can be easily replaced by spare parts. However, disassembled doors need to be assembled on-site by the end user. Therefore, a kit for door assembly is required in which the stiles are beveled prior to the assembly. The assembly kit does not require any complicated tools and ordinarily does not require use of glue.
One of the technologies used in door building and manufacturing is the use of mortise and tenon. This technology is well-known and described for example, in U.S. Pat. No. 541,450. This patent teaches a door comprising styles and rails, which are suitably mortised and tenoned together while dowel pins are inserted into the long side of the stiles and pass through both tenons while remaining invisible. This locking means is generally used to improve sturdiness of the final product but does not eliminate the use of glue during the door assembly. There is a further technology of mortise and tenon with protruding dowel also disclosed in the U.S. Pat. No. 5,086,601. This patent teaches a construction of frames for windows and doors while utilizing a joint structure with mortise and tenon.
The present invention addresses the deficiencies in prior art by providing an improved method of door assembly by reducing or virtually eliminating a use of glue. The invention also provides a kit for self-assembly of a modular door and method of manufacturing such kit.
SUMMARY OF THE INVENTION
The current invention pertains to new and useful improvements to a door assembly and an assembly process utilizing mortises, tenons and dowels as well as use of dowels (rods) for locking door stiles and rails.
In one aspect of the invention there is provided a modular door comprising:
a. at least one door panel having a top, a bottom and two sides; b. a first pre-manufactured stile having a first end, a second end and two sides; one of said sides further comprising at least one mortise, preferably a plurality of mortises, c. a second pre-manufactured stile having a first end, a second end and two sides; one of said sides further comprising at least one mortise, preferably a plurality of mortises, d. wherein each stile further comprises a first passageway having a diameter for receiving at least one rod, preferably a plurality of rods, wherein said first passageway extends from the first end of the stile to the second end of the stile passing through at least one of said mortise of the stile; e. a first pre-manufactured rail having two sides, a first end defining a first tenon and a second end defining a second tenon, wherein each tenon has an aperture having a diameter to matingly receive at least one rod, preferably a plurality of rods; f. a second pre-manufactured rail having two sides, a first end defining a first tenon and a second end defining a second tenon, wherein each tenon has an aperture to matingly receive at least one rod, preferably a plurality of rods; preferably each of said first passageway and said aperture are substantially of the same diameter; each of said stiles and rails for use in enclosing said at least one door panel; g. optionally, at least one intermediate pre-manufactured rail having two sides, a first end defining a first tenon and a second end defining a second tenon, wherein each tenon has an aperture to matingly receive at least one rod, preferably a plurality of rods, and positioned between said first rail and said second rail and enclosing said at least one door panel; h. each of said rails being attachable to the first and second stiles by said mortise of said stile engaging with said tenon of said rail, further affixed in place by at least one rod, preferably a plurality of rods; and i. wherein at least one rod, preferably two of the plurality of rods locks a single rail, preferably a plurality of rails inside the corresponding stile, wherein upon the insertion of said tenon into said mortise of each stile, the first passageway and apertures are positioned offset one to another, wherein upon insertion of at least one rod, preferably a plurality of rods, into said first passageway and apertures, each tenon is tightly locked into its corresponding mortise;
wherein the at least one of said rods further comprises at least one stabilizer.
Another aspect of the invention is to bevel and prep the hardware during the manufacturing process in such a way as to give the end user the ability to assemble a door without the use of glue or a door clamp press. The elimination of glue allows disassembly of the door if needed.
The glue-less construction of the door creates multiple advantages and options of improving the design, style, workability, integrity, reuse, and repair if needed as the process allows the end user to take the door apart after it has been assembled, resulting in a considerable savings in time and money by placing the customization factor into the users' hands.
In one embodiment, the assembly is carried out using a traditional mortise and tenon joint in the door assembly. In its preferred embodiment, an aperture is created within the tenons on the rails at both ends while a passageway is created along the entire body of the stile. This passageway stops short of the mortises at the top and bottom of the stile. Thereafter, an oversized hole is preferably drilled in the stile for accommodating a bushing. The bushing completes the passageway, by retaining integrity of the stile and enabling rods to be pre-inserted without added friction. This function is useful during assembling or disassembling multiple rail configurations.
Preferably, the corresponding apertures in the tenons and passageway are slightly off-set to one another. In this way, when assembled the stiles and rails in combination with the rod/bushings being driven into their final resting position create an opposing force so all mortise and tenons are pressed and locked together for all stiles and rails simultaneously.
Finally, driving a screw through the bushing into the stile locks the bushings and rods in place.
In another embodiment, the at least one door panel is friction-fitted by the stiles and rails. Preferably, the at least one door panel is fitted within a pre-formed channel disposed along the sides of the stiles and rails.
The current invention eliminates the use of glue and the use of a door clamp press, which has a direct result of eliminating the curing time, beveling and prepping for hardware after the assembly for the end user.
Beveling and prepping for hardware is done during the stile manufacturing process. The manufacturing process dictates the use of a clamp press with two parallel surfaces in order to prevent buckling and deformation of the door under force.
If needed, the stile can be matched to an existing opening, transcribing the original hardware placement to the new door or in this case stile. Since the single stile can be handled, the marking of the hardware makes this a much easier task to handle in place of a fully assembled door. After prepping the stile, the door can be assembled and immediately installed without a wait for glue curing and other door preparations utilized in prior art.
Another aspect of the invention is the use of one or more extensions to the rails of the door. These extensions can be used on the top and/or bottom rails. The end user's choice of different materials such as wood, metal, Plexiglas™, plastic or composite material extension will give the door a unique look. In addition, use of extensions can make it more resilient to the elements. Using a rubber or silicon cover on the extension may, for example, assist in reduction of water damage to the door. Furthermore, use of extensions would allow replacement of the extension only if it became soiled or broken, without need to replace the whole door.
In a preferred embodiment, the at least one rod, preferably a plurality of rods comprises pushing rods, locking rods, and locking/pushing rods. The pushing rods are provided to deliver the locking rods into the tenons of the intermediate rail, while the locking/pushing rods are provided to lock one rail as well as to push another locking or pushing rod through the rod receiving channel of the stile.
According to yet another aspect of the invention, the set of rods further comprises an unlocking rod having the length equal to the height of the tenon of the corresponding rail to be unlocked. These unlocking rods are positioned between the pushing rods and the locking rods, and can be pushed into the tenon of the rail while removing the locking rod from the tenon to release the intermediate rail from the stile.
According to yet another aspect of the invention, the at least one of said rods, preferably said locking rods, further comprises at least one stabilizer, preferably an o-ring, positioned on said rod, to minimize movement of said rod in said passageway and/or aperture. Preferably, said stabilizer is substantially the same diameter as the diameter of the passageway and/or aperture. In a preferred embodiment, the o-ring may be made of any material known in the art for making O-rings including, but not limited to, polymeric elastomer, natural rubber, synthetic rubber, and combinations thereof. The function of the o-ring is to ensure a snug fit of the locking rod in the passageway and/or aperture whilst minimizing the locking rod from moving around in the passageway of the stiles and aperture of the rails.
According to another embodiment, the at least one stabilizer is integral with at least one of said rods. The integral at least one stabilizer is, in one embodiment, made from the same material as the rod and may be in a shape conforming to a shape of the passageway and/or aperture. In another embodiment, the at least one stabilizer is moveable along a length of at least one of said rods. In another embodiment, the stabilizer may be in the form of a collar, for example, and also serving to join at least two of said rods. Preferably the collar has a diameter substantially the same as the diameter of the passageway and/or aperture.
According to yet another aspect of the invention the top and/or bottom rails include a receiving member to receive an extension to the door with a corresponding mating member. This extension to the door can be decorative or functional and can be easily replaced upon wear or change in utility.
According to one additional aspect of the invention, there is a kit for assembling a modular door comprising:
a. at least one door panel; b. at least two pre-manufactured stiles each having two ends and two sides, provided with mortises along one of the sides and a first passageway having a diameter and passing through said mortises; c. at least two pre-manufactured rails each having two sides and two ends with tenons provided at each end while each tenon has a predrilled aperture to receive at least one rod, preferably a plurality of rods; and d. at least one rod, preferably a plurality of rods to lock the rails to the stiles via said predrilled aperture and said first passageway,
wherein the at least one of said rods further comprises at least one stabilizer.
The at least one rod, preferably a plurality of rods, can include two short locking rods of sufficient length to lock one rail to the stile and two long locking rods of sufficient length to lock at least two rails to the stile. More preferably, the plurality of rods has at least six locking rods to lock at least three rails to the stiles, and at least two pushing rods to deliver the locking rods into the distant mortises of the stile. Still more preferably, each stile has at least one locking rod, one pushing rod pre-inserted into a first passageway proximate mortise, distant from one of the ends of the stile.
In yet another embodiment there can be an unlocking rod further positioned between the pre-inserted locking rod and pushing rod and a filler rod holding these rods in place during storage and delivery.
According to yet another aspect of the invention, the at least one of said rods of the kit, preferably said locking rods, further comprise at least one stabilizer, preferably at least one o-ring, positioned on said rod, to minimize movement of said rod in said passageway and/or aperture. Preferably, said stabilizer is substantially the same diameter as a diameter of the passageway and/or aperture. In a preferred embodiment, the o-ring may be made of any material known in the art for making o-rings including, but not limited to, polymeric elastomer, natural rubber, synthetic rubber and the like. The function of the o-ring is to ensure a snug fit of the locking rod in the passageway and/or aperture whilst minimizing the locking rod from moving around in the passageway of the stiles and aperture of the rails.
According to another embodiment, the at least one stabilizer is integral with at least one of said rods of the kit. The integral at least one stabilizer is, in one embodiment, made from the same material as the rod and may be in a shape conforming to a shape of the passageway and/or aperture. In another embodiment, the at least one stabilizer is moveable along a length of at least one of said rods. In another embodiment, the stabilizer may be in the form of a collar, for example, and also serving to join at least two of said rods. Preferably the collar has a diameter substantially the same as the diameter of the passageway and/or aperture.
Preferably the kit also has at least one door extension member capable of being attached to at least one of the rails.
According to yet another aspect of the invention, there is provided a method of assembling a modular door said door comprising at least one door panel having a top, a bottom and two sides; a first pre-manufactured stile having a first end, a second end and two sides; one of said sides further comprising at least one mortise, preferably a plurality of mortises; a second pre-manufactured stile having a first end, a second end and two sides; one of said sides further comprising at least one mortise, preferably a plurality of mortises, wherein each stile further comprises a first passageway for receiving at least one rod, preferably a plurality of rods, wherein said first passageway extends from the first end of the stile to the second end of the stile passing through at least one of said mortise of the stile; a first pre-manufactured rail having two sides, a first end defining a first tenon and a second end defining a second tenon, wherein each tenon has an aperture to matingly receive at least one rod, preferably a plurality of rods, a second pre-manufactured rail having two sides, a first end defining a first tenon and a second end defining a second tenon, wherein each tenon has an aperture to matingly receive at least one rod, preferably a plurality of rods, preferably each of said first passageway and said aperture are substantially of the same diameter; each of said stiles and rails for use in enclosing said at least one door panel; optionally, at least one intermediate pre-manufactured rail having two sides, a first end defining a first tenon and a second end defining a second tenon, wherein each tenon has an aperture to matingly receive at least one rod, preferably a plurality of rods, and positioned between said first rail and said second rail and enclosing said at least one door panel, each of said rails being attachable to the first and second stiles by said mortise of said stile engaging with said tenon of said rail, further affixed in place by at least one rod, preferably a plurality of rods, and wherein at least one rod, preferably two of the plurality of rods lock a single rail, preferably a plurality of rails inside the corresponding stile, wherein upon the insertion of said tenon into said mortise of each stile, the first passageway and apertures are positioned offset one to another, comprising the following steps of:
1. Inserting the first tenon of the first rail into a first mortise of the first stile; 2. Locking said first tenon in said first mortise with a first rod; 3. Positioning the at least one door panel adjoining said first rail and first stile; 4. Inserting the first tenon of the second rail in to a second mortise of the first stile while locking the first door panel in place; 5. Positioning a second stile on the side of the rails distant from the first stile, wherein the second tenons of each of the first rail, the second rail and the optionally at least one intermediate rail are inserted into the corresponding mortises of the second stile and the first and second door panels are also locked in place; and 6. Locking the second tenons of the rails in the second stile using a second rod;
wherein the first and second rods further comprise at least one stabilizer.
In a preferred embodiment, the method of assembling the door further comprises the steps of:
1. positioning a second door panel adjoining said second rail and the first stile; 2. inserting the first tenon of the at least one intermediate rail into a third mortise of the first stile while locking the second door panel in place; and 3. locking the First tenon of the second rail and the first tenon of the optionally at least one intermediate rail in corresponding mortises oldie first stile using a third rod;
In another preferred embodiment, the method of assembling the door further comprises the steps of:
1. Inserting a bushing in an opening of the first passageway; and 2. Inserting a screw into said bushing to secure the rods to the stiles.
According to yet another aspect of the invention, the rods used in the assembling of the door comprise at least one stabilizer, preferably at least one o-ring, positioned on the rods, to minimize movement of the rods in said passageway and/or aperture. Preferably, said stabilizer is substantially the same diameter as a diameter of the passageway and/or aperture. In a preferred embodiment, the o-ring may be made of any material known in the art for making o-rings including, but not limited to, polymeric elastomer, natural rubber, synthetic rubber and the like. The function of the o-ring is to ensure a snug fit of the rods in the passageway and/or aperture whilst minimizing the rods from moving around in the passageway of the stiles and aperture of the rails.
According to another embodiment, the at least one stabilizer is integral with at least one of said rods used in the assembly of the door. The integral at least one stabilizer is, in one embodiment, made from the same material as the rod and may be in a shape conforming to a shape of the passageway and/or aperture. In another embodiment, the at least one stabilizer is moveable along a length of at least one of said rods. In another embodiment, the stabilizer may be in the form of a collar, for example, and also serving to join at least two of said rods. Preferably the collar has a diameter substantially the same as the diameter of the passageway and/or aperture.
The assembled door does not require a use of glue or additional bonding agents during the assembly process.
The rods locking the rails inside each stile comprise at least one rod, and preferably more than two rods. The rods are selected from locking rods, pushing rods, filler rods, unlocking rods and combination thereof. Preferably, a set of bushings further locks the rods inside the stiles.
Additionally, the use of Plexiglas™ gives an even broader choice of uniqueness by shining light directly on to the Plexiglas™ and using it as a light conductor through the door body to shine out the other end without the use of wires.
Another aspect of the invention is the ability to take the door apart. Disassembly of the door brings a unique factor into effect. If a door is to be disassembled due to the size being increased, design change, and/or a damaged component in the door that needs replacing, these tasks may be done easily.
The end user can accomplish the above-named tasks by removing the screw penetrating the rail and bushing and, using the same screw, drive into the center of the bushing through the rod leaving half the screw outside of the bushing. This will lock the bushing to the rod. Using this as a clamping point, the rods that hold the tenons can be unlocked by simply removing the bushing/rod at either ends of the door. Once completed, a rod of smaller diameter may be inserted. The length is determined by the following formula:
width of the tenon+plus length of bushing/rod that was removed+one inch
The rod of smaller diameter is then inserted into the door with force needed until the tip is flush with the door. Remove the rod and repeat this procedure for all the locks. The rails are unlocked from the stiles; the door can now be disassembled.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is an exploded view of the modular door.
FIG. 2 is a see-through view of an assembled modular door.
FIG. 3 is an elevated see-through view of a rail of the modular door.
FIG. 4 is an elevated view of a stile.
FIG. 5 is a cut view of FIG. 4 through line A-A.
FIG. 6 is an enlarged top view of area B of FIG. 5 .
FIG. 7 is an elevated view of the extension insert into the rails.
FIG. 8 is a see through partial view of the bottom part of the assembled door.
FIG. 9 is an elevated view of the bushing.
FIG. 10 is a cut view of FIG. 9 through line C-C.
FIGS. 11-15 illustrate the process of disassembly of the modular door.
FIG. 16 is an illustration of stile with pre-inserted rods.
FIGS. 17A and 17B demonstrate the interaction of the rail and stile in locked and unlocked state.
FIG. 18 shows another embodiment of the locking rod.
FIG. 19 shows another embodiment of the locking rod.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates an exploded view of the modular door 10 . This modular door comprises a first stile 20 , a second stile 21 and a top rail 30 and a bottom rail 32 . The door also comprises at least one intermediate rail 31 . Depending on the design requirements, the door may include additional horizontal rails between the top and bottom rails 30 and 32 . Locked between the stiles and the rails, there are panels 11 and 12 . The panels can be manufactured any way and from any material known to a person skilled in the art of door manufacturing, and the number of panels may vary according to the number of rails.
Each stile comprises a plurality of mortises corresponding to a set of tenons positioned on the rails, best illustrated in FIG. 2 , and there are a plurality of rods ( 40 - 44 and 46 ), which retain the tenons inside the mortises of each stile.
FIG. 2 illustrates rail 31 with tenon 34 positioned proximate to its corresponding mortise 26 in stile 21 , and rail 32 with tenon 34 positioned proximate to its corresponding mortise 25 in stile 21 prior to the assembly process.
FIG. 2 illustrates the assembled door with tenon 34 of rail 31 completely inserted into mortise 26 of stile 20 and locked in this position by the means of rod 40 . Tenon 34 of rail 32 is fully inserted into mortise 25 of stile 20 and locked in this position by the means of rod 44 . Finally, tenon 34 of rail 30 is fully inserted into mortise 27 of stile 20 and locked in its position by rod 46 . Rails 30 , 31 and 32 are fixed to stile 21 on the opposite side of the door, in the same manner as they are fixed to stile 20 .
As illustrated in FIG. 2 , panel 11 is locked between rails 30 and 31 and by stiles 20 and 21 , while panel 12 is locked between stiles 20 and 21 and rails 31 and 32 .
Rail Manufacturing Process: See FIG. 3
1. Rail 30 is squared.
2. Groove 36 is cut vertically on one side of rail 32 down the center of the rail so panel 11 can be inserted into this groove during the door assembly.
3. A pair of tenons 34 is created on each end of rail 32 .
4. Apertures 35 are drilled in each tenon. These holes receive the rods locking the mortises of the stiles.
5. In one of the embodiments, first rail 30 and/or second rail 32 may have an extra mortise 33 on a side opposite groove 36 in order to receive an extension 37 . In yet another alternative embodiment second rail 32 can also have a mortise 33 to receive a bottom extension 37 . All intermediate rails 31 have two grooves 36 to receive panels on both sides.
6. In a preferred embodiment, a chamfer (not shown) is applied to the tenon for better seating on assembly of the door.
In one embodiment, second rail 32 and first rail 30 are identical and can be used interchangeably to reduce the number of manufactured pieces of the door. In yet another embodiment (not shown), rails 30 , 31 and 32 may be identical thus groove 36 on both sides of the rails can be used to receive a panel 12 or extension 37 .
Referring to FIG. 7 , extension 37 can be added to first rail 30 , second rail 32 or both by the means of insertion a mating member 38 into receiving member 33 of the rails. Mating member 38 can be of any type known in the art such a ridge, tenon, and a plurality of pins, etc.
The extensions can vary in height, preferably from ¾″ to 10″ depending on the manufacturing materials and design. Extension 37 can be constructed from various materials such as metals, wood, plastics and composite materials. Each extension 37 can be rubberized, painted or coated to protect the insert from elements and wear.
Stile Manufacturing Process ( FIGS. 4-6 ):
The manufacturing process of stile 20 is similar to the manufacturing process of stile 21 . The only difference is the preparation and positioning of the hardware on these stiles.
1. Stile 20 is squared and beveled. 2. A plurality of mortises 25 , 26 , 27 are cut into stile 20 according to design. 3. Channel 22 is cut down the center of stile 20 (opposite the bevel) so panels 11 and 12 can be inserted during an assembly process. 4. First passageway 23 is provided down the center of the stile just short of the top and bottom keeping the integrity intact. This passageway receives rods locking the tenons of the rails in the mortises of the stile. Passageway 23 can be lined (not shown) with a plastic or metal sleeve in lieu of wood. Passageway 23 is placed a few millimeters behind groove 22 that holds panels 11 and 12 in place in order not to lose the integrity of groove 22 . 5. Bushing holes 28 are drilled at the top and bottom of stile 20 continuing where the passageways left off to accept a wood, plastic, Plexiglas™ or metal bushing/rod. 6. In a preferred embodiment as illustrated in FIG. 16 , at least some of the plurality of rods 40 , 41 , 42 and 43 are strategically pre-inserted into first passageway 23 to save on assembly time of the finished door for the end user. 7. With reference to FIG. 16 , rod 40 (referred to as a “locking rod”) can be placed at the very edge of mortise 26 . It can enter from the bottom or top of the stile from which a hole was created to accept a bushing (depending on the design of the mortises). Once rod 40 has entered the passageway, a small amount of force can be applied in order to set it into place. 8. Rod 41 (referred to as an “unlocking rod”) can enter from the following mortise and be placed behind the first rod. Little to no force is needed to position this rod, as this rod has a smaller diameter than rod 40 . Rod 42 can also use the same path as rod 40 and can be placed directly against rod 41 . Little to no force is needed to position rod 42 , as it too has a smaller diameter than the rod 40 . Rod 43 can be placed against rod 42 and enter from the mortise like rod 41 (short in length). Rod 43 is provided in order to keep rods 40 , 41 and 42 in place during the transportation. A small amount of force is need to position rod 43 . This may all be repeated depending on the design chosen.
The plurality of rods have varied lengths, at least two of which are of smaller diameter and can be made of wood, plastic, Plexiglas™, metal or other material known in the art. The length of rod 40 preferably corresponds to the width of tenon 34 plus two inches.
Rod 41 has a length preferably corresponding to the width of tenon 34 and has a smaller diameter than rod 40 .
Rod 42 is preferably a few inches short of the following mortise, as well as being of a smaller diameter.
Rod 43 fills the remaining gap to the edge of the mortise and preferably has the same diameter as the passageway.
The lengths of the rods are determined by the design. If using multiple rails 31 and if locking from one side top or bottom, approximately 2 inches or the width of the tenon should be added to rod 41 for every rail added.
Rods 40 , 41 , 42 , 43 , 44 , 46 are provided to lock the tenons inside the mortises, and to move the neighboring rods into correct positions. The rods can vary in diameter from about ¼″ to about 1″. The material of the rod can vary according to the design, size and weight of the door. The material can be selected from metals (such as steel or metal alloys), wood species, Plexiglas™, plastics, etc.
According to yet another aspect of the invention, one long rod may replace all rods 40 - 44 , and this long rod may lock both rails 31 and 32 to stile 20 .
FIG. 9 provides an illustration of bushing 45 . Bushing 45 (as well as corresponding bushing 47 in FIG. 1 ) is provided to lock the rods in their position and to prevent movement of the rods away from first passageway 23 .
Bushing size can vary in length and diameter in lengths of about 1″ to about 3″ and diameters of about ½″ to about 1⅝″. The material of the bushing can be selected from metals such as steel or metal alloys, wood species, clear Or colored Plexiglas™, plastics, etc. In one preferred embodiment, bushing 45 is coupled with bottom rail rod 44 . This rod can be locked in seat 55 (see FIG. 10 ) by any means known in the art. In addition, bushing 45 has a tapered screw hole 48 allowing the bushing to be locked both to stile 20 and rail 30 .
In the same manner bushing 47 may be coupled with the top rod 46 .
FIGS. 17A and 17 B
In a preferred embodiment, aperture 35 in tenon 34 is created in an offset from the center line of first passageway 23 of stile 20 , thus creating a pre-tensioned joint. This is done in order to create a pulling force on tenon 34 into their corresponding mortises when the rods are inserted. This force therefore, closes the gap G between the two components (the gap 60 in FIG. 17B is smaller than the gap 60 in FIG. 17A ). This force causes a tight attachment between the components and therefore eliminates the need of using a clamp press for gluing the door. Further, it virtually eliminates the use of glue in the door assembly process, making the process simpler, faster and economically effective.
FIGS. 18 and 19
With reference to FIGS. 18 and 19 , rod 40 further comprises at least one o-ring 70 positioned on the rod and having substantially the same diameter as the diameter of the first passageway 23 and the aperture 35 . The o-ring is made of any material known in the art for making o-rings including, but not limited to, polymeric elastomer, natural rubber, synthetic rubber and the like. The function of the o-ring is to ensure a snug fit of the rod in the passageway and aperture and preventing the rod from moving around in the stiles and rails. In this embodiment, the resilient nature of the o-ring material allows the rod to fit snuggly within the aperture and the first passageway to prevent lateral and longitudinal movement within the aperture and the first passageway.
Process of Assembly: See FIG. 1 .
An example of the modular door assembly process is provided below.
In one of the embodiments, the mortises, tenons, channels and rods can be sprayed or covered with substances known in the art, to allow smooth insertions of tenons and rods.
1. Stile 20 is positioned on a flat surface. 2. First rail 30 is attached to the top of stile 20 with tenon 34 inserted into mortise 27 . 3. Rod 46 comprising an o-ring is inserted with appropriate force into its final resting position generating a force from the offset created in the manufacturing process to close gap 60 between stile 20 and rail 30 and locking it into position. 4. Bushing 47 locks rod 46 followed by driving a screw 48 in an angle through bushing 47 into rail 30 , locking the bushing to stile 20 and rail 34 simultaneously. In a preferred embodiment, bushing 47 is coupled with rod 46 prior to insertion into first passageway 28 to make the process of assembly more convenient and reducing the chance of damaging the dowel. 5. Panel 11 (or panels if required by design) is inserted into panel channels 36 and 22 . 6. Intermediate rail 31 (or multiple rails) is inserted into stile 20 by insertion of tenon 34 into mortise 26 . 7. Panel 12 (or panels if required by design) is inserted into panel channels 36 and 22 . 8. Second rail 32 is inserted into stile 20 by insertion of tenon 34 into mortise 25 . 9. Rod 44 comprising an o-ring is inserted with the appropriate force into its position, while at the same time pushing pre-inserted rods 40 , 41 , 42 and 43 into their final resting position. This will generate force from the offset closing the gap between stile 20 and both middle rail 31 and bottom rail 32 simultaneously.
A screw 48 is driven into bushing 45 , locking the bushing to rail 32 and stile 20 .
10. Stile 21 is placed in a corresponding position and force is applied bringing the stile down to its final seating, mating tenon 34 of rail 30 with mortise 27 , tenon 34 of rail 32 with mortise 26 and tenon 34 of rail 32 with mortise 25 . 11. Rod 46 comprising an o-ring is inserted with the appropriate force into its final resting position generating force from the offset created in the manufacturing process to close the gap 60 between stile 21 and rail 30 and locking it into position. Rod 46 is locked with bushing 47 , then a screw 48 is driven into bushing 47 to connect it to rail 30 and stile 21 . (Preferably bushing 47 is coupled with rod 46 as explained above.) 12. Finally, rod 44 comprising o-ring 70 is installed with the appropriate force into its final resting position, while at the same time pushing the pre-inserted rods 40 , 41 , 42 and 43 into their final resting position, which will generate force from the offset to close the gap between both stile 21 and mid and bottom rails 31 and 32 (and/or multiple rails) simultaneously.
Rod 44 is locked with bushing 45 and screw 48 is driven into bushing 45 ultimately to lock rail 32 to stile 21 . (Preferably bushing 45 is coupled with rod 44 as mentioned above.)
Alternatively, in a further embodiment of the invention, glue or another bonding agent can be added to all mortises and tenons to add strength to the door, if the door will not be disassembled. However, this addition of glue prior to assembly does not extend the assembly time since there is no need to wait for the glue to dry.
Disassembly Process ( FIGS. 11-15 )
There may come a time when a modular door may need to be disassembled to replace worn or damaged parts. If glue was not utilized during the assembly, disassembly is relatively easy.
Steps for the full disassembly of the modular door are provided below; but in most ases, a partial disassembly of the door will suffice.
1. Remove screw 48 locking the bushings to rail and stile. (See FIG. 11 .) 2. Drive a screw through the center of the bushing into the rod, locking the rod and bushing together. A good portion of the screw should be left protruding so that it can be used as an anchoring point for the bushing and rod to be removed (See FIG. 12 .) 3. Use a claw end of a hammer or other tool known in the art; remove the hushing and rod attached by the screw, using a technique known to a person skilled in the art. 4. Repeat the above procedure with all bushings. 5. Using a rod 50 , (preferably made of steel, with a substantially smaller diameter and having sufficient length to push the rod 41 into tenon 34 of rail 31 ) remove rod 40 from tenon 34 of rail 31 by placing rod 50 into the hole and drive it forward until the tip is flush with the edge of the door (see FIG. 15 ). 6. Rod 50 is then removed from the first passageway using tools known in the art. Rod 50 used to push the rods 40 , 41 , 42 and 43 may vary in length due to design. 7. The door can now be taken apart. The mortise and tenons are unlocked.
Advantages of the Modular Door Kit
1. Before assembly the stile can be machined for hardware installations such as hinges and or locks. A single stile simplifies handling, unlike manipulating the entire assembled door. 2. Shipping the components in a disassembled state makes the process of loading/unloading from dock level, truck, or condo elevator much easier to manage. 3. This novel process gives the customer on-the-spot flexibility in design, dimensions and integrity with multiple choices of materials and designs that can be used. For example, pre-manufactured parts of the door (such as the door panels) can be constructed from different materials to fit the custom design selected by the end user at the store. 4. This vast customization factor eliminates delays and reduces material and labour costs that are incurred as a matter of course when manufacturing custom doors. 5. After assembly is complete, the door can be installed immediately whether an end user chooses to assemble it with or without glue. 6. Do-it-yourself end users have the opportunity to assemble the door themselves, thus furthering labour cost savings. 7. The pockets 36 created on the top and bottom of the door rails provide the customer with an option of extending the height of a door to match high door openings, allowing an existing door to be reused rather than replaced. Depending on the chosen material, inserts 37 can make the door more resistant to the elements, increase its integrity or simply bring about a design change. 8. In a preferred embodiment, when the door is assembled without a bonding agent, the end user has the advantage of greater flexibility in design, dimensions, replacement of damaged components, or even disassembly that was not previously available.
In one of the alternative embodiments, by using a Plexiglas™ or other transparent material in bushing/dowel and rods the door can be illuminated. A light source can be placed on either the top or bottom of the door and, using the Plexiglas™ as a conductor to carry light through the door can create a unique look without the need to run any wires through the door.
Design options may include choosing transparent, semi-transparent, or light scattering features on selected parts of the door. For example, an illumination from the sill of the door can be transferred through hard transparent dowels to similarly constructed top and/or bottom rails, providing such a door with a unique illuminating feature. The transparent or otherwise light scattering inserts can be positioned in the rails, panels and even stiles.
The scope of the claims should not be limited by the preferred embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole.
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The present invention relates to a modular door having at least one door panel, premanufactured stiles and at least two rails, and is held together using rods optionally having at least one stabilizer; a modular door kit containing said components; and a method of assembling a modular door having said components without requiring adhesives or any extra fasteners.
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CROSS REFERENCE OF RELATED APPLICATION
The present invention claims priority under 35 U.S.C. 119(a-d) to CN 201410195912.9, filed May 11, 2014.
BACKGROUND OF THE PRESENT INVENTION
Field of Invention
The present invention relates to a field of rare earth permanent magnet, and more particularly to a high-performance NdFeB rare earth permanent magnet with composite main phase and a manufacturing method thereof.
Description of Related Arts
NdFeB rare earth permanent magnets are more and more widely used due to excellent magnetic properties thereof. For example, the NdFeB rare earth permanent magnets are widely used in medical nuclear magnetic resonance imaging, computer hard disk drivers, stereos, cell phones, etc. With the requirements of energy efficiency and low-carbon economy, the NdFeB rare earth permanent magnets are also used in fields such as automobile parts, household appliances, energy conservation and control motors, hybrid cars and wind power.
In 1983, Japanese patents No. 1,622,492 and No. 2,137,496 firstly disclosed NdFeB rare earth permanent magnets invented by Japanese Sumitomo Metals Industries, Ltd., which disclose features, components and manufacturing methods of the NdFeB rare earth permanent magnets, and confirm that a main phase is a Nd 2 Fe 14 B phase and a grain boundary phase comprises a rich Nd phase, a rich B phase and rare earth oxides. NdFeB rare earth permanent magnets are widely used because of excellent magnetic properties, and are called the king of permanent magnets. U.S. Pat. No. 5,645,651, authorized in 1997, further disclosed adding Co and the main phase having a square structure.
With the wide application of the NdFeB rare earth permanent magnets, rare earth becomes more and more rare. Especially, shortage of heavy rare earth element resource is significant, so that price of the rare earth is continuously increasing. Therefore, after a lot of exploring, double-alloy technology, metal infiltration technology, grain boundary improving or recombining technology, etc. appear. Chinese patent CN101521069B discloses a method of manufacturing NdFeB doped with heavy rare earth hydride nano-particles, wherein an alloy flake is firstly manufactured with strip casting technology, then powder is formed by hydrogen decrepitating and jet milling, the above power is mixed with heavy rare earth hydride nano-particles formed by physical vapor deposition technology, and then the NdFeB magnet is manufactured through conventional processes such as magnetic field pressing and sintering. Although the Chinese patent discloses a method to enhance coercivity of the magnet, there is problem for mass production.
Chinese patent CN1688000 discloses a method for improving coercivity of the sintered NdFeB by adding nanometer oxides in the grain boundary phase. The method is an improvement of the double-alloy method. Firstly, the main phase alloy and the grain boundary phase alloy respectively utilize the casting process to manufacture NdFeB alloy ingots, or utilize the strip casting flake process to manufacture strip casting alloy flakes, then respectively utilize the hydrogen decrepitating method or the crusher for decrepitating, then powder with jet milling to manufacture powder with a size of 2-10 μm; then add 2-20% dispersed nanometer oxides and 1-10% anti-oxidants by weight into the grain boundary phase powder and evenly mix in the mixer; then mix the grain boundary phase alloy powder doped with the nanometer oxides with the main phase alloy powder, wherein the grain boundary phase alloy powder is 1-20% by weight, and simultaneously, add 0.5-5% gasoline, evenly mix in the mixer for manufacturing mixture powder; press the mixture powder at the magnetic field of 1.2-2.0 T, then sintering for manufacturing the NdFeB magnet. The core technique of the present invention is: the grain boundary phase is modified by evenly distributing the nanometer oxides in the grain boundary phase to improve the coercivity of the NdFeB magnet; the main phase and the grain boundary phase are respectively molten, powdered and mixed repeatedly in the present invention. The NdFeB fine powder is very easy to be oxidized, so the process is complex and not easy to be controlled. Furthermore, when the main phase alloy is molten, due to low content of rare earth, a composition of the main phase alloy is close to that of Nd 2 Fe 14 B phase, it is easy to produce α-Fe so that the remanence is reduced; easy to produce the main phase while melting the grain boundary phase so that the coercivity is affected. Furthermore, due to large surface area of the nanometer oxide, it is dangerous to explode while transporting and using. The nanometer oxide has difficult manufacturing process and high cost, which affects the application of NdFeB.
SUMMARY OF THE PRESENT INVENTION
After researching and exploring, the present invention provides a high-performance NdFeB rare earth permanent magnet with composite main phase and a manufacturing method thereof, which overcomes the shortcomings of the prior art, significantly improves magnetic energy product, coercivity, corrosion resistance and processing property of the NdFeB rare earth permanent magnet. The method is suitable for mass production and uses less heavy rare earth elements which are expensive and rare. The method is important for widening application of the NdFeB rare earth permanent magnet, especially in fields such as energy conservation and control motors, automobile parts, new energy cars and wind power. The present invention also discloses that inhibition grains capable of improving magnetic energy product, coercivity, corrosion resistance and processing property of the NdFeB rare earth permanent magnet grow up, especially the La oxide particles, formed in the grain boundary by adding La, are capable of effectively inhibiting abnormal growth of grains during the sintering process. Therefore, a composite main phase structure, that a PR 2 (Fe 1-x-y Co x Al y ) 14 B main phase is the core, ZR 2 (Fe 1-w-n Co w Al n ) 14 B main phase surrounds a periphery of the PR 2 (Fe 1-x-y Co x Al y ) 14 B main phase, and no grain boundary phase exists between ZR 2 (Fe 1-w-n Co w Al n ) 14 B main phase and the PR 2 (Fe 1-x-y Co x Al y ) 14 B main phase, is formed.
A high-performance NdFeB rare earth permanent magnet with composite main phase has a composition comprising 19≦Ra≦32, 0.8≦B≦1.2, 0≦M≦4.0, 0.5≦Rb≧10, 30≦Ra+Rb≦33, Fe and impurities by weight percent,
wherein the Ra comprises at least two rare earth elements selected from a group consisting of La, Ce, Pr and Nd, wherein the Ra at least comprises Nd;
the Rb is selected from a group consisting of Dy, Tb, Ho and Gd;
the M is selected from a group consisting of Al, Co, Nb, Ga, Zr, Cu, V, Ti, Cr, Ni, Hf and Y.
Preferably, the Ra comprises at least two rare earth elements selected from a group consisting of La, Ce, Pr and Nd, wherein the R at least comprises Pr and Nd, and Pr/Nd=0.25-0.45.
A content of Al is in a range of 0.1≦Al≦0.9, and preferably, 0.2≦Al≦0.5.
A content of Co is in a range of 0≦Co≦5, and preferably, 0.8≦Co≦2.4.
A content of Cu is in a range of 0.1≦Cu≦0.5, and preferably, 0.1≦Cu≦0.2.
A content of Ga is in a range of 0.05≦Ga≦0.3, and preferably, 0.1≦Ga≦0.2.
A content of Nb is in a range of 0.1≦Nb≦0.9, and preferably, 0.2≦Nb≦0.6.
A content of Zr is in a range of 0.05≦Al≦0.5, and preferably, 0.1≦Zr≦0.2.
The high-performance NdFeB rare earth permanent magnet with composite main phase comprises a composite main phase and a grain boundary phase. In the composite main phase, a PR 2 (Fe 1-x-y Co x Al y ) 14 B main phase is the core, ZR 2 (Fe 1-w-n Co w Al n ) 14 B main phase surrounds a periphery of the PR 2 (Fe 1-x-y Co x Al y ) 14 B main phase, and no grain boundary phase exists between ZR 2 (Fe 1-w-n Co w Al n ) 14 B main phase and the PR 2 (Fe 1-x-y Co x Al y ) 14 B main phase, wherein ZR represents a group of rare earth elements in which a content of heavy rare earth is higher than an average content of heavy rare earth in the composite main phase, PR represents a group of rare earth elements in which a content of heavy rare earth is lower than an average content of heavy rare earth in the composite main phase, 0≦x≦0.3, 0≦y≦0.2, 0≦w≦0.3, and 0≦n≦0.2. Ra oxide particles and Nd oxide particles exist in the grain boundary phase, and an oxygen content in the grain boundary phase is higher that in the composite main phase.
Experiments show that the smaller w and n, the higher the magnetic properties, when w=0 and n=0, the magnetic properties are maximized, that is to say, that the core PR 2 (Fe 1-x-y Co x Al y ) 14 B main phase of the composite main phase is PR 2 Fe 14 B, the properties are best.
The high-performance NdFeB rare earth permanent magnet containing La comprises the composite main phase and the grain boundary phase, an average grain size is in a range of 3-15 μm, and preferably, 5-7 μm.
La oxide particles and Nd oxide particles exist in the grain boundary phase of the high-performance NdFeB rare earth permanent magnet with the composite main phase.
La 2 O 3 and Nd 2 O 3 particles exist in the grain boundary phase of the high-performance NdFeB rare earth permanent magnet with the composite main phase.
La oxide particles and Nd oxide particles exist in the grain boundary phase at a juncture of more than two ZR 2 (Fe 1-w-n Co w Al n ) 14 B phase grains.
The present invention is achieved by the following manufacturing method.
The raw material comprises LR—Fe—B-Ma alloy, HR—Fe—B-Mb alloy and metal oxide micro-powder, wherein the LR comprises at least two rare earth elements and comprises at least Nd and Pr, the Ma is selected from a group consisting of Al, Co, Nb, Ga, Zr, Cu, V and Mo, the Mb is selected from a group consisting of Al, Co, Nb, Ga, Zr, Cu, V, Ti, Cr, Ni, Hf, Y and Mo, the HR comprises at least one rare earth element and at least comprises Dy; preferably, the metal oxide micro-powder is rare earth metal oxides except lanthanum oxide and cerium oxide, or is selected from a group consisting of Al metal oxide, Co metal oxide, Nb metal oxide, Ga metal oxide, Zr metal oxide, Cu metal oxide, V metal oxide, Mo metal oxide, Fe metal oxide and Zn metal oxide; and further preferably, the metal oxide is selected from a group consisting of Dy 2 O 3 , Tb 2 O 3 and Al 2 O 3 .
Preferably, the LR is selected from a group consisting of Nd, Pr, Ce, Gd and Ho; and more preferably, the LR comprises Nd and Pr; and even more preferably, the LR comprises Nd and Pr, wherein a content of Nd is 74-81% and that of Pr is 26-19%. When the LR comprises Nd and Pr, remanence and magnetic energy product of the magnet is maximized, wherein when the content of Nd is 74-81% and that of Pr is 26-19%, the cost is minimized.
Preferably, the Ma comprises Al, Co and Cu; and more preferably, Ma is Al; and even more preferably, the LR—Fe—B-Ma alloy is transformed to LR—Fe—B alloy in which no Ma exists. When a content of the Ma in the LR—Fe—B-Ma alloy is reduced, remanence and magnetic energy product of the NdFeB magnet are increased, the process stability thereof is reduced, and remanence and magnetic energy product thereof are maximized when no Ma exists in the LR—Fe—B alloy.
Preferably, the Mb comprises Al, Co, Nb, Ga, Zr and Cu; and more preferably, the Mb is selected from a group consisting of Al, Co, Nb, Ga and Cu; and even more preferably, the Mb comprises Al, Co, Ga, Zr and Cu; and extremely preferably, the Mb comprises Al, Co, Ga, and Cu. When in the HR—Fe—B-Mb alloy, the Mb comprises Al, Co, Ga, and Cu, the grains of the HR—Fe—B-Mb alloy are refined to obtain the better magnetic properties and corrosion resistance of the magnet. When the Mb comprises Al, Co, Ga, Zr and Cu, the grains of the HR—Fe—B-Mb alloy are further refined to evenly distribute the grain boundary. When the Mb comprises Al, Co, Nb, Ga, Zr and Cu, the grains of the HR—Fe—B-Mb alloy are even more improved to optimize the distribution of the grain boundary.
Preferably, when the metal oxide powder is Tb 2 O 3 , the magnetic properties are highest; when metal oxide powder is Dy 2 O 3 , the magnetic properties are higher; when Al 2 O 3 is added to the metal oxide powder, the magnetic properties are lower than Dy 2 O 3 , but the corrosion resistance is best. When Tb 2 O 3 , Dy 2 O 3 and Al 2 O 3 are all added to the metal oxide powder together, the magnetic properties are improved and the manufacturing cost is reduced, and the corrosion resistance of the magnet is increased. Preferably, a particle size of the powder is less than 2 μm; and more preferably, 20-100 nm; and even more preferably, 0.5-1 μm. While powdering with jet-milling after adding the metal oxide powder, the metal oxide powder is further ground to adsorb the surface of the grain boundary phase and the composite main phase. While sintering, due to the strongest binding force of La and O, at a certain temperature and vacuum, La preferentially binds O for forming La oxide particles, the replaced metal element in the metal oxide powder enters the composite main phase or surrounds a periphery of the composite main phase, thereby significantly improving the coercivity and corrosion resistance of the magnet. When no La exists in the magnet, priorities in combination with O are from Ce to Pr to Nd.
The manufacturing method comprises steps of:
(1) melting LR—Fe—B-Ma alloy which comprises:
firstly melting an LR—Fe—B-Ma raw material under vacuum or argon protection with induction heating for forming an alloy, refining before casting the alloy in a melted state onto a rotation roller with water cooling function through a tundish, and cooling the molten alloy with the rotation roller for forming alloy flakes, wherein an average grain size of each of the alloy flakes is 1.5-3.5 μm;
(2) melting HR—Fe—B-Mb alloy which comprises:
firstly melting an HR—Fe—B-Mb raw material under vacuum or argon protection with induction heating for forming an alloy, refining before casting the alloy in a melted state onto a rotation roller with water cooling function through a tundish, and cooling the molten alloy with the rotation roller for forming alloy flakes, wherein an average grain size of each of the alloy flakes is 0.1-2.9 μm;
(3) making alloy hydrogen decrepitating which comprises:
sending the LR—Fe—B-Ma alloy and the HR—Fe—B-Mb alloy into a vacuum hydrogen decrepitation device, evacuating before injecting hydrogen for hydrogen absorption, wherein a hydrogen absorption temperature is 80-300° C.; heating after hydrogen absorption and evacuating for dehydrogenating, wherein a dehydrogenating temperature is 350-900° C., a dehydrogenating time is 3-15 h; and then cooling the alloy, wherein after evacuating for dehydrogenating, a certain amount of hydrogen may be injected within a temperature range of 100-600° C., and then the alloy is cooled;
(4) metal oxide powder surface adsorbing and powdering which comprises:
adding the LR—Fe—B-Ma alloy and the HR—Fe—B-Mb alloy which are hydrogen decrepitated in the step (3), and the metal oxide micro-powder into a mixer for mixing, wherein mixing is made under nitrogen protection, lubricant or anti-oxidant may be added, a mixing time is more than 30 min; powdering with jet milling after mixing, wherein an average particle size of the powder is 1-3.3 μm,
wherein when the LR—Fe—B-Ma alloy and the HR—Fe—B-Mb alloy which are hydrogen decrepitated in the step (3), and the metal oxide micro-powder are added into the mixer for mixing, a certain amount of hydrogen may be added;
wherein powdering with jet milling process comprises: under nitrogen atmosphere or not, adding the mixed powder into a hopper on a top portion of a feeder, moving the mixed powder into a milling room through the feeder, milling with high-speed flow from a spray nozzle, rising the powder milled with the flow; sorting powder suitable for powdering with a sorting wheel and collecting in a cyclone collector; discharging fine powder coated with the metal oxide micro-powder from an air exhaust pipe of the cyclone collector with air flow, and then collecting in a collector after the cyclone collector, and then mixing under nitrogen protection to obtain the alloy powder; and
(5) magnetic field pressing, sintering and ageing which comprises:
under nitrogen protection, magnetic field pressing the above alloy powder, and then sintering and ageing under vacuum or argon protection for manufacturing the NdFeB rare earth permanent magnet,
wherein magnetic field pressing comprises sending the alloy powder into a nitrogen protection sealed magnetic field pressing machine under nitrogen protection, weighting before adding to a cavity of a mould already assembled, then magnetic field pressing; after pressing, opening the mould and obtaining a magnetic block; surrounding the magnetic block with a plastic or rubber bag under nitrogen protection, sending the magnetic block into an isostatic pressing machine for isostatic pressing, then sending the magnetic block which is still surrounded into a nitrogen protection loading tank of a vacuum sintering furnace; unsurrounding the magnetic block with gloves in the nitrogen protection loading tank and sending to a sintering case;
wherein sintering and ageing comprises sending the sintering case in the nitrogen protection loading tank of the vacuum sintering furnace into a heating chamber of the vacuum sintering furnace under nitrogen protection, evacuating before heating, keeping a temperature at 200-400° C. for 2-10 h, then keeping the temperature at 400-600° C. for 5-12 h, then keeping the temperature at 600-1050° C. for 5-20 h to pre-sinter, then keeping the temperature at 950-1070° C. for 1-6 h to sinter, then first ageing at the temperature of 800-950° C. and second ageing at the temperature of 450-650° C., rapidly cooling after second ageing for manufacturing the sintered NdFeB permanent magnet, machining the sintered NdFeB permanent magnet and surface-processing to manufacture various permanent magnetic devices.
A density of the pre-sintered magnet is 7-7.4 g/cm 3 , and a density of the sintered magnet is 7.5-7.7 g/cm 3 .
The method of manufacturing a high-performance NdFeB rare earth permanent magnet with composite main phase is characterized in that the metal oxide micro-powder is Dy 2 O 3 micro-powder heat-processed at a temperature of 600-1200° C.
The metal oxide micro-powder is Al 2 O 3 micro-powder.
The alloy melting comprises firstly melting a raw material under vacuum or argon protection with induction heating for forming an alloy, refining at 1400-1470° C. before casting the alloy in a melted state onto a rotation roller with water cooling function with a rotating speed of 1-10 m/s through a tundish, and cooling the alloy with the rotation roller for forming alloy flakes, falling the alloy flakes onto the rotation plate for secondary cooling after the alloy flakes leaving the rotation roller, and outputting the alloy flakes after cooling.
More preferably, the alloy melting comprises firstly melting a raw material under vacuum or argon protection with induction heating for forming an alloy, refining at 1400-1470° C. before casting the alloy in a melted state onto a rotation roller with water cooling function with a rotating speed of 1-10 m/s through a tundish, and cooling the alloy with the rotation roller for forming alloy flakes, falling the alloy flakes after the alloy flakes leaving the rotation roller, decrepitating the alloy flakes after falling, then entering a material receiving box, and then cooling the alloy flakes by inert gases.
Even more preferably, the alloy melting comprises firstly melting a raw material under vacuum or argon protection with induction heating for forming an alloy, refining at 1400-1470° C. before casting the alloy in a melted state onto a rotation roller with water cooling function with a rotating speed of 1-4 m/s through a tundish, and cooling the alloy with the rotation roller for forming alloy flakes with a temperature of larger than 400° C. and smaller than 700° C., falling the alloy flakes onto a cooling plate for secondary cooling after the alloy flakes leaving the rotation roller, wherein a temperature of each of the alloy flakes is less than 400° C. after secondary cooling, then decrepitating the alloy flakes before keeping a temperature of 200-600° C., and then cooling the alloy flakes by inert gases.
The HR—Fe—B-Mb alloy melting comprises firstly melting an HR—Fe—B-Mb raw material under vacuum or argon protection with induction heating for forming an alloy, casting the alloy in a melted state into a water cooling mold for forming alloy ingots or onto a rotation roller with water cooling function through a tundish, and cooling the molten alloy with the rotation roller for forming alloy flakes, crushing the alloy ingots or the alloy flakes into small blocks with a side length less than 10 mm, adding the alloy blocks to a water cooling copper crucible of an arc heating vacuum furnace under argon atmosphere, heating the alloy blocks with arc for melting the alloy blocks into molten alloy liquid, contacting a periphery of a high-speed rotating molybdenum wheel with water cooling function with the molten alloy liquid in such a manner that the molten alloy liquid is thrown out to form a fibrous La—HR—Fe—B-Mb alloy with an average grain size of 0.1-2.9 μm.
Preferably, the average grain size of the La—HR—Fe—B-Mb alloy is 2-3 μm, and an average grain size of the HR—Fe—B-Mb alloy is 0.6-1.9 μm.
By improving the components and the manufacturing processes of the magnet, the present invention is capable of significantly improving the magnetic properties, and especially, coercivity and magnetic energy product. Under the same coercivity, the usage of the heavy rare earth is significantly reduced to save scarce rare earth resources. The NdFeB rare earth permanent magnet is easy to be oxidized, which seriously affects the applications in vehicles, wind power and other industries. The present invention significantly reduces weight loss, improves antioxidant capacity of the magnet, and expands the application ranges of the NdFeB rare earth permanent magnet.
The remanence and coercivity of La 2 Fe 14 B are obviously lower than those of Nd 2 Fe 14 B, Pr 2 Fe 14 B, Dy 2 Fe 14 B and Tb 2 Fe 14 B, and especially, the coercivity of La 2 Fe 14 B is much less than that of Nd 2 Fe 14 B, Pr 2 Fe 14 B, Dy 2 Fe 14 B and Tb 2 Fe 14 B. It is generally considered that when La is added to the magnet, the magnetic properties are decreased. By further researches, the present invention finds that a method of improving remanence, coercivity, magnetic energy product and corrosion resistance of the magnet through adding La and a new manufacturing method thereof.
These and other objectives, features, and advantages of the present invention will become apparent from the following detailed description, the accompanying drawings, and the appended claims.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The significant effects of the present invention are further illustrated by comparative embodiments.
Embodiment 1
Melting 600 Kg LR—Fe—B-Ma alloy and 600 Kg HR—Fe—B-Mb alloy respectively selected from the components of embodiment 1 in Table 1; casting the alloys in a melted state onto a rotation copper roller with water cooling function, so as to be cooled for forming alloy flakes; adjusting a cooling speed of the LR—Fe—B-Ma alloy and the HR—Fe—B-Mb alloy by adjusting a rotation speed of the rotation copper roller for obtaining the LR—Fe—B-Ma alloy with an average grain size of 2.8 μm and the HR—Fe—B-Mb alloy with an average grain size of 1.8 μm; selecting the LR—Fe—B-Ma alloy flakes and HR—Fe—B-Mb alloy flakes with a ratio in Table 1 for hydrogen decrepitating; after hydrogen decrepitating, sending the alloy flakes and metal oxides with a ratio in Table 1 into a mixer, mixing under nitrogen protection for 60 min before powdering with jet milling; sending the powder from a cyclone collector and the super-fine powder from the filter into a post-mixer for post-mixing, wherein post-mixing is provided under nitrogen protection with a mixing time of 90 min; an oxygen content in protection atmosphere is less than 100 ppm; then sending into a nitrogen protection magnetic field orientation pressing machine for pressing, wherein an orientation magnetic field strength is 1.8 T, an in-cavity temperature is 3° C., a size of a magnet is 40×30×20 mm, and an orientation direction is a 20 size direction; packaging in a protection tank after pressing, then outputting for isostatic pressing; sending into a sintering furnace for pre-sintering, wherein a pre-sintering temperature is kept at 940° C. for 15 h and a pre-sintering density is 7.3 g/cm 3 ; then sintering, firstly ageing and secondly ageing, wherein a sintering temperature is kept at 1070° C. for 1 h; taking out the magnetic block for being machined, then measuring magnetic performance and weight loss, recording results in Table 1, wherein a weight percentage ratio of the sintered magnet after testing is (Nd 0.7 Pr 0.3 ) 29.5 Dy 1.0 B 0.9 Al 0.1 Co 1.2 Cu 0.15 Fe residual , and the measurement results of magnetic energy product, coercivity and weight loss also are recorded in Table 1.
Contrast Example 1
Selecting the magnet with a composition of (Nd 0.7 Pr 0.3 ) 29.5 Dy 1.0 B 0.9 Al 0.1 Co 1.2 Cu 0.15 Fe residual of the contrast example 1 in Table 2, firstly melting alloy, casting the alloy in a melted state onto a rotation copper roller with water cooling function, so as to be cooled for forming alloy flakes; then hydrogen decrepitating, powdering with jet milling, pressing by a magnetic field orientation pressing machine, isostatic pressing, sintering, firstly ageing and secondly ageing the alloy flakes, machining, measuring magnetic properties and weight loss, and recording results in Table 1.
In spite that the embodiment 1 and the contrast example 1 has same magnetic composition, the magnetic energy product, coercivity and weight loss of the present invention of the embodiment 1 of the present invention are significantly higher than those of the contrast example 1.
The other compositions of embodiment 1 are unchanged, the content of Co is changed, when 0≦Co≦5, the metal oxide is in a range of 0.01-0.05%, the magnetic performance is changed with the increase of the content of Co, the change range is less than 4%, the performance is significantly higher than that of the contrast example 1. Preferably, the content of Co is 0≦Co≦3, the performance change is smaller. Further preferably, the content of Co is 1.0≦Co≦2.4, the performance change is much smaller and lower than 2%. The content of Co is unchangeable, the content of Cu is adjusted, when 0≦Cu≦0.3, the metal oxide is in a range of 0.01-0.05%, the performance is changed with the change of the content of Cu, the change range is less than 3%, the performance is significantly higher than that of the contrast example 1. Preferably, the content of Cu is 0.1≦Cu≦0.3, the performance is changed with the change of the content of Cu, and the change range is less than 2%. Further preferably, the content of Cu is 0.1≦Co≦0.2, the performance is changed with the change of the content of Cu, and the change range is less than 1%. Experiments show that when both Co and Cu are added, the content of Co meets 0.8≦Co≦2.4, and the content of Cu meets 0.1≦Cu≦0.2, the magnetic performance and corrosion resistance are best.
The material compositions and experimental method of embodiment 1 are unchangeable, the variety and content of the metal oxide are changed. Experiments show that when the metal oxide micro-powder is Al 2 O 3 , the content thereof is 0.01-0.05%, the magnetic performance is increased with the increase of the content, the content is 0.01-0.08%, the magnetic performance keeps higher than the performance with the content of 0.01; when the metal oxide micro-powder is replaced by Dy 2 O 3 and Tb 2 O 3 , the same rules exist, the performance of Dy 2 O 3 is higher than that of Al 2 O 3 , the performance of Tb 2 O 3 is higher than Dy 2 O 3 . Preferably, the content of the metal oxide micro-powder is 0.01-0.05%. Further preferably, the content of the metal oxide micro-powder is 0.02-0.03%. Preferably, the metal oxide is Al 2 O 3 ; and more preferably, Dy 2 O 3 , and even more preferably, Tb 2 O 3 . Preferably, both Dy 2 O 3 and Al 2 O 3 are added to further improve the performance of the magnet. More preferably, both Al 2 O 3 and Tb 2 O 3 or both Tb 2 O 3 and Dy 2 O 3 are added to further improve the performance of the magnet. Even more preferably, Dy 2 O 3 , Al 2 O 3 and Tb 2 O 3 are added to further improve the performance of the magnet.
Embodiment 2
Melting 600 Kg LR—Fe—B-Ma alloy and 600 Kg HR—Fe—B-Mb alloy respectively selected from the components of embodiment 2 in Table 1; casting the alloys in a melted state onto a rotation copper roller with water cooling function, so as to be cooled for forming alloy flakes; adjusting a cooling speed of the LR—Fe—B-Ma alloy and the HR—Fe—B-Mb alloy by adjusting a rotation speed of the rotation copper roller for obtaining the LR—Fe—B-Ma alloy with an average grain size of 2.3 μm and the HR—Fe—B-Mb alloy with an average grain size of 1.3 μm; selecting the LR—Fe—B-Ma alloy flakes and HR—Fe—B-Mb alloy flakes with a ratio in Table 1 for hydrogen decrepitating; after hydrogen decrepitating, sending the alloy flakes and metal oxides with a ratio in Table 1 into a mixer, mixing under nitrogen protection for 40 min before powdering with jet milling; sending the powder from a cyclone collector and the super-fine powder from the filter into a post-mixer for post-mixing, wherein post-mixing is provided under nitrogen protection with a mixing time of 70 min; an oxygen content in protection atmosphere is less than 50 ppm; then sending into a nitrogen protection magnetic field orientation pressing machine for pressing, wherein an orientation magnetic field strength is 1.8 T, an in-cavity temperature is 4° C., a size of a magnet is 40×30×20 mm, and an orientation direction is a 20 size direction; packaging in a protection tank after pressing, then outputting for isostatic pressing; sending into a sintering furnace for pre-sintering, wherein a pre-sintering temperature is kept at 910° C. for 10 h and a pre-sintering density is 7.2 g/cm 3 ; then sintering, firstly ageing and secondly ageing, wherein a sintering temperature is kept at 1060° C. for 1 h; taking out the magnetic block for being machined, then measuring magnetic performance and weight loss, recording results in Table 1, wherein a weight percentage ratio of the sintered magnet after testing is La 1 (Nd 0.75 Pr 0.25 ) 24 Dy 4 Tb 2 Co 1 Cu 0.1 B 0.95 Al 0.2 Ga 0.1 Fe residual , and the measurement results also are recorded in Table 1.
Contrast Example 2
Selecting the magnet with a composition of La 1 (Nd 0.75 Pr 0.25 ) 24 Dy 4 Tb 2 Co 1 Cu 0.1 B 0.95 Al 0.2 Ga 0.1 Fe residual in Table 2 to compare, the experimental method is same as that in the comparative 1, the measurement results also are recorded in Table 1.
Generally, when Pr or Nd is replaced by La, the magnetic performance is significantly reduced. It can be seen from Table 1, when 1% (Nd 0.75 Pr 0.25 ) is replaced by 1% La, the magnetic performance is significantly improved by the technical process of the present invention. The contents of other compositions are unchanged, only the content of La is changed. Experiments show when 0≦La≦2.4, the magnetic performance and the corrosion resistance are unchanged; when 2.5≦La≦3, the magnetic performance and the corrosion resistance are slightly decreased; when 3.1≦La≦4.5, the magnetic performance and the corrosion resistance can be decreased to less than 3%; when 5≦La≦9, the magnetic performance and the corrosion resistance can be decreased to less than 5%. Therefore, preferably, the content of La is 5≦La≦9, and further preferably, 3.1≦La≦4.5, and further preferably, 2.5≦La≦3.
When La is replaced by Ce, that is to say, that when the magnet with a composition of Ce 1 (Nd 0.75 Pr 0.25 ) 24 Dy 4 Tb 2 Co 1 Cu 0.1 B 0.95 Al 0.2 Ga 0.1 Fe residual is selected to test, the same rules are obtained. Therefore, preferably, the content of Ce is 5≦Ce≦9, and more preferably, 3.1≦Ce≦4.5, and even more preferably, 2.5≦Ce≦3.
Embodiment 3
Melting 600 Kg LR—Fe—B-Ma alloy and 600 Kg HR—Fe—B-Mb alloy respectively selected from the components of embodiment 3 in Table 1; casting the alloys in a melted state onto a rotation copper roller with water cooling function, so as to be cooled for forming alloy flakes; adjusting a cooling speed of the LR—Fe—B-Ma alloy and the HR—Fe—B-Mb alloy by adjusting a rotation speed of the rotation copper roller for obtaining the LR—Fe—B-Ma alloy with an average grain size of 2.8-3.2 μm and the HR—Fe—B-Mb alloy with an average grain size of 2.1-2.4 μm; selecting the LR—Fe—B-Ma alloy flakes and HR—Fe—B-Mb alloy flakes with a ratio in Table 1 for hydrogen decrepitating; after hydrogen decrepitating, sending the alloy flakes and metal oxides with a ratio in Table 1 into a mixer, mixing under nitrogen protection for 90 min before powdering with jet milling; sending the powder from a cyclone collector and the super-fine powder from the filter into a post-mixer for post-mixing, wherein post-mixing is provided under nitrogen protection with a mixing time of 60 min; an oxygen content in protection atmosphere is less than 150 ppm; then sending into a nitrogen protection magnetic field orientation pressing machine for pressing, wherein an orientation magnetic field strength is 1.5 T, a size of a magnet is 40×30×20 mm, and an orientation direction is a 20 size direction; packaging in a protection tank after pressing, then outputting for isostatic pressing; sending into a sintering furnace for pre-sintering, wherein a pre-sintering temperature is kept at 990° C. for 8 h and a pre-sintering density is 7.4 g/cm 3 ; then sintering, firstly ageing and secondly ageing, wherein a sintering temperature is kept at 1080° C. for 1 h; taking out the magnetic block for being machined, then measuring magnetic performance and weight loss, recording results in Table 1, wherein the composition of the sintered magnet after testing is Ce 1.5 (Nd 0.8 Pr 0.2 ) 20 Dy 6 Ho 2 Gd 2 Co 2.4 Cu 0.2 B 1.0 Al 0.3 Ga 0.1 Zr 0.1 Nb 0.1 Fe residual , and the measurement results also are recorded in Table 1.
Contrast Example 3
Selecting the magnet with a composition of Ce 1.5 (Nd 0.8 Pr 0.2 ) 20 Dy 6 Ho 2 Gd 2 Co 2.4 Cu 0.2 B 1.0 Al 0.3 Ga 0.1 Zr 0.1 Nb 0.1 Fe residual according to the contrast example 3 in Table 2, firstly melting alloy, casting the alloy in a melted state onto a rotation copper roller with water cooling function, so as to be cooled for forming alloy flakes; then hydrogen decrepitating, powdering with jet milling, pressing by a magnetic field orientation pressing machine, isostatic pressing, sintering, firstly ageing and secondly ageing the alloy flakes, machining, measuring magnetic performance and weight loss, and recording results in Table 1.
Compare the measurement results of embodiment 3 with those of the contrast example 3, the magnetic performance and corrosion resistance of embodiment 3 are significantly higher than those of the contrast example 3, which further illustrates the advantages of the present invention.
It can be proved by embodiments 1-3 and contrast examples 1-3 that the technical solution of the present invention has obvious advantages. Adding Al, Ga, Zr and Nb can significantly improve the magnetic performance and corrosion resistance of the magnet. Preferably, the contents of Al, Ga, Zr and Nb are respectively 0≦Al≦0.6, 0≦Ga≦0.2, 0≦Zr≦0.3, 0≦Nb≦0.3; and further preferably, 0.1≦Al≦0.3, 0.05≦Ga≦0.15, 0.1≦Zr≦0.2, 0.1≦Nb≦0.2,
TABLE 1
compound and performance in embodiments and contrast example
Contrast
Contrast
Contrast
Embodiment 1
example 1
Embodiment 2
example 2
Embodiment 3
example 3
LR-
Pr
9.15
9
7.5
5
6
4.3
Fe-B-
Nd
21.35
21
22.5
20
24
17.2
Ma
La
1.0
(Wt %)
Ce
1.5
Dy
0
1
0
4
6
Tb
0
0
0
2
Ho
2
Gd
2
Co
1.0
1.0
1.2
1.2
2.4
2.4
Cu
0.1
0.1
0.15
0.15
0.2
0.2
B
0.9
0.9
0.95
0.95
1.0
1.0
Al
0.1
0.1
0.2
0.2
0.3
0.3
Ga
0.1
0.1
0.1
0.1
Zr
0.1
0.1
Nb
0.1
0.1
Fe
residual
residual
residual
residual
residual
residual
Alloy
90%
100%
80%
100%
60%
100%
ratio
HR-
Dy
10
20
15
Fe-B-
La
1
Ma
Ce
1.5
alloy
Pr
6.15
0.25
1
(Wt %)
Nd
14.35
0.75
4
Tb
0
10
Ho
5
Gd
5
Co
1.0
1.2
2.4
Cu
0.1
0.15
0.2
B
0.9
0.95
1.0
Al
0.1
0.2
0.3
Ga
0.1
0.1
Zr
0.1
Nb
0.1
Fe
residual
residual
Alloy
10%
0
20%
0
40%
0
ratio
Oxide
Dy 2 O 3
0.01
0.02
0.03
micro-
Tb 2 O 3
0.01
0.01
powder
Al 2 O 3
0.01
0.01
(Wt %)
total
0.02
0.03
0.05
Magnetic
48
46
43
38
30
27
energy product
(MGOe)
Coercivity
21
15
33
27
36
31
(KOe)
Magnetic
69
61
76
65
66
58
energy product +
coercivity
Weight loss
1
4
2
6
3
5
(mg/cm 2 )
TABLE 2
Composition of rare earth permanent magnet alloy in contrast example
No
Composition
Contrast example 1
(Nd 0.7 Pr 0.3 ) 29.5 Dy 1.0 B 0.9 Al 0.1 Co 1.2 Cu 0.15 Feresidual
Contrast example 2
(Nd 0.75 Pr 0.25 ) 25 Dy 4 Tb 2 Co 1 Cu 0.1 B 0.95 Al 0.2 Ga 0.1 Fe residual
Contrast example 3
(Nd 0.8 Pr 0.2 ) 21.5 Dy 6 Ho 2 Gd 2 Co 2.4 Cu 0.2 B 1.0 Al 0.3 Ga 0.1 Zr 0.1 Nb 0.1 Fe residual
It is further illustrated by the embodiments and the contrast examples that the method and the device according to the present invention significantly improve the magnetic performance, coercivity and corrosion resistance of the magnet. By respectively melting two alloys, one decrepitating and adding metal oxide micro-powder while jet milling, the present invention improves the structure of the powder, and forms the ground surface of the metal oxide for reducing the further oxidation of the magnetic powder. HR—Fe—B-Mb alloy powder absorbs around LR—Fe—B-Ma alloy powder, it is alloyed while sintering to form the special metallurgical structure of the present invention. Compared with Dy infiltration technique, the present invention is not limited by the shape and size of the magnet and is a very promising technology.
One skilled in the art will understand that the embodiment of the present invention as shown in the drawings and described above is exemplary only and not intended to be limiting.
It will thus be seen that the objects of the present invention have been fully and effectively accomplished. Its embodiments have been shown and described for the purposes of illustrating the functional and structural principles of the present invention and is subject to change without departure from such principles. Therefore, this invention includes all modifications encompassed within the spirit and scope of the following claims.
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A NdFeB rare earth permanent magnet with composite main phase and a manufacturing method thereof are provided. In the composite main phase, a PR 2 (Fe 1-x-y Co x Al y ) 14 B main phase is the core, ZR 2 (Fe 1-w-n Co w Al n ) 14 B main phase surrounds a periphery of the PR 2 (Fe 1-x-y Co x Al y ) 14 B main phase, and no grain boundary phase exists between ZR 2 (Fe 1-w-n Co w Al n ) 14 B main phase and the PR 2 (Fe 1-x-y Co x Al y ) 14 B main phase, wherein ZR represents a group of rare earth elements in which a content of heavy rare earth is higher than an average content of heavy rare earth in the composite main phase, PR represents a group of rare earth elements in which a content of heavy rare earth is lower than an average content of heavy rare earth in the composite main phase. The manufacturing method includes steps of LR—Fe—B-Ma alloy melting, HR—Fe—B-Mb alloy melting, alloy hydrogen decrepitating, metal oxide micro-powder surface absorbing and powdering, magnetic field pressing, sintering and ageing.
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This is a continuation-in-part of application Ser. No. 08/310,577, filed Sep. 22, 1994, now U.S. Pat. No. 5,461,360.
FIELD OF THE INVENTION
This invention relates generally to alarm devices and, in particular to an alarm device used in conjunction with a door lock for indication of the extended presence of a key.
BACKGROUND OF THE INVENTION
Safe keeping of a home or business is a primary concern for the occupants thereof. Business offices are frequently broken into where computers, facsimile machines, telephones and the like equipment can be easily resold. It is also well known that dwellings are frequently burglarized causing the occupants fear and grief to find precious heirlooms stolen as well as televisions, stereos, cameras, and so forth taken from their lawful premises.
For these reasons elaborate alarm systems have been developed providing the occupant with a secure feeling that the premises are being guarded. A problem with the security of homes and businesses is the reliance on the human interface which is required to enable or disable the device. Despite the advances in alarm systems and locking mechanisms, unless the security device is enabled it is worthless. Further, should the occupant provide a potential burglar with the device necessary for unlocking the security mechanism, there is no security made possible by any device.
Thus, a primary level of security remains the conventional mechanical lock found on most every door that requires security. Typically the lock consists of a door handle with an integrated key lock requiring the occupant to unlock the door handle before the door can be opened. Another key lock for doors is commonly referred to as a dead bolt lock consisting of a solid bolt that engages a door jam. Should a person leave a key in a lock, the key becomes the unlocking mechanism, and if placed in the wrong hands has dire consequences. Statistics show that this event is very common and is the preferred method of potential burglars so as to avoid the need to defeat an alarm that is beyond the thieves' capability.
Occupants to a home or business frequently leave their keys in the locking mechanism in their haste to enter the dwelling. For instance, it is not uncommon for a person to attempt to carry groceries into a home leaving the keys in the door lock until they have set down the groceries and subsequently forgetting to retrieve the keys. In this event, a potential thief can simply grab the keys and use them later to gain uninhibited access to the dwelling. Similarly, a worker who opens an office can easily leave their keys in the door while they prepare for the morning's business. Again, a potential thief can easily grab the keys and use them later. A clever thief has even been known to make a copy of the key and return the key to a conspicuous location so that the rightful owner believes they have simply misplaced the keys and thus does nothing further to rectify their security breach. If the occupant of the dwelling forgets the keys they may simply think they have misplaced them and will duplicate keys as their replacement. Even if the rightful owner of the stolen keys realizes that they are stolen, they may not believe it is worth the expense to change all the locks that are associated with the lost keys. For example, a key ring may include keys to a person's home, office, automobile, neighbor's home, parents' home, boat, and so forth. A person may not be able to afford to quickly change every lock at every location. They may further avoid telling the person whose key was in their possession that their key was stolen, leaving the entrusting persons susceptible to home invasion.
Therefore, what is needed in the art is a device capable of reminding the owner of keys that they remain within the locking mechanism.
SUMMARY OF THE INVENTION
The instant invention is a key insertion reminding device which operates to signal an alarm should a key be left within a key slot for longer than a predetermined time limit. The preferred embodiment includes a micro-switch located within the key lock mechanism that is triggered upon insertion of a conventional key. Once the micro-switch is triggered it activates an adjustable timer which counts down a time suggested within five to twenty five seconds wherein if the key is not removed within that time limit an audible alarm is sounded. The micro-switch can be replaced with a photo optic sensor which can be placed within the key latch mechanism. These embodiments are well suited for new applications or replacement of existing key lock mechanisms allowing the sensing device of the instant invention to be incorporated directly into the locking mechanism.
An alternative embodiment allows for placement of the sensing mechanism external the door and can be simply secured in a position around conventional locks such as a dead bolt. In this embodiment a circular O-ring is placed around the conventional lock mechanism wherein the enlarged ring has a photo sensing device along a raised lip which must be broken upon insertion of the key. As with the aforementioned embodiment should the key not be removed within a predetermined amount of time an audible alarm will be sounded so that the person will retrieve the keys from the lock.
The instant invention is well suited for those persons who are extremely busy and most likely to forget the basic necessities of removing the keys from a door lock as they have more important things on their mind. It further provides a reminder for those persons who may not realize the necessity of removing keys from a door lock such as young children who are entrusted with an important key or the elderly who may be partially incapacitated due to an illness.
Thus, an objective of the instant invention is to provide an inconspicuous alarm that will indicate the extended presence of a key within a key lock mechanism.
Another objective of the instant invention is to provide the occupants of a premise with the increased security by alarming the rightful owners to the premise that the security keys remain available to potential thieves.
Yet another objective of the instant invention is to teach young children the importance of removing keys from the key lock mechanism by providing an instant reminder that the keys present a breach of security.
Still another objective of the instant invention is to provide an integrated key alarm mechanism that fits within the cavity of a security door providing ease of installation and operation.
A further objective of the instant invention is to provide an alternative embodiment wherein the alarm mechanism is attachable to the external facia of a security door for placement about a dead bolt key lock mechanism.
Another objective of the instant invention is to provide a low cost alarm mechanism that will provide visual indication of key insertion as a primary alert to the hearing impaired.
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 the specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an electrical schematic of the instant invention;
FIG. 2 is a cross-sectional pictorial view of a key inserted into a key lock mechanism;
FIG. 3 is a front view of an optical sensor embodiment of the instant invention;
FIG. 4 is side view of FIG. 3 with a key inserted by hidden lines for a pictorial display thereof;
FIG. 5 is an electrical schematic of another embodiment of the instant invention;
FIG. 6 is an electrical schematic, similar to FIG. 5, which also uses a separate timer circuit to drive the alarm duty cycle;
FIG. 7 is an exploded orthagonal view of one embodiment of the entire door alarm assembly;
FIG. 8 is an orthagonal view of the interior portion of the door of FIG. 7 with the bolt shield assembly in place for mounting;
FIG. 9 is a cross-sectional view of the mounted door lock assembly as embodied in FIG. 7.
FIG. 10 is an orthagonal view of the exterior portion of the door of FIG. 7 with the key in place and the alarm sounding;
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Now referring to FIG. 1 shown is a simplified electrical diagram of the instant invention. The primary intent of the invention is to detect a key left in a key hole by activating an audible alarm if the key is left in the lock mechanism for an extended period of time. T1 depicts a timer such as an LM-555 or equivalent timer having an adjustable timing circuit electrically coupled to a power supply B1. The power supply B1 is preferably disposable such as 1.5 volt lithium AA battery placed in series for a combined 3 volts. A means for detecting S1 the insertion of a key within a key lock mechanism initiates the timer T1. A micro-switch can be incorporated into the locking mechanism as further described later in this specification.
The means for detecting may also be an optical sensor or magnetic switch. In any event when S1 is closed by insertion of a key, the timer circuit T1 is adjusted between five and twenty seconds. Once a key is inserted into the switch S1 the timer mechanism T1 begins to countdown from the predetermined time and should the key remain in a position of switch S1 activation, the timer T1 will time out activating an audible alarm A1 operatively associated with the timer T1.
Referring now to FIG. 5, a simplified electrical circuit diagram of a second embodiment of the instant invention is shown. The switch SW is mechanically linked to the key lock mechanism. When a key is inserted into the lock, the normally open switch contacts close, providing power to the circuit. Upon switch SW closing, second capacitor C2 and third resistor R3 provide a reset pulse to decade counter IC2. IC1A, IC1B, IC1C and IC1D are each standard two-input NAND gates. IC1A, IC1B, first resistor R1, second resistor R2 and first capacitor C1 comprise an oscillator having a square wave output. The period of this square wave might be varied by providing an adjustable capacitance device (e.g. a variable capacitor) in place of C1. Alternatively, the square wave period could be altered by providing variable resistance devices (e.g. a potentiometer or rheostat) in place of R1 and/or R2. This configuration works best if the resistors are changed together. The square wave oscillator output is fed to decade counter IC2 wherein the first ten pulses from the oscillator are counted and latched by decade counter IC2. By varying the period of the square wave, the time required for IC2 to count ten pulses and latch can be resultingly varied.
The latched output of IC2 and the output of the square wave oscillator serve as the inputs to NAND gate IC1C. IC1C has a low output when the output of decade counter IC2 is latched high and the output of the oscillator is also high. IC1D is used as an inverter to invert the output of IC1C. Fourth resistor R4 and transistor Q1 comprise an electronic switch which is used to turn on the audible alarm. The coincidence of a high and latched IC2 output and a pulsing oscillator output allows the alarm to pulse on and off in order to better draw attention.
In the circuit of FIG. 5, it will be realized that while the use of electrical components is minimized, there are limitations as to the versatility of this circuit. For instance, if the period of the square wave oscillator is varied to change the delay period before the alarm sounds, the resulting duty cycle of the on/off alarm pulse will correspondingly be changed. For instance, a shorter delay (e.g. around 5 seconds), will produce a faster alarm duty cycle, and a longer delay (e.g. around 20 seconds) will produce a slower alarm duty cycle. Users may prefer to vary the alarm delay period and the alarm duty cycle independently from each other. Accordingly, FIG. 6 shows a variation of the circuit of FIG. 5 whereby a timer circuit IC3 is also included to provide more flexibility over the alarm circuit. In this alarm circuit, the alarm duty cycle and the alarm delay period can be independently adjusted.
As shown in this embodiment, IC3 is comprised of a timer chip which in this instance is an LM555. As configured, power is connected across pins 4 and 8 of the timer chip. Fifth and sixth resistors R5 and R6 are connected in series as a voltage divider with third capacitor C3 in series between the ground connection and pins 2,6. Resistor R6, and its resultant voltage drop, is connected across pins 7 and 2,6. Pins 1 and 5 are connected to ground with a buffering fourth capacitor R5 on pin 5. By varying the resistance of R5 and/or R6, and/or by varying the capacitance of C3, the timing period (or duty cycle) of the chip output on pin 3 can be varied. As before, to achieve this variability resistors R5, R6 might be replaced by variable resistive devices (e.g. a potentiometer or rheostat) and C3 might consist of a variable capacitive device.
In the circuit of FIG. 6, the output of the square wave oscillator is connected only to the decade counter IC2. The output of the decade counter, as before, serves as one input to NAND gate IC1C. The output of the timer chip IC3 serves as the other input to IC2. As a result, when the output of the decade counter IC2 latches high, the output of IC1C will vary with the period of the timer chip IC3 output. As before, IC1D serves an invertor and its output is connected to a resistor R4 which feeds the base of a transistor Q1. Transistor Q1 acts a switch with an alarm device connected between power and the collector of the transistor. Hence, when the output of IC1D is periodically high, the transistor turns on and current flows through the alarm device.
Referring now to FIG. 2 shown is a pictorial view of an embodiment of the alarm system of the instant invention installed within a key lock mechanism. Depicted in a cross-sectional view of a door 20 having a outer side surface 22 having an external key insertions lock mechanism 24 coupled to an inner key bolt lock shield 26 disposed along the inner side surface 28 of the door 20. In this embodiment the locking mechanism is commonly referred to as a dead bolt having a lever 30 for operation which allows the door to be locked by simple twisting of the lever 30. It should be noted that the figure sets forth a dead bolt for illustration only as the invention works equally well with any locking mechanism including those integrated into a door handle.
When the lock mechanism is engaged, a latch locks the door to an adjoining door frame to prevent entrance to the dwelling. Insertion of key 32 into an available slot in the outer lock mechanism 24 allows engagement to a coded key tumbler mechanism 34 which will only allow turning of the key 32 if the components are keyed alike. Micro-switch 36 is coupled to the internal locking mechanism 34 with engagement bar 38 which places the micro-switch 36 into a closed position when the tip 40 of the key 32 engages the micro-switch arm 38. The remaining electrical components are similarly placed within the door cavity in enclosure 42 which houses the battery(s), audible speaker 44, and timer mechanism 45.
Once the key 32 is inserted into the locking mechanism 34 and the micro-switch 36 is engaged, the timer 45 receives power from the batteries 42 and should the timer count down before the key 32 is removed from the lock mechanism 34, the audible alarm 44 will signal. Lithium batteries contained within the enclosure provide optimum life as the system need only be made operable should the key remain in the key lock mechanism for prolonged period of time. Circuitry includes indication of low battery power by providing an audible signal through the speaker. It should be noted that arrangement of the particular components is not limited to the particular order shown and described as the cavity for the lock mechanism provides sufficient room for rearrangement of components without defeating the purpose of this invention. The micro switch 36 can substituted with an optical sensor or magnetic pick-up.
Referring to FIGS. 3 and 4, an embodiment of the instant invention is set forth wherein the aforementioned components are placed within a housing secured to the outer surface 70 of a door 72. In this embodiment an optical sensor is substituted for the aforementioned micro switch. An emitter 74 directs an infrared beam 75 for receipt by receiver 76 located at the opposite end of the lock mechanism 78 surface. The optical sensor is located in housing 80 defined by a square shaped enclosure leading to a circular enclosure 82 which encompasses the locking mechanism. When a key 84 is inserted into the locking mechanism 78, the key breaks the infrared beam 75 of light causing the receiver 76 to close and provide power to the timer located in the housing 80 thus allowing the timer to countdown in the aforementioned manner. Should the key 84 remain in the key lock mechanism 78 beyond the predetermined period of time, preferably between five and twenty seconds, an audible alarm located within the housing 80 beneath screen openings 88 will provide an audible alarm. The alarm can be a Pizzo or the like audible alarm.
The housing 80 can be attached to the outer surface 70 of the door 72 by adhesive or more preferably the housing 80 and circular enclosure 82 includes a tab 90 which fits beneath the lock mechanism 78 cover shield allowing a secure installation by simply loosening the lock mechanism 78 for insertion of the support tabs 90 beneath the lock mechanism 78. The lock mechanism 78 cover shield is secured by engagement screws located on the inner side surface of the lock mechanism.
The housing 80 and associated circular ring structure 82 can be constructed of low cost thermal plastic. Alternatively, the housing and structure can be made from a high gloss material such as brass and include ornamental indicia 92 such as the monogram of the occupant placed along the front surface of the housing 80.
One skilled in the art will recognize that the components in the housing can be relocated such as within the cavity of the door yet maintain the external optical support structure 82. Similarly, the housing 80 may remain external to the door for ease of battery replacement while the micro switch, optical sensor, or magnetic pick-up is located within the door cavity.
Yet another embodiment is shown in FIGS. 7-10 wherein the battery and timing circuitry are located in the external housing which mounts on the interior side of the door 28. FIG. 7 shows an exploded view of the door lock assembly and its associated parts for mounting in a door. As before, the exterior cylinder 35 houses a tumbler mechanism 34 and a microswitch 36. A cable connector 100 is used for connecting the microswitch 36 to the circuitry unit (not shown) as located within key bolt lock shield (or turnpiece assembly) 26 via cable connector interface 122. Also housed within assembly 26 is the power source, in this case shown as a 6 volt lithium battery 43.
As assembled, the external cylinder 35 fits within guard covers 102 which fit over opening 103 in door 20. The deadbolt crank 106 fits into door opening 107 and is secured in place with screws 118 through plate 110. A coinciding plate 114 is similarly attached to the door jamb 112 via screws 116. The exterior torque blade 104 extends thorough opening 103, through crank 106, and into receptacle 124 of assembly 26. Assembly 26 and cylinder 35 are held in place via machine screws 120 which extend through assembly 26, through opening 103, and screw into openings 121 in cylinder 35.
Referring now to FIG. 8, the interior side 28 of the door 20 is shown with the shield assembly 26 and deadbolt 108 assembly in place for receipt of attachment screws 120. FIG. 9 shows a side cross-sectional view of the mounted lock assembly as similar to FIG. 2. However, in FIG. 9, the shield assembly 26 is larger to accommodate the alarm circuitry, cable interface connector 122, and battery 43 as described above. Referring to FIG. 10, an orthagonal view of the outer surface 22 of the completed door alarm assembly is shown wherein the key 32 has been in place long enough for the alarm to sound. As described, the alarm emits audible waves 125 that pulse on and off to better attract attention.
The audible alarm may be exchanged for any type of indicating device such as light and may be further coupled into a security alarm system. For the hearing impaired, the presence of a key being inserted into the door provides an early indication that someone is entering the doorway. For this reason, the timer can be set at a low level or removed from the circuit.
It is to be understood that while we have described certain forms of our 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.
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A key reminder device for use in combination with a key lock mechanism having an adjustable timer with a predetermined timer interval electrically coupled to a replaced power supply. The timer is energized upon detection of a conventional key inserted into the key lock mechanism. Should the key remain in the key lock mechanism beyond a predetermined time, the timer will activate an audible alarm to remind the owner of the keys to remove them. Should the timer be set at a low level, the device operates to indicate the presence of a key. When used in combination with a visual indicator, the key reminder provides an indicator of door entry to the hearing impaired.
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This is a Continuation-in-Part of application Ser. No. 08/619,441, filed Mar. 21, 1996, now U.S. Pat. No. 5,649,390.
BACKGROUND OF THE INVENTION
The invention relates to a decorative cover for garage doors that can be easily removably affixed to a movable hinged garage door to provide an aesthetically pleasing exterior cover that can include printed indicia.
OBJECTS AND SUMMARY OF THE INVENTION
It is an object of the invention to provide an additional type of decorating ornament for residential dwellings. This decorative ornament can be easily affixed to a surface of a garage door and can remain affixed during normal opening and closing of the garage door without interference with or by the door.
The above and other objects are achieved by: a combination garage door and decorative cover, comprising: a garage door positionable between open and closed positions; a decorative cover fixedly located on an exterior front side of the garage door; and attachment devices affixing at least top and bottom ends of the decorative cover directly to the garage door in a manner that allows partial movement of the decorative cover to allow for normal opening and closing of the garage door and taking up of slack in the decorative cover without the decorative cover riding up or down relative to the garage door.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in detail with reference to the following drawings wherein:
FIG. 1 illustrates a view of an extended decorative cover A and a garage door B;
FIG. 2 illustrates a perspective rear view of the decorative cover A installed to garage door B;
FIG. 3 illustrates a rear close up view of a lower right corner of the garage door shown in FIG. 2;
FIG. 4 illustrates another rear perspective view of the garage door and decorative cover with the garage door opened half way;
FIG. 5 illustrates a front view of the cover attached to the door by velcro;
FIG. 6 illustrates a rear view of the cover installed to the or using a buckle feature along top, bottom and sides and
FIG. 7 illustrates a preferred method of attachment of the cover to the door.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
With reference to FIG. 1, there is shown a decorative cover A for a garage door B of the type having a plurality of hinged door segments. The decorative cover A is formed preferably from a weather-resistant material, such as a tarpaulin, and can be insulative. The cover may also be formed from a stretchable material such as rubber, spandex or other woven, stretchable fabrics. Preferred decorative covers are sized to substantially or fully cover the garage door. The decorative cover A may be sized larger in at least one dimension than the garage door B to allow the cover A to wrap around the garage door B as better illustrated in FIGS. 2, 6 and 7.
At least top and bottom ends of the cover A include attachment devices, which preferably include spaced grommets 1 and tether devices 2, for attachment of the cover A directly to the garage door to prevent the cover from riding up or down during opening of the garage door. The tether devices 2 can include tether cords, hooks or the like. At least one flexible attachment device 4, such as a bungie-type or other elastic cord, is also provided. Alternatively, to the use of elastic cords, the material may be such that the cover stretches during opening and closing of the door and returns to shape when the door is closed. Preferably, the surface 3 of the cover is suitable for festive indicia or advertisement to be printed thereon.
FIG. 2 illustrates an attachment method for retaining the decorative cover A on the garage door B to allow full normal opening and closing of the garage door B. Tether devices 2, preferably a tether cord made out of nylon, for example, are tied between grommets 1 near left and right edges of the top and bottom of decorative cover A and the garage door. A suitable tying location for the opposite ends of the tether devices 2 is a hinge member of the garage door located between the top and bottom ends of the decorative cover as best illustrated in the close up view of FIG. 3.
Flexible attachment device 4, preferably a bungie-type cord, connects one or more grommets 1 in the top end of the cover A with one or more grommets 2 in the bottom end of the cover A to take up slack in the cover and to accommodate the expansion of the door as it follows the curvilinear track during opening of the garage door B as best illustrated in FIG. 4. A criss-cross attachment method is illustrated, although other attachments are contemplated. A much simpler and preferred attachment method is the use of four bungie-type, or stretchable, cords, one on each corner, attached directly to a hinge member of the garage door.
A method of installation of the decorative cover will now be described with reference to FIGS. 1-2 and 4. As previously stated, the cover A may be sized in one dimension to be larger than the corresponding garage door B, to completely cover the door and allow the attachment devices to be hidden from view on the front side. While the garage door B is at least partially open, the top and bottom ends of the cover A are wrapped around the garage door B. Tether devices 2 can then be tied from grommets 1 to the hinges on the back side of the garage door B as shown. The flexible attachment device 4 (bungie-type cord) is wrapped through one or more of the grommets 1 to elastically connect the top and bottom ends of cover A. As shown in both the closed position (FIG. 2) and the open position (FIG. 4), the flexible attachment device 4 takes up slack in the decorative cover A.
Alternatively, the attachment devices can include zippers, snaps, cords, Velcro, hooks, adhesives, magnets or other equivalent structures for removably, but stretchably, affixing the decorative cover to the garage door B to accommodate opening and closing of the garage door B. For example, hooks could be provided on the cover for attachment to the door. The hooks could be provided on the end of a strap for attachment directly to the garage door or to each other. Additional examples of these will be described with reference to FIGS. 5-7.
Velcro or snaps could also be used by providing ends of the decorative cover with velcro 5 and have mating velcro 5 attached to the garage door, either on the back side or the front side, as shown in FIG. 5. The material of the cover itself in such an embodiment would be of a stretchable material, such as spandex, so as to stretchably take up slack when the door is closed and allow expansion of the cover while the door is fully opened and closed while the ends of the cover are fixedly attached by velcro 5. Snaps fasteners, magnets, and adhesives, such as double-sided tape, could be substituted for the velcro and would operate similarly.
Alternatively, a flexible, stretchable strap may be affixed to top and bottom and/or sides of the cover with velcro or snaps at an end thereof for mating with a corresponding attachment device affixed to the door. The attachment devices may be provided on either the rear side, which retains them out of view from the outside, or on the front side of the door.
Buckles and straps could also be used by providing a top end of the cover with straps and a bottom end with buckles of a strap/buckle pair 6 that interlock with each other as illustrated in FIG. 6. If desired, sides of the cover could also be attached by the buckles and straps, or by any of the other attachment devices. In this embodiment, the straps 6 may be stretchable or, alternatively, the cover material may be stretchable to take up its own slack. Of course, the orientation could be reversed. Alternatively, the buckles/straps could be used to attach the cover directly to the garage door by one buckle/strap being affixed to the door for connection to a corresponding buckle/strap affixed to the decorative cover.
Additionally, a device may be provided for fixing a position of a part of the cover with respect to the door so that the cover remains properly positioned and does not "walk" relative to the door. Although the strap/buckle combination will eliminate slack when the door is closed, a velcro, double-sided tape or similar attachment device may be used to fix a single point of the cover to the door so the cover is returned to the same position each time the door is closed.
FIG. 7 illustrates a preferred attachment arrangement similar to FIG. 2. However, rather than providing separate tether cords 2 and flexible attachment devices 4, the tether cords 2 themselves are flexible and may be bungie-type cords. In such an arrangement, tether cords 2 are preferably provided at least top and bottom corners, although they could additionally be provided along the side, if desired, for additional support. Tether cords 2 attach grommets 1 of the decorative cover directly to the garage door.
The invention has been described with reference to the preferred embodiments thereof, which are illustrative and not limiting. Various changes may be made without departing from the spirit and scope of the invention as defined in the appended claims.
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A decorative cover for a movable garage door and method of attachment thereof are provided that allow festive ornamentation of ordinary garage doors while maintaining full use of such garage doors. The decorative cover can be made of weather resistant material and printed with various festive designs on its surface. The decorative cover is installed by draping it onto the front of the garage door. The cover is then joined together by any of several tethering and attaching methods to secure the cover to the garage door to allow full opening and closing without the cover riding up or down relative to the door. The attachment methods also take up slack in the cover.
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RELATED APPLICATION
[0001] This application claims priority from United States Application Serial No. 60/254,752 filed Dec. 11, 2000.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to the preparation and installation of doors. More particularly, the present invention relates to a door clamp which holds the door in a free-standing position while the door is modified for installation or otherwise worked on.
[0003] In the construction of buildings, and particularly framed structures such as residential housing, significant effort is often directed to the preparation and installation of doors. Aside from the cutting and planing required to properly size the door so that it properly fits within the frame and accommodates for carpet, tile or other foreign materials, the door must also be mounted to the door frame with hinges. Also, various holes must be formed and aligned and the door and door frame for the installation of locks, deadbolts and the like. Previously installed doors must sometimes be modified when new handles and locks are installed.
[0004] The carpenter installing the door typically holds the door in a vertical position, while attaching the hinges and drilling the appropriate holes for handles and locks. Doors are often rather large, bulky and heavy and can be difficult to handle. Due to the elongated nature of the door, the carpenter must hold the top of the door with one hand while bracing his or her foot and lower leg against the bottom of the door while drilling, cutting, etc. Given this awkward arrangement, it is possible that the door can slip out of grasp of the carpenter while worked on. This can present an undue safety hazard for the carpenter, as the power tool can slip when the door moves. Also, the door may slip into and damage furniture, other finished carpentry or walls.
[0005] Accordingly, there is a need for a stabilizing means for supporting and securing the door in a vertical and free-standing position while these procedures are to be performed. The present invention fulfills this need and provides other related advantages.
SUMMARY OF THE INVENTION
[0006] The present invention resides in a free-standing door supporting clamp that stabilizes and secures a door in a vertical and free-standing position so that various procedures and operations can be performed thereon, such as those described above.
[0007] The free-standing door supporting clamp generally comprises a platform for engaging an edge of a door. A first clamping member includes a leg and an arm that are angularly offset from one another, preferably by more than 90°. The first clamping member is pivotally attached to the platform. A second clamping member also having a leg and an arm which are angularly offset from one another, typically by more than 90°, is also pivotally attached to the platform, such that upon placing the door onto the platform, the arms of the first and second clamping members pivot inward into flexing contact with the door, and the legs, provide, with the platform, a stable support for the door over a floor or ground surface.
[0008] The first and second clamping members are comprised of a rod, typically of metal material, having spring properties. The legs of the first and second clamping members are generally quadrilateral in configuration, and the arms thereof are generally triangular in configuration, although the invention is not necessarily limited to such configurations.
[0009] The platform includes open-faced grooves formed in a lower surface thereof and spaced from one another for insertion of a portion of the first and second clamping members, typically intermediate the arm and leg. In order to engage and support doors of various widths, the platform may include three or more open-faced grooves.
[0010] Other features and advantages of the present invention will become apparent from the following more 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
[0011] The accompanying drawings illustrate the invention. In such drawings:
[0012] [0012]FIG. 1 is a perspective view of a door clamp embodying the present invention;
[0013] [0013]FIG. 2 is an end view of the door clamp of FIG. 1;
[0014] [0014]FIG. 3 is an opposite end view of the door clamp of FIG. 2;
[0015] [0015]FIG. 4 is a side view of the door clamp of FIG. 1;
[0016] [0016]FIG. 5 is a top plan view of the door clamp of FIG. 1;
[0017] [0017]FIG. 6 is a bottom plan view of the door clamp of FIG. 1;
[0018] [0018]FIG. 7 is an exploded view of the door clamp of FIG. 1, illustrating the assembly of the components thereof;
[0019] [0019]FIG. 8 is a perspective view of the door clamp of the present invention in an open state and having a door, shown in phantom, being placed thereon;
[0020] [0020]FIG. 9 is a perspective view of the door clamp of the present invention having the door, shown in phantom, placed thereon so as to close the clamp about the door;
[0021] [0021]FIG. 10 is a diagrammatic view of the door clamp of the present invention in an open position and having a door placed thereon such that the door clamp pivots and flexes into the closed position, shown in phantom; and
[0022] [0022]FIG. 11 is an end view of a door supported by the door clamp of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] As illustrated in the accompanying drawings for purposes of illustration, the present invention is concerned with a door clamp 10 for supporting unhinged doors in a vertical and free-standing position. The door clamp 10 is generally comprised of first and second clamping members 12 and 14 which support a platform 16 .
[0024] With reference to FIGS. 1 - 7 , the first and second clamping members 12 and 14 are each comprised of a somewhat flexible and resilient rod which is bent into an irregular shape to form a leg 18 at one end thereof and an arm 20 at an opposite end thereof with an intermediate section 22 which serves as a pivotal anchor to the platform 16 . As illustrated in FIGS. 2 and 3, the leg 18 and arm 20 do not lie in the same plane and form a V-like structure when viewed at an end thereof. Preferably, the leg 18 and arm 20 are angularly offset from one another by at least 90° in order to flex upon and pinch a door, as will be described more fully herein. As illustrated in FIG. 4, the leg 18 forms a trapezoid-like structure, and the arm 20 forms a triangle, although the invention is not limited to such a configuration. The rod is comprised of a material, such as metal or plastic having spring properties, which can be flexed from a relaxed state to a tensioned and sprung state and returned to the relaxed state when the force or pressure is removed.
[0025] With particular reference to FIG. 7, the platform 16 is comprised of a relatively rigid and durable material, such as wood, plastic, metal or the like. A top surface 24 of the platform 16 is generally flat. Two open-faced channels 26 are formed in the bottom surface 28 of the platform 16 for receipt of the intermediate sections 22 of the first and second clamping members 12 and 14 . The channels 26 extend across the entire length of the platform 16 and are spaced apart from one another by a predetermined distance. This distance is determined, in part, by the thickness of the door to which the door clamp 10 is to be applied. For example, if the door is relatively thick, the channels 26 are spaced further apart from one another, and if necessary, the platform 16 is enlarged. In contrast, if the door is relatively thin, the channels 26 are spaced much closer to one another. In order to accommodate doors of varying thicknesses, one or more channels 26 may be formed adjacent to one of the original channels 26 so that the user of the device may insert the intermediate sections 22 of the first and second clamping members 12 and 14 into the appropriate channels 26 to accommodate for the thickness of the door. The channels are configured such that the intermediate section 22 can be inserted into the channel 26 in a snap-fit manner, yet allow the intermediate section 22 to rotate or pivot therein.
[0026] With reference to FIGS. 8 - 9 , in use, the intermediate section 22 of the first clamping member 12 is inserted into a channel 26 of the platform 16 , and the intermediate section 22 of the second clamping number 14 is inserted into the appropriate channel which will allow the door clamp 10 to fully close upon the door 30 as more fully described herein. In its relaxed state, the arms 20 of the first and second clamping numbers 12 and 14 extend away from one another to provide open access to the top surface 24 of the platform 16 .
[0027] As illustrated in FIG. 8, in use, an edge, such as the bottom surface of the door 30 is inserted between the two arms 20 and onto the platform 16 . As the weight of the door 30 rests upon the platform 16 , the legs 18 of the first and second clamping numbers 12 and 14 flatten from an angled position to a near horizontal position, resulting in the two arms 20 rotating into a more vertical and upright position against the sides of the door 30 . The legs 18 of the first and second clamping members 12 and 14 , with the platform 16 , cooperatively form a stable base and the arms 20 of the first and second clamping numbers 12 and 14 act to hold the door 30 in a vertical and free-standing position.
[0028] The movement of the door clamp 10 from an opened and relaxed position to a closed position resulting from the placement of the door thereon, is shown diagrammatically in FIG. 10. FIG. 11 shows the door 30 resting upon the platform 16 and the arms 20 of the first and second clamping numbers 12 and 14 pressed or flexed against the door 30 in a near vertical position.
[0029] The carpenter may leave the door on its hinges and merely require the use of one door clamp 10 on the end of the door 30 opposite the hinges in order to mobilize the door for drilling holes and the like for the installment of handles, locks, etc. There may be other instances, however, where a door clamp 10 is positioned on both ends of the door 30 to hold it in an upright position, such as when the door is removed from the hinges. With the door 30 secured in the closed door clamp 10 , the carpenter is free to make any repairs or adjustments that are necessary without fear of the base of the door 30 slipping from its position within the door clamp 10 . When the appropriate adjustments and installations are completed, the door 30 is lifted from the platform 16 and the release of the force upon the legs 18 will cause the clamping numbers 12 and 14 to return to their relaxed state, thus opening the door clamp 10 and permitting the removal of the door 30 . In the event the door clamp 10 does not immediately return to its relaxed state, the carpenter can press down and pivot one of the legs 18 to move the arm 20 away from the door 30 and allow its removal.
[0030] It will be apparent to the reader that the door clamp 10 of the present invention provides many advantages to the carpenter. The door clamp 10 is relatively compact in size, and can be disassembled for storage and transportation. Also, doors of varying widths may be accommodated. The invention also provides a device which is very easy to assemble and use while providing a very stable support base for the free-standing door 30 . The door clamp 10 will reduce the risk of injury to the carpenter, as well as the potential damage to surrounding objects with which the door might slip into without such a stable supporting base.
[0031] Although an embodiment of the present invention has been described in detail for purposes of illustration, various modifications of each may be made without departing from the spirit and scope of the invention. Accordingly, the invention is not to be limited, except as by the appended claims.
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A free-standing door supporting clamp includes a platform for engaging an edge of a door. First and second clamping members, each having a leg and an arm angularly offset from another, are pivotally attached to the platform. The first and second clamping members are each comprised of a rod having spring properties, such that upon placing the door onto the platform of the assembled clamp, the arms of the first and second clamping members pivot inward into flexing contact with the door, and the legs provide, with the platform, a stable support for the door over a floor or ground surface.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to optical communication systems. It particularly relates to a capacity-efficient restoration architecture for an optical communication system.
[0003] 2. Background Art
[0004] The operations, administration, maintenance, and provisioning of optical fiber communication systems are described in the Synchronous Optical Network/Synchronous Digital Hierarchy (SONET/SDH) standards as specified by American National Standards Institute (ANSI) and International Telecommunication Union-Telecommunication Standardization Sector (ITU-T). SDH is specified in ITU-T G.707 Recommendation, Network node interface for the SDH.
[0005] Typical optical fiber communication systems comprise a combination of transmitters, receivers, optical combiners, optical fibers, optical amplifiers, optical connectors, and splitters. Wavelength Division Multiplexing (WDM) or Dense Wavelength Division Multiplexing (DWDM) systems also comprise couplers to enable multiple wavelength transmission over the same optical fiber. Typical optical system configurations include mesh networks and ring networks. Ring networks commonly comprise two fiber pairs connecting a plurality of nodes in a loop. One fiber pair carries bi-directional aggregate traffic between pairs of nodes in the ring. The second fiber pair is used to re-route traffic when there is a failure in the ring on a shared basis. A two-fiber ring is also available in which half the capacity within a fiber is reserved for traffic restoration. Mesh networks commonly comprise a plurality of nodes wherein a node can be connected to more than two nodes in the network enabling enhanced network reliability and higher capacity efficiency when a link failure occurs.
[0006] Optical fibers carry far greater amounts of information than carried by other communication media (e.g., electrical cables). Under the Synchronous Optical Network (SONET') standard, the commonly used OC-48 protocol operates at 2.488 Gbps supporting a capacity equivalent to over 32,000 voice circuits. The next highest protocol, OC-192, operates at 9.953 Gbps supporting a capacity equivalent to over 128,000 voice circuits. Therefore, robustness and reliability is required from such high-capacity, long-haul systems. Indeed, most Transatlantic cable systems (TAT), undersea systems which carry international telecommunication traffic, are required to have at least 25 year reliability.
[0007] However, since reliability is never absolute most optical systems require a restoration scheme to maintain some level of system performance despite fiber outages, amplifier failures, and some other equipment failure. Several common restoration schemes commercially used include those specified in the SONET standard in a point-to-point single link configuration or a ring network configuration.
[0008] Examples of these standardized traditional protection schemes are shown in FIGS. 1, 2. Particularly, FIG. 1 shows a typical one-line point-to-point 1:1 protection system in a Dense Wavelength Division Multiplexing (DWDM) scheme wherein nodes A, B are linked nodes within an optical fiber communication system. The system shown operates in accordance with the SONET/SDH standard, the standard for synchronous data transmission on optical media.
[0009] The protection system architecture 100 includes protection switches 110 , 190 , working and protection link 150 , and dense wavelength division multiplexers (DWDMs) 120 , 160 . Working and protection link 150 commonly comprises a single or multiple (cable bundle of fibers) optical fiber connection between nodes A, B. Protection switches 110 , 190 commonly comprise optical-to-electrical transducers and/or optical layer cross-connection switches that provide communication service connectivity between the protection system 100 and other communication devices (e.g., customer premises equipment). There exists a one-to-one correspondence between working channels (lines) 130 , 170 and protection channels (lines) 140 , 180 . However, both working and protection channels 130 , 170 , 140 , 180 are multiplexed by the DWDMs on to a single optical fiber connection between DWDMs 120 , 160 for one direction (e.g., A to B). Another corresponding fiber is typically used for the other direction traffic from B to A.
[0010] In response to a failure in the transmitter or receiver or cabling for a working line, the SONET/SDH signals carried by working lines 130 , 170 are switched from the working lines 130 , 170 to the protection lines 140 , 180 by protection switches 110 , 190 . However, since both working lines 130 , 170 and protection lines 140 , 180 are carried by the same working and protection link 150 , a fiber cut in link 150 or a failure in DWDMs 120 , 160 or in an optical amplifier for link 150 completely terminates optical communication services between nodes A, B over link 150 . To resume service, alternate routing (not shown) would be necessary that can be accomplished through ring switch or mesh restoration means.
[0011] [0011]FIG. 2 shows the same protection configuration but now with a two-line point-to-point 1:1 protection architecture 200 . The protection system architecture 200 includes protection switches 210 , 295 working link 250 and protection link 260 , and DWDMs 220 , 270 . DWDMs 220 , 270 multiplex working lines 230 , 280 and protection lines 240 , 290 on to separate working link 250 and protection link 260 between nodes A, B.
[0012] For this protection scheme, in response to a failure in the transmitter or receiver or cabling for a working line as well as an optical amplifier or DWDM failure, the SONET/SDH signals carried by working lines 230 , 280 are switched from the working lines 230 , 280 to the protection lines 240 , 290 by protection switches 210 , 295 . However, again, to resume service when both working and protection links 250 , 260 both fail or are cut because the fibers in lines 250 and 260 are in the same cable, alternate routing (not shown) would be necessary that can be accomplished through ring switch or mesh restoration means.
[0013] Both 1-line or 2-line 1:1 DWDM systems shown in FIGS. 1, 2 are inefficient in terms of utilization of protection capacity. Both systems use 100% idle capacity that either does not generate any revenue or provides low-grade service on the protection lines. This low-grade service can be preempted when there is a failure of the primary revenue-generating service.
[0014] [0014]FIGS. 3, 4 again show a commonly-used optical restoration system architecture that provides communication services in accordance with the SONET standard. Particularly, FIG. 3 shows a one-line 1:N protection system using DWDM. The protection system architecture 300 includes protection switches 310 , 390 working and protection link 350 , and DWDMs 340 , 360 . Nodes A, B within the system are interconnected by working and protection link 350 . In the 1:N protection scheme, there is one dedicated protection channel (line) 330 , 380 for each group of N (N>1) working channels (lines) 320 , 370 . A typical example may be ten groups of 4 (N=4) working channels therein resulting in 10 protection channels for a total number of 40 working channels. In the illustrative example shown in FIG. 2( a ), a transmitter/receiver failure on one of a group of N working channels 320 , 370 is protected by switching to a protection channel 330 , 380 dedicated for that group. Again, due to the one-line scheme for working and protection link 350 , an optical amplifier failure or fiber cut results in a termination of communication services between nodes A, B over link 350 . Working channels 320 , 370 must be re-routed using a ring or mesh restoration network (not shown).
[0015] Similarly, FIG. 4 shows a two-line 1:N (N>1) protection system using DWDM. The protection system architecture 400 includes protection switches 410 , 495 working link 450 and protection link 460 , and DWDMs 440 , 470 . Nodes A, B within the system are interconnected by working link 450 and protection link 460 . For a DWDM or optical amplifier failure, or fiber cut even in a two-line DWDM configuration, (N−1) channels from each group of N working channels 420 will not be restored. Therefore, in our current example assuming ten groups of 4 (N=4) working channels, there are only 10 restoration channels resulting in 30 channels [(N−1)*10] not being restored.
[0016] Additionally, even a 2-line 1:N protection using DWDM does not efficiently utilize idle capacity. When the working DWDM link 450 is used to its maximum capacity, only 1/N fraction (e.g., ¼ fraction for current example) of the working channels 420 is used in the protection DWDM link 460 thereby not utilizing the protection DWDM link 460 to its maximum capacity. Therefore, the two-line 1:N protection system inefficiently utilizes the capacity of the protection link although it is more capacity-efficient than the two-line 1:1 protection system which has 100% idle capacity. However, the two-line 1:1 protection system offers better reliability as all working channels in the failed working link will be effectively switched to the idle protection link as contrasted to the 1/N protection capability of the two-line 1:N system.
[0017] Another category of restoration schemes include systems which are not confined to a single link. These systems include Bi-directional line switched rings (BLSR) and mesh restoration. These systems have the advantage that the protection capacity is utilized on a shared basis for failures in multiple links within the ring. Particularly, BLSRs typically comprise four fiber rings wherein traffic in one direction travels on one fiber pair while traffic in the opposite direction travels on the other fiber pair. This scheme uses 1:1 configuration for each link of the ring, but the same protection lines of the links of a ring are also used for protection against a fiber cut type of failure when both working and protection lines of another link fail. For failures which affect only the working channel on a route, the signal is protected by using the 1:1 protection scheme previously described. For failures that affect both the working and protection lines of a route, the signal is restored using the protection line carrying traffic traveling around the other direction of the system. The same protection line is used on a shared basis when both working and protection channels fail anywhere within the ring. It would require much more capacity to provide similar reliability as a BLSR against fiber cuts using a 1:1 protection scheme. In the 1:1 scheme, the working line and the protection line between any pair of protection switch systems need to be routed via DWDMs in the opposite directions in the loop.
[0018] However, the BLSR system still does not offer the most capacity efficient network when typically there are more than two fiber routes at most of the nodes. This system is limited to particular applications and to only two types of service grades due to the two-fiber architecture. These two grades are the fully-protected service on the working channels in a fiber or the pre-emptable service carried by the protection channels.
[0019] A mesh restoration scheme offers some additional advantage by sharing the protection capacity more efficiently than BLSR. Mesh restoration offers 1-line or 2-line 1:1 protection for each link or some mesh restoration architectures use a 1:N protection scheme for each link. The protection channels are also used for restoration against a link failure. Again, 1:1 protection makes inefficient use of protection capacity while 1:N protection offers lower reliability for working channels or poor utilization of DWDM capacity in 2-line 1:N protection configuration.
[0020] In view of the above, there is a need to maintain capacity without incurring additional costs when restoring optical communication links. Idle capacity utilization needs to be improved while providing multiple grades of protection (varying priority levels) for different type of communication services. Due to the disadvantages of prior restoration techniques, there is a need to restore communication links and paths while still limiting costs and still maintaining capacity. The present invention describes such a capacity-efficient restoration architecture that dynamically restores failed optical communication links without incurring costs from idle protection links while still maintaining the same capacity or in some instances actually improving capacity from the failed link.
SUMMARY OF THE INVENTION
[0021] The present invention overcomes the previously mentioned disadvantages by using a hybrid protection architecture for an optical communication system comprising a plurality of interconnected nodes. The protection scheme uses a two-line optical fiber connection for each link between nodes but is not 1:1 protection. At least three channel groups are carried by each line wherein each channel group is assigned a different priority level for restoration. In response to a failure on a line, channels are switched in descending priority level to available restoration channels on another line or link to maintain optical communication services connectivity.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] [0022]FIG. 1 is a block diagram of a one-line 1:1 protection architecture for a known optical communication system.
[0023] [0023]FIG. 2 is a block diagram of a two-line 1:1 protection architecture for a known optical communication system.
[0024] [0024]FIG. 3 is a block diagram of a one-line 1:N protection architecture for a known optical communication system.
[0025] [0025]FIG. 4 is a block diagram of a two-line 1:N protection architecture for a known optical communication system.
[0026] [0026]FIG. 5 is illustrates an embodiment of the present invention showing a representative hybrid protection architecture for an optical communication system having a single failure
[0027] [0027]FIG. 6 illustrates an embodiment of the present invention showing a representative hybrid protection architecture for an optical communication system having multiple failures
DETAILED DESCRIPTION
[0028] The present invention provides a hybrid protection architecture to efficiently restore optical communication services within an optical communication system. The optical communication system preferably operates using the SONET/SDH standard. Therefore, it is noted that particular non-critical aspects of the standard and optical communication system are not described in great detail as they are not critical to the present invention and these aspects are well-known in the relevant field of invention. Also, it is noted that those skilled in the art will appreciate that the present invention may be equally applied to any optical communication system topology that comprises a plurality of interconnected nodes utilizing any communication format.
[0029] In reference to FIG. 5 and FIG. 6, optical fiber communication systems 500 , 600 using a representative hybrid protection architecture (HPA) in accordance with the present invention are shown. The systems 500 , 600 comprise a plurality of interconnected (linked) nodes A, B, C, D. It is noted that nodes A, B, C, D are shown as a representative number of nodes and the invention is not limited to this particular number of nodes. The HPA uses a multiple-line optical fiber connection for each link between nodes, but the protection scheme is not 1:1.
[0030] Particularly, in FIG. 5, optical fiber communication system 500 uses the representative HPA for a single interface (line) failure between node A and node B. The system 500 includes optical layer cross-connect switches (OLXC) 505 , 535 , 560 , 585 for each node A, B, C, D respectively. For both FIGS. 5 and 6, generally the OLXC can provide a plurality of functions as needed by particular communication applications. This functionality includes, but is not limited to functioning as a primarily optical domain switch wherein optical communication signals switched by the OLXC do not undergo any conversion to the electrical domain, or functioning as an optical switch including optical and electrical components for any necessary conversion (optical-to-electrical or electrical-to-optical) of the switched optical communication signals.
[0031] Referring again to FIG. 5, nodes A, B, C, D comprise interface equipment (IEs) 510 , 515 , 530 , 540 , 555 , 565 , 580 , 590 with at least two IEs for each node A, B, C, D respectively. At every node, each IE includes at least two pairs of interface ports wherein one port in each pair is used for interconnecting the IE to the OLXC while the other port in each pair interconnects the IE to another IE at a different node. The IEs are interconnected to the OLXCs, via OLXC equipment cards at the OLXC end and the interface ports at the IE end, through a pair of optical fibers for carrying bi-directional traffic (e.g., OC-48 or OC-192 channels) or through electrical lines using optical-to-electrical transducers. Advantageously, the IEs comprise wavelength division multiplexers (WDM), preferably dense wavelength division multiplexers (DWDM).
[0032] Each IE includes a two-line optical fiber connection (link), via the interface ports, to a separate node in the system 500 wherein lines 520 , 525 connect IEs 510 , 530 for link AB, lines 545 , 550 connect IEs 540 , 555 for link BC, lines 570 , 575 connect IEs 565 , 580 for link CD, and lines 595 , 598 connect IEs 515 , 590 for link AD. The line connections preferably comprise a single or multiple fiber (cable bundle of fibers) connection between nodes.
[0033] As shown in FIGS. 5 and 6 and the accompanying legends, each line, interconnected to the optical layer cross-connect switch at each node, carries multiple channel groups using the DWDMs. These channel groups preferably include super premium channels (SP), standard channels (S), and restoration channels (R). Both SP and S channels are traffic-carrying (revenue generating) channels carrying high-speed traffic (e.g., OC-48, OC-192) within the system which are protected and restored against failures using the R channels. R channels are channels of equivalent capacity to SP and S channels that are used to restore communication services carried by SP and S in response to failures in these channels. These failures include, but are not limited to single channel failures, optical amplifier failures, transmitter and receiver failures, interface port failures, and fiber cuts occurring on the optical fiber channel connection between nodes. Also, R channels carry communication services that can be preempted in response to a SP or S channel failure.
[0034] In both FIGS. 5 and 6, the OLXC switches the channels in event of failure. Generally, any network fault detection technique may be used to trigger the restoration switching. These techniques include, but are not limited to loss of signal (LOS), loss of frame (LOF), signal degradation (SD). The fault detection technique can be carried out in either the electrical or optical domain. The fault detection techniques in the optical domain can include, but are not limited to optical power loss, optical time domain reflectometer (OTDR) measurements, loss of pilot tone, or use of a dedicated port and/or wavelength.
[0035] The channel switching may occur under the control of any appropriate control system including, but not limited to an OLXC controller (not shown) or a network operations center (not shown). An advantageous control system that may be used with the present invention is described in the commonly-assigned U.S. patent application, Ser. No. 08/936,369 (Chaudhuri) which is herein-incorporated by reference. Chaudhuri particularly describes a computer-based automatic restoration methodology.
[0036] The control system may reside locally at one of the plurality of nodes A, B, C, D or be remotely located and connect with one of the nodes A, B, C, D wherein both cases the control system is interconnected to all the other nodes via data links embedded in the connections between nodes or via external data links. The data link network may advantageously comprise a Digital Communication Network (DCN) and/or a Network Operations System (NOS) which provides an ultra-reliable data network for communicating status signaling messages (e.g., alarm signals) between nodes regarding system operation, faults, etc. Also, for better reliability a redundant control system may be provided at another location or alternatively the control system may be provided at each node.
[0037] The control system can include a system processor for monitoring OLXC switch states and issuing switch commands. It would be apparent to one skilled in art how to design specific software and/or hardware implementations for addressing, monitoring, and controlling an OLXC based on the number of ports and switch configurations.
[0038] Referring to FIG. 5, an illustrative example is described. In response to a single interface failure occurring on an SP or S channel carried by line 520 between nodes A and B, the OLXC 505 switches the channel to an R channel on the other line 525 connecting nodes A and B. The single interface failure could comprise an OC-48 interface on the optical layer cross-connect switch 505 or an optical transmitter or receiver failure on the path of an SP or S channel on line 520 .
[0039] In an alternate example, the entire line 520 fails due to optical amplifier failure, a fiber cut, or some other line failure. In response to the failure, the SP channels carried on line 520 are switched by OLXC 505 to the R channels of the other line 525 linking nodes A and B. With reference to FIG. 5, the SP channel (----) carrying service 1-2-3-4-5-6-7-8 through link ABC on line 520 is switched by OLXC 505 on to R channels on line 525 such that the restored path becomes 1-2-15-16-5-6-7-8 for link ABC.
[0040] However, in response to a similar line failure, S channels carried on the failed line 520 are switched in a different manner to restore traffic carried by these channels. The S channels are restored from the end nodes of the channel path. The S channel (----) carrying service 9-17-10-11-12-13-14 through link ABC on line 520 is switched by OLXC 505 on to R channels on line 595 through link ADC such that the restored path becomes 9-17-18-19-20-21-14. This S channel restoration process can be advantageously implemented using the automatic restoration scheme described in the previously mentioned Chaudhuri application.
[0041] [0041]FIG. 6 shows an optical fiber communication system 600 using an HPA when a failure occurs on both optical fiber lines 620 , 625 between nodes A, B. The system 600 includes OLXCs 605 , 635 , 660 , 685 for each node A, B, C, D respectively. Nodes A, B, C, D comprise IEs 610 , 615 , 630 , 640 , 655 , 665 , 680 , 690 with at least two IEs for each node A, B, C, D respectively. Again, at every node, each IE includes at least two pairs of interface ports wherein one port in each pair is used for interconnecting the IE to the OLXC while the other port in each pair interconnects the IE to another IE at a different node. The IEs are interconnected to the OLXCs, via OLXC equipment cards at the OLXC end and the interface ports at the IE end, through a pair of optical fibers for carrying bidirectional traffic (e.g., OC-48 or OC-192 channels) or through electrical lines using optical-to-electrical transducers. Advantageously, the IEs comprise wavelength division multiplexers (WDM), preferably dense wavelength division multiplexers (DWDM).
[0042] Each IE includes a two-line optical fiber connection (link), via the interface ports, to a separate node in the system 600 wherein lines 620 , 625 connect IEs 610 , 630 of nodes A, B respectively, lines 645 , 650 connect IEs 640 , 655 of nodes B, C respectively, lines 670 , 675 connect IEs 665 , 680 of nodes C, D respectively, and lines 695 , 698 connect IEs 615 , 690 of nodes A, D respectively. The line connections preferably comprise a single or multiple fiber pairs (cable bundle) connection between nodes.
[0043] With reference to FIG. 3( b ), another illustrative example is described. In response to both lines 620 , 625 on link AB failing due to a fiber cut, both the SP and the S channels are restored from the end nodes of the channel path. The SP channel (______) carrying service 1-2-3-4-5-6-7-8 through link ABC on line 620 is switched by OLXC 605 on to R channels on line 695 through link ADC such that the restored path becomes 1-2-16-17-18-19-8. Also, the S channel (______) carrying service 9-10-11-12-13-14-15 through link ABC on line 620 is switched by OLXC 605 on to R channels on line 698 through link ADC such that the restored path becomes 9-10-20-21-22-23-15. Again, this end node channel restoration process can be advantageously implemented using the automatic restoration scheme described in Chaudhuri.
[0044] In this HPA protection scheme, system planning and management helps ensure restoration channel availability. Channel assignment of SP, S, and R channels in each line forming the internodal link are reciprocal to each other. The number of SP channels in one line must be equal to the number of R channels in the other line. The remaining channels are assigned as S channels provided there are sufficient R channels in each link of the network to guarantee 100% restoration of all SP channels when there is a line failure anywhere in the network.
[0045] This HPA restoration scheme effectively offers at least two grades of service (at least two priority levels for restoration). The communication services carried by the SP channels are as reliable or given as high a restoration priority level as the communication services carried by the two-line 1:1 protection scheme previously described. Also, the S channel communication services are as reliable or given as high a restoration priority level as the communication services carried by the one-line 1:1 or 1:N protection schemes described previously.
[0046] Also, the present invention has greater capacity than an optical transport system using the two-line 1:1 protection scheme assuming not all channel services require the same amount of reliability. A particular example can be used to demonstrate this capacity gain. Assuming DWDM system channel capacity of 80 channels per line, approximately 60% of all channels (total of SP and S) on a link can be designated as reserved to guarantee restoration of all working traffic against a line failure in any link in the network. Therefore, 30 channels per line are left to be designated as R channels. Of the remaining 50 channels, 30 can be designated as SP channels and 20 as S channels. Therefore, for every two-line link, there are 60 SP channels, 40 S channel used for revenue-generating traffic with two grades of service reliability (two priority levels for restoration). Each grade or priority level is protected against equipment failures as well as fiber cuts. The HPA carries a total of 100 working channels on the two-line link as compared to 80 working channels in the two-line 1:1 protection scheme since no protection capacity is used for revenue-generating traffic in the two-line 1:1 scheme. Therefore, the present invention provides a capacity-efficient architecture resulting in a 25% gain of highly reliable revenue-generating capacity. The 60 R channels in the two DWDM lines can still be used for low-priority traffic that may be preempted in response to failure of SP and S traffic.
[0047] The present invention provides several advantages to service providers of optical communication services. The hybrid protection architecture described herein enables a reliable optical communications network that provides varying grades of communication services while improving idle capacity utilization when restoring communication services on alternate optical fiber communication paths in the network.
[0048] Although the invention is described herein primarily using a mesh topology example utilizing DWDM, it will be appreciated by those skilled in the art that modifications and changes may be made without departing from the spirit and scope of the present invention. As such, the method and apparatus described herein may be equally applied to any optical communication system topology comprising a plurality of nodes utilizing any other architecture.
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A method and system provide capacity-efficient restoration within an optical fiber communication system. The system includes a plurality of nodes each interconnected by optical fibers. Each optical fiber connection between nodes includes at least three channel groups with different priority levels for restoration switching in response to a connection failure. The system maintains and restores full-capacity communication services by switching at least a portion of the channel groups from a first optical fiber connection to a second optical fiber connection system based on the priority levels assigned to the channel groups. Service reliability is effectively maintained without incurring additional costs for dedicated spare optical fiber equipment by improving idle capacity utilization.
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CROSS-REFERENCE TO RELATED APPLICATIONS
A key requirement in the application of this patent is the prior use of the Steam Explosion Process as outlined in Canadian Patents No. 1,217,765 or 1,141,376 entitled "A Method for Rendering Lignin Separable from Cellulose and Hemicellulose in Lignocellulosic Material and the Product so Produced" or competing versions thereof. A patent application related to this topic is entitled "A Method for Extracting the Dissociated Chemical Components of Steam Exploded Lignocellulosic Materials, Their Partitioning into Discrete Substances or Classes, Followed by Bleaching of the Residual Cellulose".
FIELD OF THE INVENTION
This invention relates to the isolation of reproducible Lignin fractions from dissociated lignocellulosics obtained by a Steam Explosion Process, and th eir purification. In particular, the Lignin fractions are partitioned by solubility in selected solvents in order to provide lignins with different but reproducible properties for particular applications. For instance, many copolymer applications require a thermosetting only fraction of the lignin. As used herein, "thermosetting lignin" means lignin which can be thermally set initially, but not thermally re-set thereafter. Other applications require a thermoplastic only lignin. As used herein, "thermoplastic lignin" means lignin which can be thermally set and thermally re-set thereafter. In other applications the presence of vegetable oil could be either an advantage or a disadvantage. This invention describes methods for separating the dissociated lignin into consistently reproducible products tailored for particular end use applications.
BACKGROUND OF THE INVENTION
Lignin is the second most abundant organic chemical after Cellulose. It is associated with hemicellulose in both woody and fibrous plants, as the adhesive which holds the bundles of Cellulose fibrils together. It is found in the primary wall, the middle lamella and within the fibre bundle or core. FIG. 3 is a representation of a lignocellulosic fibre where the dotted area 46 is called the Middle Lamella. The Middle Lamella 46 is the glue which holds adjacent fibres together. It contains crosslinked lignin and xylan in a ratio of about 70 to 30. The Primary Wall 48 is the outer casing around the fibre core much like the casing on an underground telephone cable. It contains crosslinked lignin and xylan in about equal quantities with a small amount of cellulose to provide structural strength. The fibre bundle or core 50, 51 and 52 consists of closely bound cellulose fibrils. Each fibril is bound to the adjacent fibrils by a further coating of crosslinked lignin and xylan. The ratio of lignin to xylan in the fibre core is 30 to 70, but because of its large volume relative to the Middle Lamella and Primary Wall, 70 percent of the lignin is found in the fibre bundle. The fibrils in the fibre bundle form a slight spiral along the direction of the fibre and each fibril is hinged by an amorphous area about every 300 glucose molecules in the fibril. It is this hinge which is the weakest area in the fibril and is the point where fibrils are converted to microfibrils by the Explosion Process when operated at or above 234 degrees centigrade according to the teachings of Canadian Patent 1,217,765. Finally, the lumen 54 is a hollow area in the middle of the fibre bundle where liquids migrate through the lignocellulosic composite to provide nourishment to the plant.
The overall description of how Lignin is generated in vivo can be briefly summarized as an oxidative coupling of monolignols. Three types of starting materials are used in different proportions depending upon the plant type: coniferyl alcohol, syringyl alcohol, and to some extent, p-coumaryl alcohol. Each of these three unsaturated alcohols has four or more reactive sites, by which they may undergo coupling. As the Lignin polymer grows larger, the number of permutations for coupling increases rapidly. Furthermore, the chain becomes highly branched and cross-linking between chains occurs. Hemicellulose, in the form of a linear Xylan polymer containing side groups of 4-0-methyl-(alpha)-D-glucuronic acid residues in aspen for example, becomes cross-linked to the Lignin. These Lignin-hemicellulose bonds can be likened to spot welds which soften and become increasingly fragile above the glass transition temperature of the Xylan (165 degrees celcius). Many of the bonds between the lignol fragments are of the benzyl ether type and may be labile to electrophilic cleavage. Other bonds include the resistant carbon-carbon type and biphenyl ethers.
To conceptualize, the model of Lignin in the original lignocellulosic material is that of an infinite gel made up of a cage of Lignin which is swollen with water and has embedded in it, stiff chains of short substituted xylans (DP approx. 100-200) spot welded to the Lignin. This material acts as an adhesive to bind the macromolecular Cellulose chains together for structural purposes.
SUMMARY OF THE INVENTION
The apparatus to implement this process is shown in FIG. 1, where 1 is a pressure vessel having a valved outlet 2 at the base and a loading valve 3 at the top. 4 is the steam input valve. 5 & 6 are thermocouples designed to measure the temperature of the material in the pressure vessel. 9 is a thermocouple in the steam input line to measure the temperature of the input steam. 10 is a pressure gauge to measure the input steam pressure. 7 is a condensate trap to hold water condensate which is produced during the heating cycle of the material, when the hot steam is admixed with the much colder input lignocellulosic material. As the material draws heat from the steam, the condensate runs to the bottom of the digester and into the condensate trap 7. 8 is an optional die which can provide various orifice constrictions to provide more or less abrasion during explosive decompression dependent of the end application of the processed material. 11 is mechanically divided input lignocellulosic feedstock.
In brief, the Steam Explosion Process brings the whole lignocellulosic material to a softened state (at the glass transition temperature of the Cellulose) by heating the material to 234 degrees celcius, at which point it is explosively decompressed through an orifice. The tremendous shearing forces present during the explosion, degrade the macromolecules into smaller units, mechanically. Cellulose is fractured at its amorphous hinges, which are the weakest links in the Cellulose chain. This results in Cellulose at a DP in the range of 220 to 300. The crosslinks between the hemicellulose and the Lignin are fractured and the Lignin becomes carbohydrate free. The Lignin itself is extensively, but randomly depolymerized. Polymer theory indicates that non linear polymers, on random degradation produce polydisperse molecules. That is, even if the Lignin polymer was a regular, branched polymer, this degradation would result in a large range of molecular weights. Since Lignin is so irregular, the polydispersity is one of very complex materials. In fact, its molecular weight ranges from monolignols to complexes of more than one million daltons. Finally, the rapid thermal quenching of the reaction at the end of the explosion, (the steam temperature falls instantly due to adiabatic expansion from 234 degrees celcius to below 100 degrees celcius), prevents the more reactive components of the lignins from reforming into larger Lignin molecules by re-cross-linking.
In conventional pulping systems, chemical reagents are used to remove the Lignin, usually caustic with sulfur dioxide (sulfite process) or with sodium sulfide (alkaline or Kraft process). The sulfur acts as a nucleophile on the benzyl ether linkages, with cleavage of the Lignin into smaller molecules and with concomitant insertion of sulfur into the Lignin. The hemicellulose linkages are often left intact. Conventional lignins are therefore equally polydisperse, but they contain sulfur not present in the original material, and they usually contain variable amounts of carbohydrate. Chemical methods of degradation are very susceptible to process parameters. The chemical properties of conventional Lignin preparations are prone to change from batch to batch, making quality control difficult. The major problem of conventional lignins is the lack of reproducibility and their positive sulfur content. The latter is harmful if the Lignin is to be burnt as a fuel due to sulfur-containing emissions, and the presence of sulfur groups reduces the reactivity of sulphonated lignins. Explosion Process lignins are unique.
After the Explosion Process the lignins contained in the dissociated mixture of chemical components of the starting lignocellulosic material are very pure and reactive. Their methoxyl content is about 19% as compared to a theoretical content of 21% in 100% native lignin. Their ash content is only 1.5% and even this is partly mineral residue from the water used in fractionation. They are highly reactive because of the near instant thermal quenching, which occurs immediately following their dissociation during the explosion and, they are obtained in high yield, in pure form, sulfur-free and are generally low enough in molecular weight to be soluble in simple organic solvents. Even so, for applications requiring reproducibility, the polydispersity factor demands that the Lignin be fractionated and that these fractions be limited in molecular weight range for good quality control, where needed. It is for these process parameters and the product so produced that protection is sought in this important dissociation, extraction and fractionation process.
Lignin obtained from the Steam Explosion processing of lignocellulosics can be divided into 8 fractions. Fraction "A" is water-soluble and is recovered from the water by liquid/liquid extraction with dichloromethane. In this specification, "dichloromethane" is used as a representative of the class of compounds of the type 'halocarbons' (which includes the class of "freons"), as well as other solvents or mixtures thereof which are both water immiscible and low in boiling point, as well as being good solvents for low molecular weight aromatics. Compounds dissolved in the dichloromethane which result from the decomposition of carbohydrates, namely furfural, 5-methylfurfural, 5-hydroxymethylfurfural, and Acetic Acid are removed by distillation or liquid chromatography. The remainder of the dichloromethane solubles (Fraction A) is a mixture of monolignols and related products including vanillin, syringaldehyde, and dilignols. These products can be recovered as pure chemicals by means current to the art such as distillation and commercial chromatography.
FIG. 2 is a sketch of a column, which is used to dissolve and thereby achieve a first stage separation of the various dissociated chemical components of the Explosion Processed lignocellulosic material. The column 1 is a tube open at both ends. The tube can be almost any geometric configuration in cross section from circular to triangular to rectangular and so on. The column 1 is loaded with loosely packed processed lignocellulosic material 6. At the base of the column is a filter 2 which is fine enough to prevent the processed material from passing through, yet course enough to allow dissolved solids laden eluant to flow through as fast as the column of material will permit. The column is mounted on a reducing base 3 to bring the eluant to a neck with a valved outlet 4 to control the flow rate of the column when necessary. Temperature, pH, flow rate and other sensors are mounted in the column base to provide control information to the column Command and Control System. A fine screen 5 is mounted in the top of the column to disperse the input solvent evenly over the material at the top of the column. This prevents undue compression of the material in the column.
Solvents such as water 7, followed by alcohol 8, followed by mild caustic 9 followed by bleach, or any combination of these can then be introduced into the top of the column and their eluants laden with solids, soluble in that particular solvent, will flow through the processed lignocellulosic material in a plug flow fashion and be collected for product recovery from the base of the column as water solubles 11, alcohol solubles 12, caustic solubles 13, and bleach solubles 14 or any combination thereof. The column can be used for various treatments such as acid or alcohol impregnation where uniform treatment of the residual material is desired.
In one embodiment of this specification, after the dissociated lignocellulosic material has been water extracted in a column, alcohol (one of the series methanol, ethanol, propanol, isopropanol), is added to the top of the same column and allowed to drain through the material. The alcohol is at ambient temperature usually, but it may be warmed to increase flow rates in the column. When alcohol is percolated in a plug flow manner down through the water laden lignocellulosic residue, some mixing occurs at the water/alcohol interface. This mixing causes a water/alcohol mixture gradient to occur. At about 20% water the alcohol is a more efficient solvent than either near dry alcohol or alcohol with more than 20% water in the water/alcohol mixture. Thus lignin components which are not soluble in near dry alcohol are eluted at the bottom of the column as a near first out eluant. The lignin extracted by this alcohol extraction (lignin "B") contains a combination of residual lignin "A" (Vanillin and Syringaldehyde), lignin "C" (Vegetable oil, and Plant Steroids), lignin "D" (thermoplastic lignin) and lignin "E" (thermosetting lignin). The wet alcohol eluant is collected at the bottom. Water is then added to precipitate this Fraction "B" Lignin from the alcohol/water eluant. Alternatively, the alcohol/water eluant can be heated to distill off the alcohol preferably under vacuum to prevent modification of the lignin and thereby precipitate the Fraction "B" Lignin. Salt is added (typically sodium chloride or calcium chloride, but others may be used as well) to make a 0.2-2% brine. This causes the Fraction "B" Lignin to flocculate and form large particles which can be filtered readily. Once collected by filtration the product may be air dried or vacuum dried. An increased yield of vanillin is obtained if the brine solution or the water/lignin mixture is sent to the liquid-liquid extractor containing dichloromethane for recovery of the organics in the brine or water/lignin mixture. Reverse osmosis can also be used to separate the Lignin from the water/alcohol eluant and the filtrate can be liquid/liquid extracted with dichloromethane to increase the yield of vanillin. Various combinations of the above are possible dependent on end product requirements.
Fraction "C" is soluble in a paraffinic solvent, typically one of the group pentane, hexane, heptane, petroleum ether 30-60 and petroleum ether 60-80, as well as dichloromethane and alcohols. This fraction contains mainly non-Lignin related materials such as vegetable oil and plant steroids. In aspen, for example, this vegetable oil resembles linseed oil in its chemical characteristics, due to the presence of glycerides of linoleic acid as its major component. The nature of the vegetable oil will depend upon the species of lignocellulosic material used as feedstock in the Steam Explosion Process. Lignin "C" also contains highly colored substances, as yet undefined, some of which may be Lignin related. They are low in molecular weight (typically 600 daltons).
Fraction "D" is soluble in dichloromethane, mild caustic and alcohol, but is insoluble in paraffinic solvents. This fraction contains pure, thermoplastic Lignin. It has a melting point range of 130-140 degrees celcius, and a number average molecular weight of 800-1000 daltons.
Fraction "E" is soluble in an 80/20 alcohol/water mixture and aqueous caustic, but insoluble in paraffinic solvents and dichloromethane, and only partially soluble in dry alcohol. It is collected as a fine powder by precipitating the alcohol/lignin solution in dilute brine. The salt is added to promote flocculation. Alternatively, heat (typically 40-80 degrees celcius) may be applied to achieve similar results. This fraction contains pure thermosetting Lignin, having a melting point range of 170-180 degrees celcius, and a number average molecular weight of 1500-2000 daltons. It is an ideal co-polymer for thermosetting plastic and resin applications.
Fraction "F" is soluble in aqueous caustic only and is a very high molecular weight product. This is termed a "pseudolignin". It does not melt below 250 degrees celcius but sinters or chars. It is believed to contain Lignin which has been modified by crosslinking with furfural from degraded pentoses during the heating cycle of the Steam Explosion Process.
Fraction "G" is obtained by extracting the water extracted residue with a mild, less than two percent, caustic solvent selected from the group of sodium hydroxide, ammonium hydroxide and potassium hydroxide, and acidifying to pH 3-4. Fraction "G" is the same as Fraction "B" lignin except that it contains the Fraction "F" lignin in addition to fractions "A" "C" "D" and "E"
Fraction "H" is the same as Fraction "G" except that it contains no fraction "D" lignin. Fraction "H" is obtained by acidifying the caustic solution and gel to pH 3 to pH 4. The mixture is then heated to a temperature between 40 and 80 degrees celcius. At this temperature the gel breaks down into a particulate precipitate and the thermoplastic lignin "D" is converted to thermosetting lignin "E".
Upward transformations in molecular weight can be achieved by manipulation of the Explosion stage of the process parameters as well as post dissociation treatment with acid. Yields of the above fractions can also be manipulated by varying the parameters of the Explosion Process. Canadian Pat. No. 1,141,376 is but one example of this phenomenon.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The Lignin in the lignocellulosic material is first dissociated from the hemicellulose by the Stream Explosion Process as outlined in Canadian Pat. Nos. 1,217,765 and 1,141,376. This freshly exploded, moist material is transferred to an extractor column (See FIG. 2), which has an upper opening through which solvent can be added and a lower opening for the removal of the eluant. In this specification, "eluant" means a solvent, with its dissolved or suspended materials, which is removed from the columns. The column can be a cylinder or any other reasonable cross-sectional geometry (square or rectangular for example), open at the top and having a drainage system for recovering the eluants at the bottom. Typical depths of dissociated lignocellulosic material range from one foot to twenty feet, but a two to five foot depth is preferred. No packing or agitation of any type is to be applied to the column contents at any time. to drain through the dissociated material. In a typical five foot column, two column volumes are sufficient to displace all but 1% of the water soluble components of the material. For single extraction column operations, the whole aqueous eluant, after removal of the protein to prevent rag, is sent to a liquid-liquid extractor containing Dichloromethane to remove the water-soluble Lignin components (Fraction A). Water exiting the liquid-liquid extractor is heated to 50 degrees celcius to distill off the small amount of Dichloromethane which is dissolved in the water. The Dichloromethane vapours are recondensed and sent via a return line to the liquid-liquid extractor. Lignin fraction "A" is obtained by distillation at 50 degrees Celsius to remove the Dichloromethane. Fractional distillation at 80 degrees celcius removes the Acetic Acid, and under slight vacuum at the same temperature, the furfural, 5-methylfurfural, and 5-hydroxymethylfurfural (if any) are removed. The residue contains the monolignols, dilignols, vanillin and syringaldehyde which are recovered by commercial chromatography or hard vacuum distillation or a combination thereof to give pure, discrete chemicals.
For large scale operations, more than one extraction column is practical. In this case, only the first twenty percent or so of the water soluble fraction, after protein removal, is sent to the liquid-liquid extractor, the remainder of the eluant is used to wash a portion of the subsequent lignocellulosic extraction column in series. All other parameters remain the same. Conventional pulp washers and filter systems or other liquid/solid solvent extraction systems can be used to make these extractions but the column technology is significantly more efficient.
At the completion of the water extraction stage, the remaining material is extracted using an alcohol selected from the group ethanol, methanol and isopropanol. This extraction stage can be done by conventional wash and filter processes or preferably the alcohol extraction is accomplished by placing the alcohol in the column on top of the water extracted material and collecting the alcohol soluble fraction "B" eluant from the bottom of the column (See FIG. 2). The main component of this alcohol soluble fraction "B" is a thermoplastic Lignin, fraction "D", but it also contains some high molecular weight thermosetting Lignin, fraction "E" which is soluble in molten thermoplastic lignin (fraction "D"), thereby increasing the melting point range of the combination above that of fraction "D". Fraction "B" is highly reactive and has a melting temperature in the range of 150-160 degrees celcius. It will react to a full thermosetting fraction when heated to this temperature in the presence of an acid catalyst. Also included in this fraction is some vegetable oil and plant steroids (fraction "C") as well as a further yield of vanillin and syringaldehyde (fraction "A")
The alcohol soluble fraction "B" can be partitioned into pure fractions by sequential triturations of the solid form of "B" by selected solvents, after precipitation and filtration. To obtain dry material, the eluant from the alcohol extraction stage (which contains lignin, water and alcohol) is either evaporated or added to brine to precipitate the solids and collected by filtration. The lignin "B" product can then be triturated with a paraffinic liquid, typically one of the group of pentane, hexane, heptane, petroleum ether 30-60 or petroleum ether 60-80 or the like and filtered. The filtrate is concentrated by distillation to recover the solvent and the residue is lignin "C", namely the vegetable oil and other hydrocarbons such as the plant steroids. The filter cake consists of a mixture of thermoplastic lignin "D" and thermosetting lignin "E" which is now oil-free.
By triturating this filter cake with dichloromethane one can dissolve the thermoplastic lower molecular weight fraction "D". Filtration and recovery by evaporation of the dichloromethane from the filtrate yields lignin "D". The filter cake from this trituration is mainly lignin "E". But to purify lignin "E", it can be further triturated in an 80/20 alcohol/water mixture. If all of the sample dissolves, the lignin "E" is pure and is recovered by solvent removal. In some cases a residue, lignin "F" is present. Then lignin "E" is found in the filtrate after solvent recovery and the residue after filtration is lignin "F" pseudolignin. The Lignin "E" fraction increases and the lignin "D" fraction decreases in yield when the eluant "B" is stored for more than a few hours.
TABLE 1______________________________________ ##STR1## ##STR2## ##STR3##______________________________________
The Lignin "E" residue is the pure form thermosetting lignin. It constitutes about 30% of the original wet alcohol soluble lignin. It has a melting point of 170-180 degrees celcius and has a number average molecular weight of 1500-2000 daltons. The dichloromethane soluble Lignin "D" fraction is recovered by evaporation of the dichloromethane or precipitated by the addition of a paraffinic solvent. It is thermoplastic and it has a melting point of 130-140 degrees celcius and an average molecular weight of 800 to 1000 daltons. It constitutes about 60% of the original, wet alcohol soluble Lignin "B" fraction.
The paraffinic solvent soluble Lignin "C" fraction contains plant steriods, a vegetable oil and about 30 highly coloured plant substances some of which are lignin derivatives. The vegetable oil consists of glycerides of fatty acids (mono, di, and tri-substituted) containing an even number of carbon atoms ranging from C16 to C26. In those lignocellulosics containing Linoleic Acid as the C18 fatty acid, no saturated C18 acid is found. In aspen, Linoleic Acid Glycerides constitute more than 90% of this vegetable oil. It is the presence of this poly unsaturated material that gives aspen vegetable oil its chemical characteristics similar to linseed oil. These multiple double bonds react with atmospheric oxygen to form hydroperoxides which initiate repolymerization of the steam exploded lignin. If this type of oil is not separated from the rest of the steam exploded lignin soon after preparation, crosslinking begins to occur and the yield of reactive low molecular weight thermoplastic Lignin is reduced and the amount of thermosetting lignin increases. Solubility in dichloromethane is thereby decreased. Aspen bark contains a total of 10-20% by weight of this vegetable oil, which is rich in Linoleic Acid Triglyceride. High yields of vegetable oil are found in most bark species.
The wet alcohol insoluble but caustic soluble material, fraction "F", constitutes only a few percent of the whole dissociated lignin material. Fraction "F" is a product having an average molecular weight in excess of 1 million daltons and does not melt below 250 degrees celcius, but sinters or chars instead. This material contains Lignin crosslinks formed by condensation with furfural and related materials from hemicellulose degraded by the Explosion Process, and hence is termed a "pseudolignin".
In another embodiment of this specification, a dilute (less than two percent) caustic is used instead of alcohol, to remove the Lignin from the waterwashed, dissociated lignocellulosic material. The caustic used is usually one of the set: sodium hydroxide, ammonium hydroxide, potassium hydroxide. Overall yields of extract are higher than for alcohol extraction. On acidification (typically with one of the set sulfuric acid, hydrochloric acid, or Acetic Acid) to pH 3-4, the caustic Lignin is precipitated in a gel form. This gel can be collected by filtration. The residue contains salt from the caustic, necessitating a rewashing with water. After re-washing, the dark coloured granules are easily dried. Processing of the water solubles and the Lignin are performed as described above for alcohol Lignin. The time the Lignin is in the caustic and the acid influences the yield of each of the fractions. Increased thermosetting Lignin (fraction "E") yields are realized with caustic extraction and acid precipitation because of conversion of some of the thermoplastic fraction "D" Lignin to thermosetting fraction "E" Lignin.
In yet another embodiment of this specification, the caustic extracted eluant is acidified to pH 3-4 and then the mixture is heated to 40-80 degrees celcius. This results in a particulate precipitate rather than a gel. It is salt-free, brown in colour, and dries to a powder form. When dried, because of the reaction caused by the heat at low pH, the product contains little or no thermoplastic fraction "D" Lignin. This crude, very finely divided material takes a long time to dry on standing in air, and it is therefore probably best dried in a spray drier, and used as a copolymer in thermosetting plastic and resin applications.
The alcohol or caustic eluants can be fractionated into several ranges of molecular weights using reverse osmosis membranes. Alternatively, the alcohol or caustic eluants can be concentrated by removal of the alcohol and the caustic using reverse osmosis membranes until the lignin precipitates and then recover the lignin precipitate by filtration. These fractions can then be re-extracted with combinations of a paraffinic solvent, dichloromethane and alcohol to produce the "A", "C", "D", "E" and "F" fractions. The thermoplastic "D" fraction can be converted to a thermosetting "E" fraction by the use of heat in the presence of acid.
Because treatment of the thermoplastic Fraction "D" Lignin with acid converts it from thermoplastic to thermosetting Lignin, the percentage yields given above are process dependent. It was also observed that venting the gun prior to explosion as described in Canadian Patent 1,141,376, dramatically reduced the "A" fraction by over 90%. This result demonstrates that the effect of the explosion, rather than hydrolysis, clearly dominates the depolymerization of the Lignin during the Explosion Process when practiced according to Canadian Patent 1,217,765. Venting results in increased yields of the higher molecular weight thermoplastic and thermosetting fractions of the Lignin as well as a higher DP cellulose fraction.
Temperature of the lignocellulosic material and time are very important to the effectiveness of the Explosion Process. To achieve total lignin dissociation the entire subunit (eg: chips or straw) of the lignocellulosic material must achieve 234 degrees celcius temperature before the lignocellulosic material is explosively discharged to atmosphere or vented followed by explosive decompression as in Canadian Patent 1,141,376. Thermal transfer is slow in lignocellulosic material, therefore sufficient time must be allowed to ensure that the interior of the material particles reaches the desired temperature. When the reaction time is too short (for example, eleven seconds for aspen wood wafers), yields of extractable Lignin are low (5%) because most of the Lignin/hemicellulose crosslinks and the cellulose fibrils have not been sufficiently weakened by temperature to be broken by the force of the explosive decompression and abrasion. If too long a reaction time is permitted (for example, eighty seconds for aspen wood wafers), the hemicellulose exceeds its degradation temperature for too long a period and is extensively degraded to furfural which crosslinks with the Lignin to form high yields of pseudolignin. Thus, by varying the process parameters, and the use of acid in the extraction and fractionation processes, it is possible to alter the relative amounts of water soluble lignols, thermoplastic, thermosetting and pseudolignins obtained from a single source of lignocellulosic starting material.
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The chemical components of lignocellulosic material which have been dissociated by a steam explosion process can be extracted from the mixture of components using a solvent extraction process. The solvents are water, alcohol and a mild caustic in that order, or the alcohol step can be by-passed and only water and caustic are used. The caustic is a stronger solvent and it will extract the alcohol solubles along with the caustic only solubles. The eluant from the these extractions contains a range of lignin derived substances, which have different applications, such as thermoplastic and thermosetting characteristics. This invention describes a method for partitioning these lignin components into reproducible fractions having definable characteristics for particular applications. For instance, many copolymer applications require a thermosetting only fraction of the lignin. Other applications require a thermoplastic only lignin. The patent also describes a process for converting the thermoplastic lignin fraction to thermosetting lignin.
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When velvets are manufactured, unavoidable nonuniformities are often covered with deliberate imperfections. Slub yarns are often introduced into the weft of expensive woven velvets to create a "stria" effect which many consumers prefer for its elegant look. This technique cannot normally be used in knitted velvets because it is difficult for knitting machines to handle slubbed yarns. This invention concerns a method and apparatus for quickly and inexpensively introducing a "stria" effect into woven, tufted, or knitted velvets having thermoplastic piles. Basically, the stria effect is introduced by heating the pile of the fabric with a radiant heater and then pressing the pile against a cool, multi-bladed pattern member and cooling the fabric while the pile is in contact with the pattern member thereby setting the "stria" effect into the pattern. This method produces crisp, well defined lines which closely simulate the woven "stria" fabric. Further, the effect is surprisingly long-lasting and remains permanently set into the pile of the fabric.
Previously, velvets have been embossed by pressing a heated pattern member against the pile of the velvet and then cooling the velvet after the pattern member has been removed. The effect produced when the prior art method is used with a pattern roll having thin blades is not as crisp and well defined as that produced by the method of the present invention. It is thought that this difference may be due to the limited thermal conductivity of the pile which makes it difficult to heat and crimp more than one layer of tufts with a thin heated blade.
The apparatus of the present invention includes; a means for advancing a pile fabric, a non-contact heater for heating the pile of the fabric without disturbing the lay of the fibers in the pile; a pattern roll which the pile fabric is wrapped partially around and means for cooling the fabric while it is in contact with the pattern roll. It is extremely advantageous to use radiant heat to heat the pile of the fabric since radiant heat does not move the fibers in the pile thus the pile lay is undisturbed. When forced convection heaters or contact heaters are used, the pile is inevitably disturbed. It is also of great advantage to wrap the fabric around a substantial portion of the pattern roll, since this makes it possible to cool the pile while it is in contact with the pattern. Preferably, the pattern roll will rotate at a speed which matches its peripheral speed to the speed of the fabric. Conveniently, the roll will be driven by the fabric and will have a plurality of slots and a plurality of blades disposed in each slot. Each blade will be a thin planar member wherein the edge which is in contact with the pile is curved so that the central portion of the blade projects further from the roll than the two ends of the blade. This curved shape produces an indentation which tapers toward the end closely simulating the appearance of an actual slub.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a schematic side elevation illustrating apparatus for producing a simulated stria fabric.
FIG. 2 illustrates the arcuate support member.
FIG. 3 illustrates the pattern roll for producing a simulated stria fabric.
FIG. 4 is a sectional view taken along section 4--4 in FIG. 3.
FIG. 5 illustrates a blade for use on the pattern roll.
In FIG. 1, pile fabric 10 passes over rollers 12, then past infra red heater 14 which heats the pile of pile fabric 10 to a temperature above its glass transition temperature and softens the fibers in the pile without disturbing the orientation which has been previously imparted to the fibers in the pile.
After fabric 10 has been heated, it passes over arcuate support member 16 closely adjacent to stria pattern roll 18. Arcuate support member 16 is thin and preferably is closely adjacent to pattern roll 18.
As shown in FIG. 2, arcuate support member 16 is segmented having a plurality of slits 19 formed in its central portion. This construction helps to stabilize the shape of arcuate support member 16 which would have a tendency to warp or buckle if unsegmented since its leading edge becomes hot because it is in contact with heated fabric 10. The portions of arcuate support member 16 which contact the selvages of fabric 10 are not segmented since the selvage might catch. It is very advantageous for support member 16 to be both closely adjacent to pattern roll 18 and substantially parallel to the periphery of pattern roll 18 so that heater 14 can be closely adjacent to pattern roll 18. In this manner, excessive cooling of fabric 10 between heater 14 and pattern roll 18 can be avoided, thus minimizing the temperature to which fabric 10 must be heated to allow proper patterning and reducing the danger of over-heating. To further minimize the danger of over-heating, non-contact temperature measuring means such as infra-red camera 21 may be used to measure the temperature of fabric 10 as it leaves heater 14. Advantageously, the output of infra-red camera 21 acting through controller 23 may be used to control heater 14.
As shown in FIGS. 3 and 4, pattern roll 18 is substantially cylindrical and has a plurality of slots 20 cut into its outer surface 22. A plurality of blades 24 of varying lengths are mounted on pattern roll between shims 25 within each slot 20. As shown in FIG. 5, each blade 24 is a substantially planar member having an outer edge 26 wherein center portion 28 is essentially a straight line parallel to the axis of rotation of pattern roll 18 while end portions 30 of outer edge 26 curve inward toward the center of pattern roll 18. Blades 24 are shaped in this fashion to produce indentations which taper at the ends and therefore closely simulate the appearance of slubs in woven velvets.
While fabric 10 is wrapped around pattern roll 18, jet 32 exhausts cool air against the back of fabric 10 and thereby cools the pile of the fabric 10 to a temperature below its glass transition temperature while it is still in contact with pattern roll 18. If low production speeds can be tolerated, the fabric may be allowed to cool by natural convection only.
Since radiant heaters are used to heat the pile of fabric 10, it is possible to easily obtain a variety of effects which are not so easily obtained using the prior art methods. In particular, it is possible to conduct pile fabric 10 through the device with the pile leaning in any desired direction. For example, in FIG. 1, the pile indicated at 9 is leaning in the direction of advance of the fabric while the pile indicated at 11 is leaning in the direction opposite to the direction of travel of the fabric. For convenience, it is stated that the pile indicated at 9 is going through the machine in the "rough" direction while the pile indicated at 11 is going through the machine in the "smooth" direction.
When the fabric is passed through the machine in the smooth direction and the multi-bladed pattern roll is allowed to rotate freely, the effect produced closely simulates the appearance produced by actual slubs but if the fabric is passed through the machine in the rough direction, the effect, while pleasing, does not simulate the appearance produced by slubs. Consequently, it is not in demand by consumers. Conveniently, brush 40 may be included to impart the desired orientation to the pile fabric 10 before it passes through radiant heater 14. Alternatively, the fabric may be brushed beforehand.
To produce the illusion of larger slubs, pattern roll 18 may be retarded so that the peripheral velocity of blades 24 is slightly less than the speed of fabric 10. FIG. 1 illustrates one convenient method of braking pattern roll 18 wherein sheave 34 is attached to pattern roll 18 and line 36 having weight 38 attached is passed over sheave 34 to retard roll 18.
To allow the device to be operated at higher speeds, pattern roll 18 may be cooled by jet 42 which exhausts air against the portion of pattern roll 18 which is not in contact with fabric 10.
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An apparatus for producing velvet having an appearance similar to that of a woven velvet wherein slubbed yarns are used in the weft. The apparatus includes a non-contact heater for heating the pile of a fabric which is then pressed against a cool pattern roll where it is cooled to permanently set the pattern into the pile.
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FIELD OF THE INVENTION
[0001] The present invention relates to a method for realizing Differentiated Services in the wireless access network of the universal mobile telecommunication system, and particularly relates to a method for implementing the IP packet classification and the marking of a DiffServ Code Point (DSCP) while achieving guaranteed QoS (Quality of Service) by applying Differentiated Services (DiffServ) in the IP-based UMTS wireless access network (UTRAN).
DESCRIPTION OF THE RELATED ART
[0002] The UMTS (Universal Mobile Telecommunication System) is the third-generation mobile communication system of wireless technology using the WCDMA and its standardization is conducted by the 3GPP. So far, there have been four versions thereof, namely, the known Release 99 , Release 4 , Release 5 and Release 6 . Version R 5 is the first version of All-IP (or All-Packetization) and has the following improvements in the wireless access network respect: the High-speed Downlink Packet Access (HSDPA) technology is set forth so that the downlink rate can reach 8-10 Mbps, which has greatly improved the efficiency of an air interface; IP-based optional transmission modes are added to Iu interface, Iur interface, and Iub interface so that the wireless access network realizes the IP.
[0003] In the network system architecture of the UMTS as shown in FIG. 1 , the core network (CN) 1 is connected to the UTRAN (Wireless Access Network) via an Iu interface, and the UMTS wireless access network UTRAN is connected to the UE (user equipment) via a Uu interface. FIG. 2 further shows a network architecture of the UMTS wireless access network, wherein a radio network control (RNC) 4 is connected to a circuit-switched (CS) domain of the core network 1 via an Iu-CS interface, and connected to a packet-switched (PS) domain of the core network 1 via an Iu-PS interface. The RNCs are connected to each other via Iur interfaces, and one RNC 4 is connected to one or more node(s)B 5 (Node B) via Iub interfaces. One Node B 5 contains one or more cells 6 , and the cell is a basic unit for the wireless access by the UE. The RNC 4 usually performs the PDCP (Packet Data Convergence Protocol), RLC (Radio Link Control), and MAC (Medium Access Control) and other flnctions in the radio interface protocols, while the Node B 5 performs the physical layer finction in the radio interface protocols. In addition, for the mobility of the UE, the radio bearer of one UE can be connected by a Controlling Radio Network Controller (CRNC) to a Serving Radio Network Controller (SRNC) via the Iur interface, and at this time, the CRNC is called a Drift Radio Network Controller (DRNC).
[0004] FIG. 3 is a schematic view showing the architecture of the UMTS wireless access network UTRAN interface protocol. It can be seen that, the UTRAN interface protocol is divided into a radio network layer and a transport network layer in a horizontal direction; and in a vertical direction, the UTRAN interface protocol is divided into two protocol stacks: a control plane and a user plane, and it further includes a transport network control plane for controlling the transport network layer. In the UTRAN of Release 5 , when the transport network layer uses. the IP RAN (IP-based Radio Access Network) technology, the transport network control plane is not needed. FIG. 4 shows the user plane transport network layer protocol stack of Iu, Iur and Iub interfaces based on the IP RAN technology in the UMTS of Release 5 . In FIG. 4 , RTP, UDP and GTP-U represent real-time transport protocol, user data protocol and user plane GPRS tunnel protocol, respectively. In the user plane radio network layer, the Iu interface is the Iu UP (User Plane) protocol, and the Iur/Iub interfaces are FP (Frame Protocol) data frame protocols corresponding to respective transmission channels. FIG. 5 shows Iu, Iur and Iub interface control plane protocol stacks based on the IP RAN technology in the UMTS of Release 5 . In FIG. 5 , SCCP, M3UA and SCTP represent signaling connection control part, SS7 MTP3 User Adaptive Layer, and Streaming Control Transmission Protocol, respectively, wherein the radio network layer application protocols of the Iu/Iur/Iub interfaces are RANAP (Radio Access Network Application Part), RNSAP (Radio Network Sub-system Application Part) and NBAP (Node B Application Part), respectively. For the details of the above interface protocols of the UMTS wireless access network UTRAN, TS 25.4xx serial protocol documents of the 3GPP (Third Generation Partnership Project) can be consulted. Furthermore, according to TS25.442, Iub and other interfaces in the UTRAN further have IP-based O&M (Operation and Maintenance) data streams transmitted.
[0005] It can be seen from FIG. 4 and FIG. 5 that, the Iu, Iur and Iub interface control planes and user planes in the IP RAN are all IP networks based on IPv6 (IPv4 is an optional IP version) in the transport network layer. According to protocols TS25.414, TS25.426, TS25.422, TS25.432 and the like, the Iu, Iur and Iub interface transport network layers all need to support the marking of DiffServ Code Points (DSCP), so as to support the guaranteed QoS (Quality of Service) technology based on the DiffServ (Differentiated Services) in the IP RAN.
[0006] As above-described, the FP data frames of the Iur/Iub interface user plane radio network layers correspond to respective transmission channels, and besides the FP data frames, the FP frame protocols further comprise inband control signaling frames. In the Iur/Iub interfaces, there exist FP data frames corresponding to the Dedicated Transmission Channel (DCH), and in the Iur interfaces, common transmission channels corresponding to the FP data frames include the RACH (Random Access Channel) and the CPCH (Common Packet Channel) in the uplink direction, and the FACH (Forward Access Channel), the DSCH (Downlink Shared Channel) and the HS-DSCH (Hgh-Speed Downlink Shared Channel) in the downlink direction. In the Iub interfaces, the common transmission channels corresponding to the FP data fiames include the Random Access Channel (RACH) and the Common Packet Channel (CPCH) in the uplink direction, and the Forward Access Channel (FACH), the Downlink Shared Channel (DSCH), the High-Speed Downlink Shared Channel (HS-DSCH) and the Paging Channel (PCH) in the downlink direction. One FP data frame of the Iub interface bears all the transmission blocks of the corresponding physical channel within a TTI (Transmission Time Interval). As above-described, in the Iur interfaces, the FP data frames corresponding to the Dedicated Transmission Channel (DCH) are the same as those in the Iub interfaces. However, the size and number of the service data units (SDU) of a Medium Access Control (MAC) layer borne by one PP data frame of the common transmission channels, except for the High-Speed Downlink Shared Channel (HS-DSCH), depend on the flow control mechanism adopted and the specific realization. The situation of the HS-DSCH in the Iur/Iub interfaces is similar to that of the above common transmission channels in the Iur interfaces. For detailed description about the Iur/Iub interface FP data frame protocols, TS25.427, TS25.425 and TS25,435 serial protocol documents of the 3GPP can be consulted.
[0007] The FP data frame protocol corresponding to the DCH is completely the same in the Iur/Iub interfaces. This is because the radio interface protocol function entities corresponding to the DCH, such as PDCP/RLC/MAC are all located in the Serving Radio Network Controller (SRNC), that is, the DCH FP data frames bear the MAC layer PDUs (Protocol Data Units, i.e., transmission blocks) corresponding to the DCH. Thus, with respect to the DCH, the DRNC only provides a passage which transparently routes the DCH FP data frames from the SRNC to the Node B controlled by the SRNC. In addition, since part of the MAC layer function entities MAC-hs of the HS-DSCH are located in the Node B, the situation of the HS-DSCH is similar to that of the DCH, that is, the FP data frame protocol of the HS-DSCH is the same in the Iur interfaces as that in the Iub interfaces, and the DRNC only provides a transparent transmission.
[0008] Compared with the FP data frame protocol corresponding to the DCH, the FP data frame protocols corresponding to common transmission channels, excepting for the HS-DSCH, in the Iurs are different from those in the Iub interfaces. This is because the MAC layer function entities MAC-c/sh corresponding to the common transmission channels are realized in the Controlling Radio Network Controller (CRNC). Therefore, the FP data frames corresponding to the Iur interface common transmission channels bear the MAC layer SDUs (Service Data Units) corresponding to the common transmission channels, while the FP data frames corresponding to the Iub interface common transmission channels bear the MAC layer PDUs (namely, transmission blocks) corresponding to the common transmission channels.
[0009] In order to further expound the method as proposed by the present invention, the DiffServ-based QoS technology used in the IP network is briefly introduced as follows. The IP QoS presented by the IETF (Internet Engineering Task Force) mainly comprises integrated services (IntServ) and differentiated services (DiffServ), wherein the DiffServ is considered to be the most promising technique to solve the QoS problem of the IP network because of its excellent expansion performance,.
[0010] The basic idea of the DiffServ is to classify the data streams of users according to QoS requests. The data streams of any user have a free access to the network, but when the network is congested, the data streams with a high degree will have a higher priority than that with a lower degree in aspect of queue and source occupancy. The DiffServ only promises a relative QoS but does not promise a specific QoS index to any user.
[0011] Under the DiffServ mechanism, it is necessary to negotiate a service level agreement (SLA) between a user and a network management department. According to the SLA, the data streams of the users are assigned special priority levels, and when the data streams pass through the network, the router will process the packets within the streams by using the corresponding mode which is called a Per-Hop Behavior PHB.
[0012] The DiffServ only includes a limited number of service levels and have little condition information, thus easy to be achieved and expanded.
[0013] In the DiffServ technology, an edge node of the network classifies packets and marks a DiffServ Code Point (DSCP), and the “Per-Hop Behavior” (PHB) in the classified forwarding of the packets performed by an intermediate node is determined by a DSCP. In the IP network, the field used by a DSCP in IPv4 is a “TOS” (Type of Service) field in the IP header, while the field used by a DSCP in IPv6 is a “Traffic Class” field in the IP header.
[0014] In the DiffServ, as shown in FIG. 6 , the PHB is divided into three classes: Best Effort (BE) PHB, Expedited Forwarding (EF) PHB and Assured Forwarding (AF) PHB. The packets of BE PHB class are unnecessary to be particularly treated, thus the relating service is the service for making best efforts to deliver; the packets marked with EF should be forwarded with the minimum delay and the packet loss ratio should be lower; AF PHB is further divided into several sub-classes represented by AFxy, wherein x represents the AF classes, thus to allocate different queues for packets according to the AF classes, and y represents a discarding precedence of packet. The AF packets with the same class, namely having the same x, enter the same queue, and when it is necessary to discard a packet during network congestion, the packet having a lower discarding precedence, namely having a greater y value, in the same queue will be firstly discarded.
[0015] In the standard TS23.107 of the 3GPP, the QoS architecture of the UMTS is defined, as shown in FIG. 7 . In FIG. 7 , UMTS bearer services consist of radio access bearer (RAB) service and core network bearer service, and the RAB service further consists of radio bearer service and Iu bearer service. According to TS23.107, the UMTS services are divided into four QoS classes, namely, conversational class, streaming class, interactive class and background class, and with regard to each traffic class, a plurality of parameters reflecting the QoS attributes are further defined, as shown in FIG. 8 . According to TS23.107, Iu bearer services and core network bearer services can use the DiffServ to realize the QoS, while the radio bearer services meet the demand for the QoS in the radio interface protocols.
[0016] In the UMTS wireless access network UTRAN, the DSCPs of the IP packets in the downlink direction of the Iu interface are marked by the core network 1 according to the QoS attribute parameters of the services requested, and the specific mapping relation between the QoS attribute parameters and the DSCPs is configured by an operator according to the network configuration and operation strategies or the like. Since the UTRAN and the core network are two different DiffServ domains, and the radio network layer data streams on the Iur/Iub interfaces are completely different from the radio network layer data streams on the Iu interfaces, it is necessary to reclassify the IP packets on the Iur/Iub interfaces and remark the DSCP values in the RNC.
[0017] In the RNC, two types of QoS-related information can be obtained, namely, the QoS attribute parameters of the RAB provided by the core network during the RAB establishment or modification, and the DSCP values from the Iu interfaces marked by the core network. In the present invention, the QoS-related information and the information associated with radio resources will be used to perform an effective classification to the IP packets in the IP RAN, and are respectively mapped to different DSCP values, so as to guarantee the QoS in the IP RAN transmission.
[0018] As above-described, the relevant protocols of the 3GPP present that the transport network layers of Iu, Iur and Iub interfaces need to support the marking of DSCPs so as to support the guaranteed QoS technology based on the Diffserv in the IP RAN, however, how to realize the DiffServ in the IP RAN is still a problem to be solved. The present invention aims at this problem and provides a method for implementing the IP packet classification and the marking of a DiffServ Code Point (DSCP) while achieving the guaranteed quality of service (QoS) by applying the DiffServ (DiffServ) in the IP-based UMTS wireless access network.
SUMMARY OF THE INVENTION
[0019] In order to realize the DiffServ in the IP RAN, the present invention provides a method for using Differentiated Services (DifServ) to implement the IP packet classification and the marking of a DiffServ Code Point (DSCP) for the guaranteed quality of service (QoS) in the wireless access network of the IP-based universal mobile telecommunication system, wherein said mobile communication system comprises a core network, one or more universal terrestrial radio access networks (UTRANs) and a plurality of user equipments (UEs), wherein the core network communicates with the UTRAN via an Iu interface, and said UTRAN communicates with one or more UEs via Uu interfaces, each of said UTRAN comprises a plurality of radio network controllers (RNCs) and one or more Nodes B communicating with said RNC via Iub interfaces, and each Node B comprises one or more cells, and the communication between the RNCs being performed via Iur interfaces; said method comprising the following steps of:
[0020] in the outgoing direction of the Iub interfaces at the Node B side, classifying all the uplink Iub interface data streams generated by the Node B into DCH FP data frames, RACH/CPCH FP data frames, and Node B Application Part (NBAP) signaling and Operation & Maintenance (O&M) data streams, and assigning and adjusting the priorities of the classified data streams according to the principles for optimizing the QoS and radio resources;
[0021] in the outgoing direction of the Iub interfaces at the RNC side, classifying the transmitted data into: uplink DCH FP data frames transparently forwarded from the Iub interfaces; uplink RACH/CPCH FP data frames from the Iub interfaces, medium access control (MAC) layer service data units (SDU) processed by the MAC layer functional entity (MAC-c/sh) forming the corresponding upward Iur interface RACH/CPCH FP data frames; downlink Iur interface PP data frames generated by the RNC as a SRNC and transmitted to a Drift Radio Network Controller (DRNC); and radio network sub-system application part (RNSAP) signaling streams, and assigning and adjusting the priorities of the classified data streams according to the principles for optimizing the QoS and radio resources; and
[0022] in the outgoing direction of the Iur interface at the RNC side, classifying the transmitted data into: downlink DCH/HS-DSCH FP data frames transparently forwarded from the Iur interfaces; downlink DSCH FP data frames from the Iur interfaces, the MAC layer SDUs processed by the MAC-c/sh forming the corresponding downlink Iub interface DSCH FP data frames; downlink Iur interface FACH FP data frames which, after being processed by the MAC-c/sh, are multiplied with logic channels and form downlink Iub interface downlink FACH FP data frames; downlink Iub interface FP data frames generated by the RNC and directly transmitted to the Node B; and NBAP signaling and O&M data streams, and assigning and adjusting the priorities of the classified data streams according to the principles for optimizing the QoS and radio resources.
[0023] When the network is congested, the data stream with a high level will have a higher priority than that with a lower level in queue and source occupancy, and the packet with a lower discarding precedence in the same queue is discarded. The DiffServ only contain a limited number of service levels and have little condition information, thus easy to achieve and expand.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The preferred embodiments of the present invention are described as follows by referring to the drawings and examples taken.
[0025] FIG. 1 is a schematic view showing the UMTS (Universal Mobile Telecommunication System) network system architecture.
[0026] FIG. 2 is a schematic view showing the UTRAN network architecture.
[0027] FIG. 3 is a schematic view showing the UTRAN interface protocol architecture.
[0028] FIG. 4 is a schematic view showing the user plane transprot network layer protocol stacks of Iu, Iur and Iub interfaces based on the IP RAN technology in the UMTS of Release 5 .
[0029] FIG. 5 is a schematic view showing the control plane protocol stacks of Iu, Iur and Iub interfaces based on the IP RAN technology in the UMTS of Release 5 .
[0030] FIG. 6 is a schematic view showing suggested values of DSCPs for the standard PHB in the DiffServ
[0031] FIG. 7 is a schematic view showing the QoS architecture of the UMTS defined in the Standard TS23.107 of the 3GPP.
[0032] FIG. 8 is a schematic view showing the QoS attribute parameters of the UMTS bearer services.
[0033] FIG. 9 is a schematic view showing the IP RAN transmission network.
[0034] FIG. 10 ( a ) is a flow diagram of marking DSCPs of IP packets sent from the Iub interfaces at the Node B side according to the present invention.
[0035] FIG. 10 ( b ) is a flow diagram of marking DSCPs of IP packets sent from the Iub interfaces at the RNC side according to the present invention.
[0036] FIG. 10 ( c ) is a flow diagram of marking DSCPs of IP packets sent from the Iur interfaces at the RNC side according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0037] According to the above-mentioned descriptions and the protocol documents. TS25.427, TS25.425, TS25.435 and the like of the 3GPP, the following conclusions about the multiplexing situation of the user plane FP data frames of the Iur/Iub interfaces are drawn:
[0038] 1. In the uplink direction, one FP data frame of the iub interfaces corresponding to the Common Transmission Channel RACH/CPCH only contains transmission blocks of the RACH/CPCH channel of a certain user equipment UE, and different FP data frames may correspond to the RACH/CPCH channels of different UEs. After passing through the MAC-c/sh function unit in the CRNC, the FP data frames of one RACH/CPCH on the Iur interfaces still only contain SDUs of the RACH/CPCH channel of a certain UE. However, since the MAC-c/sh functional entity does not exist in Node B, it is impossible to differentiate RACH/CPCH data frames of different users at the Iub interfaces of the Node B.
[0039] 2. In the downlink direction, the FP data frames of the Iur interface corresponding to the Common Transmission Channel FACH/DSCH only contain MAC-c/sh SDUs of the FACH/DSCH channel of a certain UE. Meanwhile, the FP data frame of each FACH/DSCH further contains a 4-bit CmCH-PI (Common Transmission Channel Priority Indicator) field for the priority handling of packet scheduling function in the MAC-c/sh. After passing through the MAC-c/sh function unit in the CRNC, the FACH may simultaneously transmit logic channels of a plurality of UEs, the BCCH (Broadcast Control Channel) generated in the CRNC, the CCCH (Common Control Channel), the CTCH (Common Traffic Channel) and other logic channels within one TTI, while the Downlink Shared Channel (DSCH) can only transmit logic channels of one UE within one TTI. Thus, the FP data frames of one DSCH of the Iub interfaces only contain transmission blocks of the DSCH channel of a certain UE.
[0040] 3. In the downlink direction, the PCH FP data frames of the Iub interfaces contain transmission blocks of the Paging Channel (PCH) within one TTI. The PCH bears PCCH (Paging Control Channel) logic channels generated by the CRNC, and the PCCH bears TYPE I paging message generated by the RRC (Radio Rouse Control) layer in the CRNC.
[0041] 4. In the downlink direction, the FP data frames of a Iur/Iub interface of the HS-DSCH only contain PDUs generated by the MAC-d in the SRNC of a certain UE.
[0042] 5. Even if the FP data frames of the Iur/Iub interfaces only bear the user plane data units of one UE, for the existence of multi-service multiplexing condition required by different QoSs, a plurality of transmission channels may be multiplexed on one physical channel. Thus, one FP data frame may have transmission blocks of transmission channels required by different QoSs.
[0043] According to the above analysis and based on the principles for optimizing QoS and radio resources, the present invention proposes a method (hereinafter shortly referred to as “priority determining rules”) for determining the priority of data streams in the Iur/Iub interfaces aiming at the problem of applying the DiffServ in the IP RAN.
[0044] (1) According to the above analysis, in addition to the FP data frames of the FACH and PCH of the Iub interfaces, the FP data frames of other Iur/Iub interfaces only contain user data blocks of one UE. Therefore, the priority of the IP packets bearing FP data frames can be determined according to the known QoS-related information of the RNC, namely, the QoS attribute parameters of a radio access bearer (RAB) supplied by the core network during the RAB establishment or modification process and the DSCP values from the Iu interfaces marked by the core network. Regarding the case where one FP data frame may have transmission blocks of the transmission channels required by different QoSs, the priority can be determined according to the highest data rate in the multiplexed services or the service required by the highest QoS. Since the RRC signaling and user data share the same radio bearer (the RRC message and the core network higher signaling which is directly and transparently transmitted by the RRC are borne by the DCCH), the FP data frames which contain RRC signaling data can be assigned a higher priority.
[0045] (2) Regarding the FACH data frames of the Iub interfaces, the priority can be determined according to the service required by the highest QoS in the multiplexed. logic channel, but a predefined priority can be used for easy realization. Since the. paging message is non-connected RRC information, the PCH FP data frames can be assigned a lower priority.
[0046] (3) The MAC-c/sh functional entity does not exist in a Node B, and as a result, it is impossible to differentiate RACH/CPCH data frames of different users at the Iub interface of the Node B. Thus, regarding the RACH/CPCH data frames of the Iub interfaces, the same predefined priority can be simply used. Regarding the RACH/CPCH data frames of the Iur interfaces, two methods can be used for determining the priority, namely, using the same predefined priority as that of the RACH/CPCH data frames of the Iub interfaces without discriminating the users, or assigning different priorities to the RACH/CPCH data frames of the Iur interfaces of different users according to the different QoS requests.
[0047] (4) All the IP packets which bear control plane radio application protocols of the radio network layer including radio network sub-system application part (RNSAP) and Nobe B application part (NBAP) are assigned the highest priority. The O&M data streams in the UTRAN can be assigned a lower priority.
[0048] (5) In the same situation, the uplink data streams have a lower priority than the downlink data streams. The reason is that, the uplink data streams are the data directly from an air interface and have consumed radio resources as resource bottleneck. When the IP transmission network is congested and some IP packets need to be discarded, the discarding of the IP packets of the uplink data in the same situation will result in the consumption of radio resources, while the downlink data is the data from the core network and has not occupied radio resources before reaching the Node B, so it is considered to be firstly discarded.
[0049] (6) When a UE is in a soft handoff state, in the uplink direction, if the FP data frames corresponding to the DCH will come from the DRNC, then the DCP FP data frames through the DRNC will have a higher priority than the DCH FP data frames which arrive directly via the Iub interface. The reason is that, in the uplink direction, the SRNC will complete the micro-diversity operation (the DRNC may complete part of the micro-diversity operation), i.e., optionally incorporating soft handoff branches. In order to complete the micro-diversity operation, it is necessary for all the uplink soft handoff branches to arrive within certain time, so as to prevent from generating a greater delay to the radio bearer service and needing a larger buffer memory. Therefore, the uplink DCH FP data frames through the DRNC are assigned a higher priority, which is good to the improvement of the soft handoff performance and the QoS. Similarly, in order to prevent the loss of the downlink soft handoff branches, in the downlink direction, if the FP data frames corresponding to the DCH need to reach the controlled Node B through the DRNC, the DCH FP data frames through the DRNC have a higher priority than the DCH FP data frames which are directly sent to the Node B via the Iub interface
[0050] (7) When a radio link control (RLC) uses an AM (Assured Mode), in order to reduce transmission delay at the radio interface to improve the performance of the high layer protocol, such as a TCP (Transmission Control Protocol), having the end-to-end flow control finction, the IP packets which bear and contain the radio link control (RLC) re-transmission PDUs should be assigned a higher priority. In addition, the RLC using the AM mode further has STATUS, RESET, RESET ACK and other control protocol data units (PDUs), and the IP packets which bear and contain this kind of RLC control PDUs should be assigned a higher priority. Since the UTRAN only has downlink RLC entities, this principle can only be used in the downlink direction.
[0051] The DSCP is marked by the IP network edge node, and therefore, in order to classify Egress IP packets and mark the DSCP values for these packets in the RNC and the Node B, the user plane IP packet data streams outgoing from the Node B at the Iub interface and from the RNC at the Iur and Iub interfaces will be further analyzed as follows.
[0052] The data streams outgoing from the Iub interface at the Node B are the uplink Iub interface FP data frames, NBAP signaling and operation and maintenance (O&M) data streams.
[0053] The data outgoing from the Iur interfaces from the RNC include:
uplink DCH FP data frames transparently forwarded from the Iub interfaces; uplink RACH/CPCH FP data frames from the Iub interface, the MAC layer SDUs processed by the MAC-c/sh forming the corresponding uplink Iur interface RACH/ECPCH FP data frames; downlink Iur interface FP data frames generated by the RNC as a SRNC and transmitted to a DRNC; and RNSAP signaling streams.
[0058] The data outgoing from the Iub interfaces of the RNC include:
downlink DCH/HS-DSCH FP data frames transparently forwarded from the Iur interfaces; downlink DSCH FP data frames from the Iur interfaces, the MAC layer SDUs processed by the MAC-c/sh forming the corresponding downlink Iub interface DSCH FP data frames; downlink FACH FP data frames from the Iur interface, which, after being processed by the MAC-c/sh, are multiplexed with other logic channels and form the downlink Iub interface FACH FP data frames; downlink Iub interface FP data frames generated by the RNC and directly transmitted to the Node B; and NBAP signaling and O&M data streams.
[0064] FIG. 9 shows the IP RAN transmission network. Since the transmission networks of the Iur/Iub interfaces are the same IP network, when the DSCP is marked at the Iur/Iub Egress port by the RNC and at the Iub Egress port by the Node B, the same strategy should be used to classify the IP packets and mark the DSCPs.
[0065] According to the above analysis and the method for determining the priority of the Iur/Iub interface data streams as set forth in the present invention, the method for classifying the IP packets outgoing from the Iub interfaces at the Node B side, the IP packets outgoing from the Iub interfaces at the RNC side and the IP packets outgoing from the Iur interfaces at the RNC side and for marking the DSCP values is shown in FIG. 10 ( a ), FIG. 10 ( b ) and FIG. 10 ( c ), respectively.
[0066] As shown in FIG. 10 ( a ), in step S 11 , in the Iub interface outgoing direction at the Node B side, regarding all the uplink Iub interface data streams generated by the Node B, including DCH FP data frames and RACH/CPCH FP data frames, NBAP signaling and O&M data streams, the priority of the unified IP packets of the control plane and user plane of the RNC/Node B is determined according to the above priority determining rules (1), (3) and (4). Since what are outgoing from the Iub interfaces at the, Node B side are all the uplink data streams, step S 12 is performed subsequently, and according to the priority determining rule (5), the priority of the IP packets from the Node B is increased. Next, step S 13 is performed, regarding the DCH PP data frames which arrive at the SRNC through the DRNC, the priority of the IP packets bearing the DCH FP data frames should be increased according to the priority determining rule (6). In step S 14 , according to the priority of the IP packets and based on the unified mapping relation of the RNC/Node B, the DSCP values of the IP packets are marked.
[0067] As shown in FIG. 10 ( b ), in the outgoing direction of the Iub interfaces at the RNC side, the data fiames or data streams to be differently processed have three coordinate cases. Case 1: in step S 21 , regarding the downlink Iub interface FP data frames generated by the RNC and directly transmitted to the Node B, the NBAP signaling and O&M data streams, the priority of the unified IP packets of the control plane and user plane of the RNC/Node B is determined according to the priority determining rules (1), (2) and (4); next is step S 22 , in which if the FP data frames contain RAB data units of the RLC using the AM mode, regarding the IP packets bearing the RLC re-transmitted PDUs and the IP packets bearing STATUS, RESET, RESET ACK and other RLC control PDUs, the priority of the corresponding IP packets should be increased according to the priority determining rule (7). Case 2: in step S 23 , regarding the downlink Iub interface FACH FP data frames processed by the MAC-c/sh, the priority of the unified corresponding packets of the RNC/Node B is determined according to the priority determining rule (2). Once the priority of the IP packets of the above two types of data streams is determined, step S 25 is performed and the DSCP values of the IP packets are marked according to the unified mapping relation of the RNC/Node D. Case 3: in step S 24 , regarding the downlink DCH/HS-DSCH FP data frames from the Iur interfaces that need to be transparently forwarded and the Iub interface DSCH FP data frames formed after being processed by the MAC-c/sh, the DSCP field of the IP packets of the corresponding data frames originally entering from the Iur interface are regarded as the DSCP of the IP packets of the corresponding data frames transmitted to the Iub interfaces.
[0068] As shown in FIG. 10 ( c ), in the outgoing direction of the Iur interfaces at the RNC side, the data frames or data streams to be differently processed have three coordinate cases. Case 1: in step S 31 , regarding the downlink Iur interface FP data frames generated by the RNC as a SRNC and transmitted to the DRNC, and the RNSAP signaling, the priority of the unified IP packets of the control plane and user plane of the RNC/Node B is determined according to the above priority determining rules (1) and (4); next is step S 34 , in which if the FP data frames contain RAB data units of the RLC using the AM mode, regarding the IP packets bearing the RLC re-transmitted PDUs and the IP packets bearing STATUS, RESET, RESET ACK and other RLC control PDUs, the priority of the corresponding IP packets should be increased according to the priority determining rule (7); step S 35 is subsequently performed, in which if the FP data frames are the DCH FP data frames which need to arrive at the SRNC through the DRNC, the priority of the IP packet bearing the DCH FP data frames should also be increased according to the priority determining rule (6). Then step S 36 is performed, and once the priority of the IP packets for the above type of data streams is determined, the DSCP values of the IP packets can be marked according to the unified mapping relation of the RNC/Node B. Case 2: in step S 32 , regarding the uplink DCH FP data frames from the Iub interfaces which need to be transparently forwarded, the DSCP fields of the IP packets of the corresponding data frames originally entered from the Iur interfaces are copied as the DSCPs of the IP packets of the corresponding data frames transmitted to the Iub interfaces. Case 3: in step S 33 , regarding the uplink Iur interface RACH/CPCH FP data frames processed by the MAC-c/sh, the priority is determined and the DSCP is marked according to the priority determining rule (3).
[0069] Need to note that, with regard to the aforesaid rules for determining priority of the data streams across the Iur/Iub interface as presented in the present invention, some or all of them can be optionally used in the specific implementation according to need, for example, in order to reduce the complexity for realization. Thus, if some of the “rules for determining priority” are not adopted, then the corresponding steps containing these rules can be omitted in the method for determining priority of the data streams across the Iur/Iub interface as shown in FIG. 10 ( a ), FIG. 10 ( b ) and FIG. 10 ( c ).
[0070] In addition, the present invention is not limited to the mapping relation between the priority of the data streams across the Iur/Iub interface and the DSCP, and it can be configured by network operators according to the specific network configuration and operation strategies in the specific implementation.
[0071] The following descriptions will give further explanations about the method for implementing the IP packet classification and the marking of a Differential Service Code Point (DSCP) while achieving the guaranteed QoS by applying DiffServ in the IP RAN as proposed in the present invention.
[0072] FIG. 11 shows a typical example of the assignment of priority of UTRAN data streams and PHB classes of the DiffServ. In this example, the priority is divided into 10 levels, wherein according to the priority determining rule (4), the data streams of RNSAP/NBAP and other control plane radio application protocols have a highest priority taking the value of 1, and the O&M data streams have a lowest priority taking the value of 10.
[0073] As above-described, two types of QoS-related information can be obtained in the RNC, namely, the QoS attribute parameters of the radio access bearer (RAB). supplied by the core network during the RAB establishment or modification process, and the DSCP values from the Iu interfaces marked by the core network. In this example, the UMTS bearer service data streams are simply assigned different priorities according to the traffic class in the QoS attribute parameters of the RAB supplied by the core network during the RAB establishment or modification process, namely that, the priority of the conversational class service is 2, the priority of the streaming class service is 3˜5, the priority of the interactive class service is 6˜8, and the priority of the background class service is 9. Regarding the streaming class service and interactive class service, the initial priority is 3 and 6, respectively. FIG. 11 further shows the mapping relation between the priority and the PHB class of the DiffServ, wherein the high priorities 10 and 9 correspond to the EF class of the DiffServ, the priorities 8, 7 and 6 respectively correspond to AF 11 , AF 12 and AF 13 of the DiffServ, and the priorities 5, 4 and 3 respectively correspond to AF 21 , AF 22 and AF 23 , and the low priorities 2 and 1 correspond to the BE class of the DiffServ. In this example, the mapping relation between the PHB class of the DiffServ and the DSCP uses typical values as shown in FIG. 6 .
[0074] In the outgoing direction of the Iub interfaces at the Node B side, firstly regarding all the uplink Iub interface data streams generated by the Node B, including DCH FP data frames, RACH/CPCH FP data frames, and NBAP and O&M data streams, the priority of the IP packets is determined according to the priority determining rules (1), (3) and (4). More specifically, the DCH can bear various traffic classes while the RACH and CPCH can typically bear the interactive class and the background class services, therefore, the priority of the corresponding DCH FP data frames and RACH/CPCH FP data frames can be assigned according to the traffic classes borne, as shown in FIG. 11 . Regarding the NBAP signaling and O&M data streams, the priority takes 10 and 1, respectively.
[0075] What are outgoing from the Iub interfaces at the Node B side are the uplink data streams, so the priority of all the IP packets from the Node B is increased by 1 according to the priority determining rule (5); regarding the DCH FP data frames which need to reach the SRNC through the DRNC, the priority of the IP packets bearing the DCH FP data frames is increased by 1 according to the priority determining rule (6). If the priority of one data stream is greater than 10 after being increased, then it will still take 10. After the priority is determined, the DSCPs of the data streams outgoing from the Iub interface at the Node B side can be marked according to the mapping relation between the priority and the PHB class of the DiffServ as shown in FIG. 11 and the mapping relation between the PHB class of the DiffServ and the DSCP as shown in FIG. 6 .
[0076] Meanwhile, in the outgoing direction of the Iub interface at the RNC side, regarding the downlink Iub interface FP data frames generated by the RNC and directly transmitted to the Node B, the NBAP signaling and O&M data streams, the priority of the IP packets is determined according to the priority determining rule (1), (2) and (4). More specifically, the priority of the IP packets corresponding to respective FP data frames can be assigned according to the traffic classes borne by the corresponding transmission channels, as shown in FIG. 11 . Regarding the NBAP signaling and O&M data streams, the priority takes 10 and 1, respectively.
[0077] If the FP data frames contain the RAB data units of the RLC using the AM mode, according to the priority determining rule ( 7 ), regarding the IP packets bearing the RLC re-transmitted PDUs and the IP packets bearing STATUS, RESET, RESET ACK and other RLC control PDUs, the priority of the IP packets corresponding to the FP data frames is increased by 1. Regarding the downlink Iub interface FACH FP data frames processed by the MAC-c/sh, the priority of its corresponding IP packets is determined according to the priority determining rule (2). In this example, the priority of the IP packets corresponding to the downlink Iub interface FACH FP data frames fixedly takes the value of 3, while the priority of the IP packets corresponding to the PCH FP data frames fixedly takes the value of 2.
[0078] Once the priorities of the IP packets of the above two types of data streams are determined, the DSCPs of the data streams outgoing from the Iub interfaces at the RNC side can be marked according to the mapping relation between the priority and the PHB class of the DiffServ as shown in FIG. 11 and the mapping relation between the PHB class of the DiffServ and the DSCP as shown in FIG. 6 . In addition, regarding the downlink DCH/HS-DSCH FP data frames from the Iur interfaces which need to be transparently forwarded, and the Iub interface DSCH FP data frames formed after being processed by the MAC-c/sh, the DSCP field of the IP packets of the corresponding data frames originally entered from the Iur interface is regarded as the DSCP of the IP packets of the corresponding data frames transmitted to the Iub interfaces.
[0079] In the outgoing direction of the Iur interface at the RNC side, regarding the downlink Iur interface FP data frames generated by the RNC as a SRNC and transmitted to the DRNC, and the RNSAP signaling, the priority of the IP packets is determined according to the priority determining rules (1) and (4). More specifically, the priorities of the IP packets corresponding to respective FP data frames can be assigned according to the traffic class borne by the corresponding transmission channel as shown in FIG. 11 , while the priority of the RNSAP signaling takes 10.
[0080] If the FP data frames contain the RAB data units of the RLC using the AM mode, according to the priority determining rule (7), regarding the IP packets bearing the RLC re-transmitted PDUs and the IP packet bearing STATUS, RESET, RESET ACK and other RLC control PDUs, the priority of the IP packets corresponding to the FP data frames is increased by 1. If the FP data frames are the DCH FP data frames that need to reach the SRNC through the DRNC, the priority of the IP packets corresponding to the FP data frames is increased by 1 according to the priority determining rule (6). Regarding the corresponding uplink Iur interface RACH/CPCH FP data frames formed after being processed by the MAC-c/sh, in this example, for simplification, a predefined priority which is the same as that of the Iub interface RACH/CPCH data frames is used without differentiating the users, namely, the priority takes 3.
[0081] Once the priority of the IP packets of the above data streams is determined, the DSCPs of the data streams outgoing from the Iur interface at the RNC side can be marked according to the mapping relation between the priority and the PHB class of the DiffServ as shown in FIG. 11 and the mapping relation between the PHB class of the DiffServ and the DSCP as shown in FIG. 6 . In addition, regarding the uplink DCH FP data frames from the Iub interfaces which need to be transparently forwarded, the DSCP fields of the IP packets of the corresponding data frames originally entered from the Iur interfaces is copied as the DSCPs of the IP packets of the corresponding data frames transmitted to the Iub interfaces.
[0082] As an exemplary one, the above-mentioned example adopts an example of the assignment of priority of data streams in the IP RAN and the PHB class of the DiffServ. However, as above-stated, the method set forth in the present invention is not limited to the specific mapping relation between the priority of the data streams across the Iur/Iub interfaces and the DSCPs, and it can be configured by network operators according to the network configuration and operation strategies in the specific implementation.
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The present invention provides a method for using Differentiated Services (DiffServ) to implement the IP packet classification and the marking of a Differential Service Code Point (DSCP) for the quality of service (QoS) in the wireless access network of the IP-based universal mobile telecommunication system (UMTS). The present invention makes a classification to the data stream which is outgoing from the Iub interface at the Node B side, data stream which is outgoing from the Iub interface at the RNC side and data stream which is outgoing from the Iur interface at the RNC side according to the direction and the process of the respective data streams, and assigns and adjusts the priority of the data stream classified according to the principles for optimizing QoS and radio resources. When the network is congested, the data stream with a high level will have a higher priority than that with a lower level in queue and source occupancy, and the packet with a lower priority in the same queue is discarded. The DiffServ only contains a limited number of service levels and has little condition information, thus easy to be achieved and expanded.
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RELATED APPLICATION
[0001] This application claims priority to European Application EP16167320.7 filed Apr. 27, 2016, and titled “A Process of Preparing a Dyed Fabric Including a Bacterial Biopolymer and Having Unique Appearance,” the contents of which are incorporated by reference herein, as if set forth in their entirety.
TECHNICAL FIELD
[0002] The present invention relates to a process for the production of a fabric having a unique appearance, to a fabric obtained with said process and to clothing articles, i.e. garments, including said fabric. In particular, the present invention relates to a process for producing a woven fabric having a unique, e.g. “used” (i.e. worn-out) or “multi-shaded” appearance, wherein said process comprises the use of a bacterial biopolymer.
BACKGROUND
[0003] Worn out fabrics, especially denim, have enjoyed popularity in fashion industry due in particular to the finishing processes that can be applied to the fabric in order to create different appearances and thus different visible effects on the front side of the fabric, i.e. on the surface that is visible when the article made by the fabric is worn. In fact, the success in denim industry largely depends on creativity coming from a variety of fabric finishing processes that gives fabrics unique appearances.
[0004] The exterior appearance of a fabric, and thus of a clothing article made by the fabric, can be modified by using different finishing techniques.
[0005] A “used” or “vintage” or “worn-out” look of the fabric can be achieved by treating the fabric with a finishing process that is generally carried out on the garment or on the fabric. The known finishing processes may use specific chemicals, or mechanical abrasion, such as processes using stone-washing, acid wash, laser treatment and sandblasting. For example, in the stone washing, the fabric is washed in a cylinder in the presence of pumice stones. While the wash cylinder rotates, the fabric is contacted by the stones that will remove part of the yarn fibers including the dye present on said fibers.
[0006] In this case, when a fabric and, in particular, an indigo dyed woven fabric is used, wherein the indigo dye is located on the surface of the yarns leaving the core of the yarns undyed, a stone wash (or sand blast) finishing process can be applied to allow varying amounts of the undyed cores of the indigo yarns to become visible.
[0007] These different finishing treatments result in different visible effects, in particular worn-out appearance, which make the fabric fashionable in the clothing and textile industries. However, the visible effects and appearance that are obtainable by the known finishing treatments, are limited. Therefore, garments made by different producers are often similar one to another, thus reducing the commercial desirability of the product and the possibility to distinguish a product from those of another producer.
[0008] A further disadvantage of traditional stone washing is that the stones can damage the fabric.
SUMMARY
[0009] It is an aim of the present invention to solve the above mentioned problems and to provide a process for the production of a fabric having a “unique” appearance; with “unique appearance” it is here meant an appearance different from the known ones, i.e. a look that was previously not attainable with known finishing processes, such as an improved “used” or “vintage” or “worn-out” appearance, in particular a distinctive worn-out appearance previously not obtainable with known processes.
[0010] Another aim of the present invention, is to provide a process for the production of a fabric having a “unique” appearance which is commercially desirable, recognizable and readily distinguishable from other products.
[0011] Still another aim of the present invention is to provide a process wherein damage to the yarns and the fabric made thereof is substantially avoided or is reduced, during the manufacturing and finishing processes. A further aim of the invention is to provide a finishing process that avoids or reduce the environmental costs of known finishing processes and that is less expensive than said processes.
[0012] These and other aims are achieved by a process for producing a treated fabric, which results in the production of a treated fabric, the fabric suitable for the manufacture of a garment.
[0013] In particular, the present invention refers to a process for producing a fabric, comprising the following steps:
a. Providing at least one plurality of warp yarns and at least one plurality of weft yarns; b. Weaving said at least one plurality of warp yarns with said at least one plurality of weft yarns to provide a woven fabric, having a front side and a back side; c. Providing at least a layer of at least one bacterial biopolymer on said yarns or on at least part of at least one side of said woven fabric to provide a composite fabric; d. Dyeing at least part of said composite fabric, whereby at least part of the fabric yarns are dyed together with said biopolymer layer; e. Removing at least part of said layer of bacterial biopolymer from said composite fabric to obtain a treated fabric.
[0019] Various embodiments are recited in the claims.
[0020] In one embodiment, after step d and before step e the fabric is made, i.e. it is tailored, into a garment; the finishing processes may be applied to the fabric or to the garment including the fabric. In the following description reference will be made to the “fabric” to also identify a garment as far as at least the finishing processes are concerned, without limiting the scope of protection to treatment of the fabric only. As a matter of fact, the process of claim 1 may be carried out on a garment; claim 1 thus encompasses the treatment of a fabric in a garment.
[0021] By means of a process according to the invention, a “treated fabric”, i.e. a woven fabric after finishing processes, with an improved (i.e. a “unique”) aesthetical effect, can be obtained. The obtained fabric, i.e. the “treated” fabric, presents a “multi-shaded” effect, namely a “multi-shaded” appearance, previously not available through known finishing processes. Specifically, the obtained “multi-shaded” effect, is a distinctive appearance, preferably a “used” or “worn-out” appearance, which comprises a plurality of shades of color, which are distributed throughout the fabric (and, thus, throughout a garment comprising it) according to a non-reproducible distribution, such that the same distribution of shades cannot be reproduced from a fabric to another.
[0022] Without being bound to a specific scientific explanation, a possible explanation is that a bacterial biopolymer layer, being produced by living microorganisms, may not be structurally identical to another bacterial biopolymer layer, even if it has been produced by the same microorganisms and in the same conditions.
[0023] Therefore, it has been observed that two different bacterial biopolymer layers provide for two different dyeing-results of the bacterial biopolymer layers themselves and of the fabrics (or yarns) coupled therewith, as well.
[0024] As above mentioned, by means of a process according to the invention a “treated fabric”, i.e. a woven fabric after finishing processes, with a “unique” aesthetical effect, can be obtained; in other words, two woven fabrics that are “treated” with the disclosed process, show two different aesthetical results, i.e. the same distribution of color shades is not reproduced from a fabric to another. Thus, each “treated fabric”, obtained by the process of the invention, shows an aesthetical appearance that is substantially “unique”, i.e. an aesthetical appearance that is substantially “not reproducible”.
[0025] The treated fabric of the invention, as obtained after the removal of at least part of the bacterial biopolymer layer from the dyed composite fabric, shows a plurality of color shades, according to the amount of dye which has been absorbed by the bacterial biopolymer layer and reached the underlying woven fabric.
[0026] This is particularly true when, according to various embodiments, said at least one bacterial biopolymer layer has a thickness “T” that is non-uniform throughout the extension of the bacterial biopolymer layer, i.e. that is not the same throughout the whole extension of the bacterial biopolymer layer.
[0027] In fact, without being bound to a specific scientific explanation, it has been observed that the dye uptake of the fabric provided with the claimed bacterial biopolymer layer as obtained in step c of the process of the invention, is variable in relationship with the variable thickness of the bacterial biopolymer layer.
[0028] In particular, it has been observed that, the higher is the thickness T, the higher is the dye uptake of the layer of bacterial biopolymer, i.e., the amount of dye which is absorbed by the bacterial biopolymer layer, and the less is the amount of dye that arrives to the yarns and that dyes the yarns provided with the biopolymer layer. In other words, when, for example, a composite fabric comprises a bacterial biopolymer layer having non-uniform (i.e. “variable”) thickness, different amounts of dye reach the underlying surface (for example, the front side) of the woven fabric, according to the thickness of the bacterial biopolymer layer so that the fabric yarns take on different amounts of dye in different regions.
[0029] It has to be noted that the thickness (“T”) of the bacterial biopolymer layer of a composite fabric according to the invention and the amount of the dye which reaches the woven fabric provided with the biopolymer layer are inversely proportional. In other words, the higher is the thickness of the bacterial biopolymer layer, the lower is the amount of dye that reaches the woven fabric provided with the biopolymer layer. For example, if the thickness of the bacterial biopolymer layer of a composite fabric according to the invention is high, a high amount of dye is absorbed by the bacterial biopolymer layer and only a low amount of dye (or none) reaches the woven fabric provided with the biopolymer layer. Therefore, after the removal of the bacterial biopolymer layer, a treated fabric that is slightly colored (i.e. that is a colored in a light shade of color) or that is substantially non-colored is obtained.
[0030] On the contrary, for example, if the thickness “T” of the bacterial biopolymer layer is low, a low amount of dye is absorbed by the bacterial biopolymer layer, and thus a high amount of dye reaches the surface (i.e., for example, the front side) of the woven fabric provided with the biopolymer layer. Therefore, after the removal of the bacterial biopolymer layer, a treated fabric that is intensely colored (i.e. that is colored in a dark shade of color) is obtained.
[0031] As used herein, the term “thickness”, refers to the distance between the top and bottom or front and back surfaces of something; e.g., the distance between the top and bottom surfaces of the bacterial biopolymer layer. The bottom surface of the bacterial biopolymer layer is the surface of the bacterial biopolymer layer which contacts the fabric or yarns. The top surface of the bacterial biopolymer layer is the surface of the bacterial biopolymer layer, opposite to the bottom surface, which does not contact the fabric or yarns.
[0032] As used herein, the term “uniform thickness”, refers to a thickness that is substantially constant (substantially non-variable); e.g. the distance between the top and bottom surfaces of the bacterial biopolymer layer does not substantially change along the extension of the bacterial biopolymer layer.
[0033] On the contrary, as used herein, the term “non-uniform thickness”, refers to a thickness that is variable; e.g. the distance between the top and bottom surfaces of the bacterial biopolymer layer varies (i.e. “changes”, i.e. it is not constant) along the extension of the bacterial biopolymer layer.
[0034] According to some embodiments, at least part of said bacterial biopolymer layer is a discontinuous layer.
[0035] For example, a bacterial biopolymer layer can be a discontinuous biopolymer layer, i.e. a bacterial biopolymer layer can have interruptions along its extension. In this case, for example, a fabric or a yarn that is provided with a discontinuous biopolymer layer presents regions on its surface (e.g. the front side of a woven fabric) that are not “covered” by the bacterial biopolymer layer.
[0036] Advantageously, considering, for example, a composite fabric (as obtainable in step c of the process of the invention) wherein the bacterial biopolymer layer is discontinuous, i.e. wherein the bacterial biopolymer layer presents interruptions throughout its extension, regions of the woven fabric provided with bacterial biopolymer layer, result to be “not-covered” by the biopolymer layer. Therefore, when the composite fabric is dyed according to step d of the process of the invention, regions of the woven fabric that are “not-covered” by the biopolymer layer are completely and “directly” dyed; in other words, where the woven fabric is not “covered” by the biopolymer layer, the dye is applied directly on the woven fabric.
[0037] Advantageously, when a composite fabric comprises a discontinuous bacterial biopolymer layer, a treated fabric having a patterned multi-shaded effect can be obtained.
[0038] In other words, a discontinuous bacterial biopolymer layer according to the invention can present a predetermined “patterned” distribution of “interruptions” in order to provide a treated fabric with a predetermined pattern of regions of the woven fabric that are “completely” and “directly” dyed, as above mentioned. Therefore, once the bacterial biopolymer layer is removed according to step e of the process of the invention, a treated fabric having a multi-shaded effect further comprising a patterned distribution of “completely dyed” regions can be obtained. On the contrary, where the woven fabric is provided with the bacterial biopolymer layer, once the bacterial biopolymer layer is removed after the dyeing, regions having multi-shaded effect, as above defined, are obtained. In other words, the bacterial biopolymer layer can act as a “stencil” when the composite fabric is dyed.
[0039] According to embodiments of the invention, variation within the weaving pattern of the woven fabric provides further visual effects. In fact, it has been observed that the weaving pattern contributes to the final appearance.
[0040] According to one embodiment, the bacterial biopolymer layer is a non-uniform discontinuous layer. In other words, a bacterial biopolymer according to the invention can have a variable thickness and interruptions throughout its whole extension.
[0041] According to embodiments of the invention, the woven fabric is provided with at least one bacterial biopolymer layer on at least the front side and/or the back side.
[0042] As used herein, the term “front side” of the fabric, refers to the side of the fabric which is the external visible side when a garment comprising the fabric is worn. As used herein, the term “back side” of the fabric, refers to the side of the fabric which is the internal not visible side when a garment comprising the fabric is worn.
[0043] According to embodiments, the woven fabric is provided with at least one bacterial biopolymer layer on both the front side and the back side.
[0044] For example, a woven fabric according to the invention can be provided with two bacterial biopolymer layers, namely with a first biopolymer layer on its front side and with a second biopolymer layer on its back side, thus providing a composite fabric comprising a woven fabric and two bacterial biopolymer layers.
[0045] According to exemplary embodiments, the first biopolymer layer (on the front side) and the second biopolymer layer (on the back side) can comprise the same or a different bacterial biopolymer.
[0046] As used herein, the terms “bacterial biopolymer layer”, “bacterial polymer layer”, “biopolymer layer” and “polymer layer” refer to a layer comprising at least one bacterial biopolymer.
[0047] As used herein, the terms “bacterial biopolymer” and “bacterial polymer” refers to all the polymers the can be produced by a microorganism, where the term “microorganism” encompasses not genetically modified (i.e. wild type) microorganisms and genetically modified microorganism. For example, a microorganism can be genetically modified in order to produce a bacterial biopolymer which is not produced by the same microorganism when it is not genetically modified (i.e., when it is a wild type microorganism).
[0048] As used herein, the term “microorganism” refers to small unicellular or multicellular living organisms that are too small to be seen with naked eye but are visible under a microscope, and encompasses bacteria, yeast, fungi, viruses and algae. As above mentioned, the term “microorganism” encompasses not genetically modified (i.e. wild type) microorganisms and genetically modified microorganism as well.
[0049] In the present description, reference is made to “bacterial biopolymer” for sake of simplicity, without however limiting the scope of the invention to polymers produced by “bacteria” only, but encompassing all the polymers the can be produced by a microorganism as above defined.
[0050] According to embodiments of the invention, the bacterial biopolymer layer comprises a sugar-based biopolymer or an amino acid-based biopolymer or a mixture thereof.
[0051] As used in the present description, the term “sugar-based biopolymer” encompasses linear and branched polysaccharides, variants and derivatives thereof. One example of sugar-based biopolymer is bacterial cellulose.
[0052] As used in the present description, the term “amino-acid based biopolymer” encompasses linear and branched polypeptides, variants and derivatives thereof. One example of an amino acid-based biopolymer, is bacterial collagen.
[0053] According to various embodiments, the bacterial biopolymer is selected from bacterial cellulose, bacterial collagen or mixtures thereof.
[0054] According to some embodiments of the invention, said bacterial biopolymer layer comprises a bacterial biopolymer selected from bacterial cellulose, bacterial collagen, bacterial cellulose/chitin copolymer, bacterial silk, and mixtures thereof. These biopolymers are known per se in the art.
[0055] For example, a bacterial biopolymer according to the invention (e.g., the bacterial cellulose) can be produced by culturing bacterial biopolymer-producing microorganisms, which may be selected from bacteria, algae, yeast, fungi and mixtures thereof.
[0056] For example, a layer of bacterial collagen can be provided to the front side of the woven fabric and a layer of bacterial cellulose can be provided to the back side of the woven fabric.
[0057] According to embodiments of the invention, bacterial biopolymer-producing bacteria are selected from Gluconacetobacter, Aerobacter, Acetobacter, Achromobacter, Agrobacterium, Azotobacter, Salmonella, Alcaligenes, Pseudomonas; Rhizobium, Sarcina, Streptoccoccus and Bacillus genus, and mixtures thereof. According to embodiments of the invention, bacterial biopolymer-producing algae are selected from Phaeophyta, Rhodophyta and Chrysophyta , and mixture thereof.
[0058] For example, bacterial cellulose can be produced by culturing strains of Acetobacter bacteria, such as strains of Acetobacter xylinum , and/or by culturing strains of Gluconacetobacter, such as strains of Gluconacetobacter hansenil.
[0059] For example, bacterial collagen can be produced by culturing bacterial strains of Bacillus, Pseudomonas, Streptoccoccus or bacterial strains which have been genetically modified to obtain modified strains that produce collagen. Advantageously, bacterial collagen can be produced on the fabric to provide an artificial leather-like material, (“artificial leather” or “artificial skin”, wherein the main structural component of “leather” and “skin” is type I collagen in the form of strong fibrils). For example, bacterial cellulose/chitin copolymer can be produced by culturing strains of Acetobacter xylinum which have been genetically modified to obtain modified strains that produce bacterial cellulose/chitin copolymer.
[0060] According to exemplary embodiments of the invention, the bacterial biopolymer producing microorganisms are a mixture of wild type and genetically modified microorganisms.
[0061] According to various embodiments, step c of the process is carried out by contacting at least part of at least one plurality of warp yarns and/or at least part of at least one plurality of weft yarns, or at least part of a woven fabric with a culture of bacterial biopolymer-producing microorganisms, and culturing said bacterial biopolymer-producing microorganisms, to provide at least part of said at least one plurality of warp yarns and/or at least part of said at least one plurality of weft yarns, or at least part of said woven fabric with a bacterial biopolymer layer.
[0062] In other words, a composite fabric according to step c of the present invention can be obtained by providing a woven fabric with a bacterial biopolymer layer, that is “grown” (i.e. produced) directly on the fabric.
[0063] For example, a composite fabric according to the invention, can be advantageously obtained by contacting the front side and/or the back side of a woven fabric, with a culture of bacterial biopolymer-producing microorganisms, and culturing said bacterial biopolymer-producing microorganisms. More in detail, once the woven fabric is contacted with a culture of bacterial biopolymer-producing microorganisms, bacterial biopolymer-producing microorganisms are cultured, to produce a layer of bacterial biopolymer directly on the fabric, thus providing a composite fabric according to step c of the process of the invention.
[0064] According to embodiments, at least part of at least one plurality of warp yarns and/or at least part of at least one plurality of weft yarns, as provided in step a of the process of the invention, are provided with a bacterial biopolymer layer before the weaving according to step b.
[0065] For example, a bacterial biopolymer layer (e.g. a bacterial cellulose layer), advantageously a thin bacterial biopolymer layer (e.g. a “film” of bacterial biopolymer) can be grown directly on cotton yarns.
[0066] Advantageously, a bacterial biopolymer layer, provided onto yarns (warp and/or weft yarns) before the weaving, act as sizing agent, thus protecting the yarns during the weaving process.
[0067] Additionally, the bacterial biopolymer provided onto the yarns protects the yarns from damages also after the weaving step.
[0068] Moreover, when the bacterial biopolymer layer (e.g. a bacterial biopolymer film) is grown (i.e. produced) directly on the warp and/or weft yarns, it is possible to skip the step of sizing the yarns before the weaving and to skip the step of de-sizing after the weaving, thus reducing the costs for the production.
[0069] According to exemplary embodiments, at least part of at least one plurality of warp yarns and/or at least part of at least one plurality of weft yarns, as provided in step a of the process of the invention, are provided with a bacterial biopolymer layer and dyed before the weaving step according to step b.
[0070] For example, a bacterial biopolymer according to the invention can be produced (i.e. “grown”) on the yarns by contacting said yarns, with a culture of bacterial biopolymer-producing microorganisms, and culturing said bacterial biopolymer-producing microorganisms, before the weaving, thus providing “composite yarns”.
[0071] According to embodiments of the invention, the “composite yarns” may be woven to provide a woven fabric provided with a biopolymer layer, which may be subsequently dyed. Alternatively, or additionally, the composite yarns may be dyed before the weaving step.
[0072] According to exemplary embodiments, a bacterial biopolymer layer may be provided to a woven fabric according to step c by growing, i.e. producing, the biopolymer layer on the fabric, or by coupling the woven fabric with a bacterial biopolymer layer which is separately produced.
[0073] For example, a bacterial biopolymer layer separately produced can be coupled with a woven fabric by lamination, e.g. the layer of bacterial biopolymer is attached to the woven fabric through a cross-linking process; in other exemplary embodiments, the bacterial biopolymer layer is sewn on the front side and/or the back side of the woven fabric.
[0074] According to embodiments, the bacterial biopolymer layer is produced and dissolved and, subsequently, the yarns and/or the woven fabric are contacted with the dissolved biopolymer, to provide a composite fabric according to step c of the invention.
[0075] According to some embodiments, step c of the process of the invention is carried out by contacting at least part of the woven fabric (or at least some of the yarns before weaving) with a culture of bacterial biopolymer-producing microorganisms, and culturing said bacterial biopolymer-producing microorganisms, to provide the woven fabric with a bacterial biopolymer layer, thus obtaining a composite fabric.
[0076] Advantageously, by producing (i.e. growing) the bacterial biopolymer layer on the woven fabric (or on at least some of the yarns before weaving), a non-uniform bacterial biopolymer layer, as above discussed, can be obtained.
[0077] According to exemplary embodiments, the woven fabric (or the yarns before the weaving) may be contacted with a culture of bacterial biopolymer-producing microorganisms, by dipping the fabric (or the yarns) into the culture of bacterial biopolymer-producing microorganisms.
[0078] In other words, according to exemplary embodiments, at least part of the woven fabric, or at least part of the yarns (e.g. the yarns before the weaving) is contacted with a culture of microorganisms producing a bacterial biopolymer, by dipping said at least part of said woven fabric or at least part of said yarns into said culture of bacterial biopolymer-producing microorganisms. Advantageously, when the woven fabric is dipped into the culture of bacterial biopolymer-producing microorganisms, the bacterial biopolymer layer grows on both the sides (i.e. the front side and the back side of the woven fabric), thus providing a composite fabric wherein the woven fabric is provided with two bacterial biopolymer layers, which comprise the same biopolymer.
[0079] According to other exemplary embodiments, the culture of bacterial biopolymer-producing microorganisms is sprayed on at least part of said woven fabric (or on at least some of the yarns before weaving), such as on at least part of the front side of said woven fabric.
[0080] According to embodiments, the culture of bacterial biopolymer-producing microorganisms is sprayed on at least part of said woven fabric through a mesh wire.
[0081] Advantageously, by spraying the culture of bacterial biopolymer-producing microorganisms on at least part of said woven fabric through a mesh wire, the bacterial biopolymer layer is grown, i.e. produced, on the woven fabric as a discontinuous and non-uniform bacterial biopolymer layer, as above discussed.
[0082] The mesh wire may be removed before dyeing once the bacterial biopolymer is grown on the woven fabric. Advantageously, when the mesh wire is removed after the bacterial biopolymer is grown on the woven fabric, a bacterial biopolymer layer having a defined pattern is obtained.
[0083] According to embodiments, a dissolved biopolymer is sprayed on at least part of said woven fabric, advantageously on at least part of the front side of said woven fabric, thus providing a composite fabric according to step c of the process of the invention. Advantageously, by spraying the dissolved biopolymer on at least part of said woven fabric through a mesh wire, a discontinuous (uniform or non-uniform) bacterial biopolymer layer, as above defined, can be obtained.
[0084] According to various embodiments, the warp yarns and/or weft yarns are hydrophilic yarns.
[0085] Advantageously, when the warp yarns and/or the weft yarns are hydrophilic yarns, the culture medium of the bacterial biopolymer-producing microorganisms is absorbed by the yarns (before the weaving) or by the woven fabric, thus providing nutrients to the microorganisms and ingredients for the synthesis of the bacterial biopolymer layer, directly on the woven fabric.
[0086] According to embodiments of the invention, hydrophilic yarns are natural yarns, i.e. yarns that are made of natural fibers.
[0087] The natural yarns may comprise natural fibers selected from cotton, wool, flax, kenaf, ramie, hemp, and mixtures thereof.
[0088] According to embodiments of the invention, hydrophilic yarns are synthetic yarns, i.e. yarns that are made of synthetic fibers.
[0089] The synthetic yarns may comprise synthetic fibers selected from polyester, rayon, nylon, lycra and mixtures thereof. According to some embodiments, synthetic yarns and/or synthetic fibers are treated (i.e. finished) in order to provide synthetic yarns and/or synthetic fiber having hydrophilic properties.
[0090] For example, a synthetic yarns and/or synthetic fibers, that is not hydrophilic per se, can be treated with a hydrophilizing agent in order to gain hydrophilic features. According to embodiments, hydrophilic yarns are mixed yarns, i.e. yarns that comprise both natural and synthetic fibers. In this case, for example, a hydrophilic mixed yarn can be obtained by mixing hydrophilic natural fibers and hydrophobic synthetic fibers.
[0091] In embodiments of the invention, the warp yarns and/or the weft yarns are selected from natural yarns, synthetic yarns and mixed yarns. According to some embodiments, warp yarns and/or weft yarns are natural yarns. The natural yarns may comprise natural fibers selected from cotton, wool, flax, kenaf, ramie, hemp, and mixtures thereof.
[0092] In other embodiments of the invention, the warp yarns and/or the weft yarns are synthetic yarns, such as thermoplastic yarns which may advantageously be thermoplastic elastomeric yarns. The synthetic yarns may be synthetic fibers selected from polyester, rayon, nylon, Iycra and mixtures thereof.
[0093] In various embodiments of the invention, the warp yarns and/or the weft yarns of the woven fabric are mixed yarns, i.e. yarns comprising both natural fibers and synthetic fibers. In various embodiments of the invention, natural fibers and yarns are hard fibers and yarns. In exemplary embodiments of the invention, synthetic fibers and yarns are elastomeric fibers and yarns.
[0094] Suitable elastomeric yarns are yarns containing elastomeric fibers. An “elastomeric fiber” is a fiber made of a continuous filament or a plurality of filaments which have an elongation at break of at least 100%, independent of any crimp. Break elongation may be measured e.g. according to ASTM D2256/D2256M-10(2015). An “elastomeric fiber” is a fiber that after being stretched to twice its length and held for one minute at said length, will retract to less than 1.5 times its original length within one minute of being released.
[0095] According to one embodiment, a woven fabric suitable for use in the invention comprises warp yarns and weft yarns woven together, and has a front side and a back side, wherein said warp yarns and at least one plurality of weft yarns form a base layer of said woven fabric, and wherein a plurality of warp yarns and/or at least one plurality of weft yarns forms an additional layer of loop portions, on at least one of the sides of said woven fabric.
[0096] According to exemplary embodiments, fabric structures suitable to be used as “woven fabric” in a process according to the present invention are disclosed in patent application publication US2015/0038042 (see in particular paragraphs [0013], [0019]-[0027], [0030], [0031], [0033], [0049]-[0051], [0054], [0055], [0060], [0066], [0068][0071], [0075], [0076], [0078]-[0083], [0086], [0089]-[0117]) and in patent application US2013/0048140 (see in particular paragraphs [0007], [0010], [0013]-[0018], [0041]-[0046], [0048]-[0050], [0054]-[0059]and Examples 1, 3-8 and 10) whose descriptions are incorporated herein by reference.
[0097] In various embodiments, at least part of said additional layer of loop portions is included, e.g. embedded, into the bacterial biopolymer layer. The composite fabric of the present invention, may be a composite fabric as disclosed in co-pending application having title “Composite fabric comprising a bacterial biopolymer layer” in the name of the present applicant.
[0098] According to various embodiments, the woven fabric is a denim fabric.
[0099] According to embodiments of the invention, step d of the process of the invention is carried out by print-dyeing, such as by indigo print-dyeing or by dipping the composite fabric into a dye bath (for example, an indigo bath).
[0100] The best results are obtained with print-dyeing, dye-coating where the dye is applied only on the side of the fabric where the bacterial biopolymer (e.g. bacterial cellulose) is grown. That way the bacterial biopolymer (e.g. bacterial cellulose) behave as a barrier, hence unique visual effects can be obtained.
[0101] However, very good results were also obtained via conventional indigo dyeing methods, where the fabric is dipped into indigo bath (both sides of the fabric are dyed) and only during the washing treatments, as the bacterial biopolymer (e.g. bacterial cellulose) is removed, the color-shade variation appears. Here again, the thickness of the bacterial cellulose has an important role. The thicker the bacterial biopolymer (e.g. bacterial cellulose) is, the less of the dye can penetrate to the center of individual fibers, hence a shallow ring effect is observed and vice versa when the thickness is less the ring effect is deeper. This overall, creates visual color variations especially during washing treatments.
[0102] Advantageously, when the composite fabric, as obtained in step c, is dyed by print-dyeing, the print-dyeing is carried out on the side of the composite fabric where the bacterial biopolymer layer is placed.
[0103] In this case, advantageously, the bacterial biopolymer layer acts as a barrier during the print-dyeing process, thus preventing damages to the woven fabric underlying the bacterial biopolymer layer, and preventing the penetration of a great amount of dye into the woven fabric. For example, as above discussed, depending on the thickness and/or the pattern (i.e. continuity or discontinuity) of the bacterial biopolymer layer, the amount of dye which reaches and penetrates into the woven fabric varies.
[0104] According to embodiments, step d is carried out by dyeing said composite fabric with a dye selected from the group of indigo dye, sulfur dye, pigment dye, reactive dye. One method of application of the selected dye is print-dyeing; when print dyeing is used, any dye such as vat, direct, reactive can be used.
[0105] According to embodiments, step e of the process of the invention is carried out by finishing treatments, e.g. rinse wash, enzyme washing, stone washing, laser treatments etc., as well as laundry washing, in order to remove at least part of said at least one bacterial biopolymer layer from said composite fabric, thus providing a treated fabric according to the invention.
[0106] In other words, a bacterial biopolymer layer can be removed, at least in part, from the composite fabric by washing, e.g. laundry washing, the dyed composite fabric with water, thus substantially avoiding the use of chemical agents. According to embodiments, the step e of the process of the invention is carried out by abrading at least part of said at least one bacterial biopolymer layer from said composite fabric.
[0107] In other words, the removal of the bacterial biopolymer layer from the composite fabric, to obtain a treated fabric is carried out by abrading (i.e. “rubbing”, “scraping”) the bacterial biopolymer layer, damaging the biopolymer layer, removing substantially all the biopolymer layer, without damaging the fabric.
[0108] According to various embodiments, step e may be carried out by stone-washing said dyed composite fabric obtained in step d.
[0109] Advantageously, the stone washing of the composite fabric as obtained in step d of the process of the invention, i.e. the washing of the composite fabric in the presence of pumice stones, allows the effective and fast removal of the bacterial biopolymer layer, without damaging the woven fabric underlying the biopolymer layer, thus providing a treated fabric having a multi-shaded effect without affecting (i.e. reducing) the mechanical integrity and the properties of the fabric, such as the tensile strength.
[0110] According to an embodiment, step e is carried out by bio-stoning said dyed composite fabric obtained in step d.
[0111] Advantageously, the bio-stoning of the composite fabric as obtained in step d. of the process of the invention, i.e. the washing of the composite fabric in the presence of enzymes able to provide the removal of the bacterial biopolymer layer from the composite fabric, provides a treated fabric having a multi-shaded effect without affecting (i.e. reducing) the mechanical integrity and the properties of the fabric, such as the tensile strength, and substantially avoiding the use chemical agents and pollutants.
[0112] According to embodiments of the invention, step e. is carried out by laundry washing and/or stone washing and/or bio-stoning a garment comprising a composite fabric as obtainable in step d. of the process of the invention.
[0113] According to embodiments of the invention, step e. is carried out by laser treatment.
[0114] Another object of the invention is a treated fabric as obtainable by a process according to the invention.
[0115] Advantageously, a treated fabric obtained through the process of the invention presents a “multi-shaded” effect, namely a “multi-shaded” appearance, previously not available through known finishing processes. Specifically, as above discussed, the obtained “multi-shaded” effect comprises a plurality of shades of color, which are distributed throughout the fabric (and throughout a garment comprising it) according to a non-reproducible pattern, such as the same distribution of shades cannot be reproduced from a fabric to another.
[0116] According to an aspect of the invention, the “multi-shaded” effect of the treated fabric, depends on the thickness and/or the pattern (i.e. the continuity or discontinuity) of the bacterial biopolymer layer, which is provided onto the non-treated woven fabric, according to point c. of the process of the invention. For example, a “non-treated” woven fabric is provided with a bacterial biopolymer layer, thus providing a composite fabric. The composite fabric is subsequently dyed. At least part of the bacterial biopolymer layer is then removed from the dyed composite fabric, thus providing a treated fabric having a “multi-shaded” effect.
[0117] As above mentioned, the “multi-shaded” effect of the treated fabric, depends of the thickness and/or the pattern (i.e. the continuity or discontinuity) of the bacterial biopolymer layer. For example, a bacterial biopolymer layer can have a thickness T which schematically assumes three different values, namely T 1 , T 2 and T 3 , where T 3 >T 2 >T 1 .
[0118] In this case, the dye uptake of the biopolymer layer where the thickness is T 3 is more than the uptake where the thickness is T 2 , which is, in turn, more than the uptake where the thickness is T 1 . Therefore, if a certain amount of dye reaches the woven fabric underlying the bacterial biopolymer layer where the thickness of the biopolymer layer is T 1 , a lower amount of dye reaches the woven fabric where the thickness of the biopolymer layer is T 2 , and an even lower amount of dye reaches the woven fabric where the thickness is T 3 . In this case, a treated fabric having three different shades of color can be obtained.
[0119] It has to be noted that the above-mentioned example is merely a schematic description, in fact, the treated fabric of the invention has a “multi-shaded” appearance, i.e. the treated fabric presents numerous different color shades, due to the different penetration of the dye throughout the bacterial biopolymer layer.
[0120] According to embodiments of the invention, a treated fabric according to the invention comprises dyed yarns and portions of a dyed biopolymer layer; in other words, in embodiments of the invention a treated fabric as obtainable by a process according to the invention comprises residual bacterial biopolymer regions, i.e. regions wherein the bacterial biopolymer layer has been not completely removed.
[0121] A further object of the present invention is a garment comprising a treated fabric as obtainable by the process of the invention.
[0122] According to some embodiments, in a garment according to the invention, the front side of the treated fabric is the external visible side when the garment is worn, and the back side of the treated fabric is the internal not visible side when the garment is worn.
[0123] Another object of the present invention is a garment comprising a composite fabric as obtainable with the process of the invention. The fabric may be tailored into a garment after step b or c of the process of the invention.
[0124] According to embodiments of the invention, when a garment comprises a composite fabric as obtainable in step c or step d of the process of the invention, a “multi-shaded” effect can be advantageously obtained by removing at least part of the bacterial biopolymer layer from the garment, i.e. by removing at least part of the bacterial biopolymer layer from the composite fabric, after the composite fabric has been used for the production of a garment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0125] Further aspects and advantages of the present invention will be discussed more in detail with reference to the enclosed drawings, given by way of non-limiting example, wherein:
[0126] FIG. 1 is a perspective view of a portion of an exemplary woven fabric according to the invention, before undergoing step c of the process of the invention, i.e. a not-treated woven fabric;
[0127] FIG. 2 is a perspective view of a portion of a composite woven fabric according to the invention, as obtainable after step c of the process of the invention, i.e. a woven fabric provided with a bacterial polymer layer;
[0128] FIG. 3 is a perspective view of a portion of an exemplary composite fabric according to the invention, as obtainable after step d of the process of the invention, i.e. a dyed composite fabric;
[0129] FIGS. 4, 5, 6 and 7 are perspective views of exemplary embodiments of the treated fabric as obtainable by the process of the invention;
[0130] FIG. 8 shows an embodiment of the invention, wherein a culture of bacterial biopolymer-producing microorganisms is sprayed on an exemplary woven fabric through a mesh wire;
[0131] FIG. 9 is a perspective view of a portion of an exemplary composite fabric according to the invention, having a discontinuous bacterial biopolymer layer;
[0132] FIG. 10 is a perspective view of a portion of an exemplary composite fabric according to the invention, having a discontinuous bacterial biopolymer layer, after the dyeing process;
[0133] FIG. 11 is a perspective view of an exemplary embodiment of the treated fabric as obtainable by the process of the invention.
DETAILED DESCRIPTION
[0134] According to an aspect of the invention, the structure of the treated fabric is substantially the same of the non-treated woven fabric (i.e. the woven fabric before steps c, d and e of the process identified above). In other words, the process of the invention does not substantially modify the structure of the woven fabric which is subjected to the process of the invention.
[0135] Therefore, in this embodiment the “woven fabric” 1 (i.e. the fabric before steps c, d and e of the process of the invention) and the “treated fabric” 100 (i.e., the fabric after step e. of the process of the invention) shall be interpreted to be the same fabric before and after the process of the invention. In other words, a treated fabric is the woven fabric after having been treated according to the invention.
[0136] FIG. 1 is a perspective view of a portion of an exemplary woven fabric 1 according to the invention, before undergoing step c of the process of the invention, i.e. a not-treated woven fabric.
[0137] FIG. 1 shows a woven fabric 1 , having warp yarns 2 and weft yarns 3 , and having a front side 5 and a back side 6 . Weft yarns 3 and warp yarns 2 are woven in a pattern wherein weft yarns 3 pass over two warp yarns 2 , on the front side 5 of the fabric, and under one warp yarn 2 on the back side 6 .
[0138] It has to be noted that the weaving pattern illustrated in the present figures have to be intended as merely representative, and not limiting of the scope of the invention; in fact any kind of weaving pattern have to be considered as included in the scope of the claims. As above mentioned, the weaving pattern may contribute to the final appearance.
[0139] The woven fabric 1 represented in FIG. 1 is not dyed.
[0140] FIG. 2 is a perspective view of a portion of an exemplary composite fabric 10 , as obtainable after step c of the process of the invention. A woven fabric 1 is provided with a bacterial biopolymer layer 4 , on its front side 5 , thus providing a composite fabric 10 .
[0141] The back side 6 of the woven fabric 1 is also indicated in FIG. 2 . In this case, the back side 6 of the woven fabric 1 corresponds to the back side of the composite fabric 10 .
[0142] In the embodiment of FIG. 2 , the bacterial biopolymer layer 4 is schematically represented as a continuous and uniform layer, i.e a layer that covers continuously (i.e. without interruptions) the front side 5 of the woven fabric 1 and that maintains substantially the same thickness T over its entire extension. According to some embodiments, the bacterial biopolymer layer 4 is produced directly on the woven fabric 1 , namely by culturing bacterial biopolymer-producing microorganisms directly on the woven fabric 1 .
[0143] For example, the woven fabric 1 can be contacted with a culture of bacterial biopolymer-producing microorganisms, which are cultured directly on the woven fabric 1 . By culturing the microorganisms directly on the woven fabric 1 , the growing (i.e. the production) of a bacterial biopolymer layer 4 on the woven fabric 1 can be obtained.
[0144] In embodiments of the invention, the bacterial biopolymer layer 4 is a non-uniform layer, i.e. it has a thickness T which is variable throughout the extension of the bacterial biopolymer layer 4 .
[0145] In embodiments of the invention, the bacterial biopolymer layer 4 is a discontinuous layer, i.e. is an interrupted layer, thus providing areas of the woven fabric 1 which are not provided (i.e. not covered) with the bacterial biopolymer layer 4 .
[0146] FIG. 3 is a perspective view of a portion of an exemplary composite fabric 10 , as obtainable after step d of the process of the invention, i.e. a dyed composite fabric. FIG. 3 shows, in particular, the bacterial biopolymer layer 4 after dyeing. Similar to FIG. 2 , the bacterial biopolymer layer 4 is schematically represented as a continuous and uniform layer, i.e. a layer that covers continuously (i.e. without interruptions) the front side 5 of the woven fabric 1 and that maintains substantially the same thickness T over its entire extension. However, as above mentioned, in embodiments of the invention the bacterial biopolymer layer 4 is discontinuous and/or non-uniform. The back side 6 of the woven fabric 1 is also indicated in FIG. 3 . In this case, the back side 6 of the woven fabric 1 corresponds to the back side of the composite fabric 10 .
[0147] FIG. 4 shows a perspective view of an exemplary embodiment of a treated fabric 100 as obtainable by the process of the invention, i.e. after that at least part of the bacterial biopolymer layer 4 is removed from the composite fabric 10 .
[0148] FIG. 4 shows a treated fabric 100 , having warp yarns 2 and weft yarns 3 , and having a front side 5 and a back side 6 . Weft yarns 3 and warp yarns 2 are woven in a pattern wherein weft yarns 3 pass over two warp yarns 2 , on the front side 5 of the fabric, and under one warp yarn 2 on the back side.
[0149] FIG. 4 shows, schematically, an embodiment wherein the bacterial biopolymer layer 4 has been completely removed from the composite fabric 10 , e.g. from the front side 5 of the woven fabric 1 .
[0150] The treated fabric 100 , in the embodiment represented in FIG. 4 , presents, on its front side 5 , first regions 7 that are intensely colored, second regions 8 that are slightly colored (i.e., dyed with a lighter shade of color than the first regions 7 ), and third regions 9 that are substantially not colored, i.e. not dyed. FIG. 4 shows an embodiment if the treated fabric 100 wherein first regions 7 cover the most of the front side 5 of the treated fabric 100 . The treated fabric 100 of FIG. 4 presents second regions 8 which are colored with a lighter shade of color than the first regions 7 , and also presents third regions 9 which are substantially not dyed.
[0151] Accordingly, a treated fabric 100 as shown in FIG. 4 is substantially intensely dyed, and presents regions in a lighter shade and not-dyed regions, thus providing a substantially “light on dark” shade effect, namely a “light on dark” worn out look.
[0152] It has to be noted that FIG. 4 is merely a schematic representation of a treated fabric 100 according to the invention; in fact, the treated fabric 100 of the invention have a “multi-shaded” appearance, i.e. the treated fabric 100 presents numerous different color shades, due to the different penetration of the dye throughout the bacterial biopolymer layer 4 , namely through the thickness T of the bacterial biopolymer layer 4 .
[0153] This is particularly true in the embodiments of the invention, where the bacterial biopolymer layer 4 has a thickness T that is non-uniform, i.e. that is not the same throughout the extension of the bacterial biopolymer layer 4 ; in other words, where thickness T assumes different values in different regions of the bacterial biopolymer layer 4 .
[0154] In fact, if the composite fabric 10 presents a bacterial biopolymer layer 4 having variable thickness T, the dye uptake of the composite fabric 10 is variable in relationship with the variable thickness T of the bacterial biopolymer layer 4 .
[0155] In particular, it has been observed that, the higher is the thickness T, the higher is the dye uptake of the bacterial biopolymer layer 4 . In other words, when a composite fabric 10 presents a bacterial biopolymer layer 4 having variable thickness T, different amounts of dye reach the surface (i.e., for example, the front side 5 ) of the woven fabric 1 , in relationship with the variation of the thickness T along the extension of the bacterial biopolymer layer 4 .
[0156] For example, if the thickness T of the bacterial biopolymer layer is high, only a little amount (or none) dye reaches the surface (i.e., for example, the front side 5 ) of the woven fabric 1 , thus providing a treated fabric 100 with second regions 8 that are slightly colored and/or third regions 9 that are substantially not colored, i.e. not dyed.
[0157] On the contrary, for example, if the thickness T of the bacterial biopolymer layer is low, a greater amount of dye reaches the surface (i.e., for example, the front side 5 ) of the woven fabric 1 , thus providing a treated fabric 100 with first regions 7 , that are intensely colored.
[0158] According to various advantageous embodiments of the invention, growing the bacterial biopolymer layer 4 directly on the woven fabric 1 , a bacterial biopolymer layer 4 having a variable thickness T can be obtained.
[0159] For example, a treated fabric 100 , according to FIG. 4 , can be obtained when the bacterial biopolymer layer 4 (removed according to step e of the process of the invention) has a thickness T having value T 1 in correspondence of the first regions 7 , a thickness T 2 >T 1 in correspondence of second regions 8 , and a thickness T 3 >T 2 >T 1 in correspondence of third regions 9 . In this case, according to FIG. 4 , where the thickness T of the bacterial biopolymer layer 4 is T 3 , substantially all the dye is absorbed by the bacterial biopolymer layer 4 ; in other words, the dye does not substantially reach the surface (e.g. the front side 5 ) of the woven fabric 1 , thus providing a treated fabric 100 having third regions 9 that are substantially not colored. Additionally, where the thickness T of the bacterial biopolymer layer 4 is T 2 , only part of the dye reaches the surface (e.g. the front side 5 ) of the woven fabric 1 , thus providing a treated fabric 100 having second regions 8 that are slightly colored.
[0160] Moreover, where the thickness T of the bacterial biopolymer layer 4 is T 1 , substantially all the dye reaches the surface (i.e. the front side 5 ) of the woven fabric 1 , thus providing a treated fabric 100 having first regions 7 , that are intensely colored.
[0161] Accordingly, a treated fabric 100 as shown in FIG. 4 is substantially dyed, and presents not-dyed regions (namely third regions 9 ), and regions colored in a lighter shade (namely second regions 8 ), thus providing a “light on dark” shade effect, namely a “light on dark” worn out look.
[0162] FIG. 5 shows a perspective view of an exemplary embodiment of a treated fabric 100 as obtainable by the process of the invention, i.e. after that at least part of the bacterial biopolymer layer 4 is removed from the composite fabric 10 .
[0163] FIG. 5 shows a treated fabric 100 , having warp yarns 2 and weft yarns 3 , and having a front side 5 and a back side 6 . Weft yarns 3 and warp yarns 2 are woven in a pattern wherein weft yarns 3 pass over two warp yarns 2 , on the front side 5 of the fabric, and under one warp yarn 2 on the back side 6 .
[0164] FIG. 5 shows an embodiment, wherein the bacterial biopolymer layer 4 has been completely removed the composite fabric 10 , e.g. from the front side 5 of the woven fabric 1 , in step e of the process of the invention.
[0165] FIG. 5 represents a treated fabric 100 having, in its front side 5 , first regions 7 that are intensely colored, second regions 8 that are slightly colored (i.e., dyed with a lighter shade of color than the first regions 7 ), and third regions 9 that are substantially not colored, i.e. not dyed. FIG. 5 shows an embodiment of the treated fabric 100 wherein third regions 9 cover the most of the front side 5 of the treated fabric 100 . Treated fabric 100 presents first regions 7 , which are intensely dyed, and second regions 8 which are colored with a lighter shade of dye than the first regions 7 .
[0166] Therefore, a treated fabric 100 as shown in FIG. 5 is substantially not dyed, and presents intensely dyed regions (namely first regions 7 ), and slightly colored regions (namely second regions 8 ), thus providing a “dark on light” shade effect, namely a “dark on light” worn out look.
[0167] For example, a treated fabric 100 according to FIG. 5 can be obtained, when the bacterial biopolymer layer 4 (removed with step e of the process of the invention) has a thickness T 1 in correspondence of the first regions 7 , a thickness T 2 >T 1 in correspondence of second regions 8 , and a thickness T 3 >T 2 >T 1 in correspondence of third regions 9 .
[0168] For example, a bacterial biopolymer layer 4 having variable thickness T can be obtained by growing (i.e. producing) said biopolymer directly on the surface of the fabric, namely, on the front side 5 of the woven fabric 1 .
[0169] In this case, according to FIG. 5 , where the thickness T the bacterial biopolymer layer 4 is T 3 , substantially all the dye is absorbed by the bacterial biopolymer layer 4 ; in other words, the dye does not substantially reach the surface (e.g. the front side 5 ) of the woven fabric 1 , thus providing a treated fabric 100 having third regions 9 that are substantially not colored. Additionally, where the thickness T of the bacterial biopolymer layer 4 is T 2 , only part of the dye reaches the surface (e.g. the front side 5 ) of the woven fabric 1 , thus providing a treated fabric 100 having second regions 8 that are slightly colored. Moreover, where the thickness T of the bacterial biopolymer layer 4 is T 1 , substantially all the dye reaches the surface (i.e. the front side 5 ) of the woven fabric 1 , thus providing a treated fabric 100 having first regions 7 , that are intensely colored.
[0170] As already mentioned, FIG. 5 , as FIG. 4 , has to be intended as a schematic representation of a treated fabric 100 according to the invention, because, the treated fabric 100 according to the invention presents numerous different color shades (i.e. a multi-shaded effect), due to the different penetration of the dye, through the thickness T of the bacterial biopolymer layer 4 .
[0171] FIG. 6 , shows a perspective view of an exemplary embodiment of a treated fabric 100 , having warp yarns 2 and weft yarns 3 , and having a front side 5 and a back side 6 , as obtainable by the process of the invention, i.e. after that at least part of the bacterial biopolymer layer 4 is removed from the composite fabric 10 .
[0172] FIG. 6 shows an embodiment, wherein the bacterial biopolymer layer 4 has been completely removed from the composite fabric 10 , e.g. from the front side 5 of the woven fabric 1 , in step e of the process of the invention.
[0173] FIG. 6 shows an embodiment of the treated fabric 100 wherein second regions 8 cover the most of the front side 5 of the treated fabric 100 . Treated fabric 100 presents first regions 7 , which are intensely dyed, and third regions 9 which are substantially not dyed.
[0174] Therefore, a treated fabric 100 as shown in FIG. 6 is substantially “slightly dyed”, and presents intensely dyed regions (namely first regions 7 ), and substantially not-dyed regions (namely third regions 9 ), thus providing a “mixed” shade effect, i.e. a combination of a “dark on light” shade effect and a “light on dark” shade effect, e.g. a “mixed” worn out look.
[0175] For example, a treated fabric 100 according to FIG. 6 can be obtained, when the bacterial biopolymer layer 4 (removed with step e of the process of the invention) has a thickness T 1 in correspondence of the first regions 7 , a thickness T 2 >T 1 in correspondence of second regions 8 , and a thickness T 3 >T 2 >T 1 in correspondence of third regions 9 . For example, a bacterial biopolymer layer 4 having variable thickness T can be obtained by growing (i.e. producing) said biopolymer directly on the surface of the fabric, namely, on the front side 5 of the woven fabric 1 . In this case, according to FIG. 6 , where the thickness is T 3 , the dye does not substantially reach the surface (i.e. the front side 5 ) of the woven fabric 1 , thus providing a treated fabric 100 having third regions 9 that are substantially not colored. Where the thickness of the bacterial biopolymer layer 4 is T 1 , substantially all the dye reaches the woven fabric 1 , thus providing a treated fabric 100 having first regions 7 , that are intensely colored.
[0176] Additionally, where the thickness is T 2 , only part of the dye reaches the surface (i.e. the front side 5 ) of the woven fabric 1 , thus providing a treated fabric 100 having second regions 8 that are slightly colored.
[0177] FIG. 7 , illustrates an exemplary embodiment of the treated fabric 100 , having warp yarns 2 and weft yarns 3 , and having a front side 5 and a back side 6 , as obtainable by the process of the invention, i.e. after that at least part of the bacterial biopolymer layer 4 is removed from the composite fabric 10 .
[0178] FIG. 7 shows an embodiment, wherein the bacterial biopolymer layer 4 has been partially removed (i.e. not completely removed) from the composite fabric 10 , e.g. from the front side 5 of the woven fabric 1 , in step e of the process of the invention.
[0179] FIG. 7 shows an embodiment of the treated fabric 100 wherein residual bacterial biopolymer regions 4 a are present on the front side 5 of the treated fabric 100 . Said residual bacterial biopolymer regions 4 a are dyed.
[0180] The embodiment of FIG. 7 presents third regions 9 , which cover the most of the front side 5 of the treated fabric 100 ; in other words, the most of the front surface of the treated fabric 100 is not dyed. Treated fabric 100 presents first regions 7 , which are intensely dyed, and second regions 8 that are slightly colored (i.e., dyed with a lighter shade of color than the first regions 7 ).
[0181] The presence of the dyed residual bacterial biopolymer regions 4 a on the treated fabric 100 , provide a further “visual effect” which combines the peculiar color shade of the dyed bacterial biopolymer layer 4 with all the other shades of color on the treated fabric 100 . Additionally, the presence of the residual bacterial biopolymer regions 4 a provides the treated fabric 100 with a hand feel that is different from the hand feel of a fabric wherein the bacterial biopolymer layer 4 has been completely removed. With the varying of the amount of residual bacterial biopolymer layer 4 on the treated fabric 100 different hand touch effects can be obtained.
[0182] FIG. 8 shows an embodiment of the process of the invention, wherein the culture of bacterial biopolymer-producing microorganisms 200 is sprayed on an exemplary woven fabric 1 through a mesh wire 300 . Woven fabric 1 , has warp yarns 2 and weft yarns 3 , and has a front side 5 and a back side 6 . The woven fabric 1 represented in FIG. 8 is not dyed. In the embodiment of the process of the invention illustrated in FIG. 8 , the culture of bacterial biopolymer-producing microorganisms 200 is sprayed on an exemplary woven fabric 1 through a mesh wire 300 , by spraying means 201 . The mesh wire 300 is placed between the woven fabric 1 and the spraying means 201 , and has a mesh wire structure 301 defining mesh wire windows 302 .
[0183] Spraying the culture of bacterial biopolymer-producing microorganisms 200 through the mesh wire 300 , results in a non-homogeneous distribution of the biopolymer-producing microorganisms on the woven fabric 1 . For example, a patterned distribution of the biopolymer-producing microorganisms can be obtained, thus providing the woven fabric 1 , with regions that are contacted by the culture of biopolymer-producing microorganisms 200 and other regions that are not contacted by the sprayed culture of bacterial biopolymer-producing microorganisms 200 . The mesh wire 300 may be made of any material; application of the bacterial culture may be made by screen-printing.
[0184] In other words, the mesh wire 300 , that is placed on the front side 5 of the woven fabric 1 , “hides” some regions of the woven fabric 1 , i.e., the regions of the woven fabric 1 which lie under the mesh wire structure 301 . The regions of the woven fabric 1 that are “hidden” by the mesh wire structure 301 are substantially not contacted by the culture of bacterial biopolymer-producing microorganisms 200 which is sprayed from the spraying means 201 .
[0185] On the contrary, the sprayed culture of bacterial biopolymer-producing microorganisms 200 can reach the woven fabric 1 by passing through the mesh wire windows 302 of the mesh wire 300 , which do not hide the woven fabric 1 , and leave the portion of the woven fabric 1 in correspondence of the mesh wire windows 302 free to be contacted by the culture of bacterial biopolymer-producing microorganisms 200 , sprayed by the spraying means 201 .
[0186] As above mentioned, by culturing the bacterial biopolymer-producing microorganisms directly on the woven fabric 1 , it is possible to grow (i.e. to produce) a bacterial biopolymer layer 4 directly on the woven fabric 1 .
[0187] In exemplary embodiments, when the distribution of the biopolymer-producing microorganisms on the woven fabric 1 is a non-homogeneous distribution, a discontinuous (i.e. interrupted), bacterial biopolymer layer 4 can be obtained.
[0188] For example, as above mentioned, by spraying the culture of bacterial biopolymer-producing microorganisms 200 through the mesh wire 300 it is possible to obtain a woven fabric 1 having regions that are contacted by the culture of biopolymer-producing microorganisms 200 and other regions that are not contacted by the sprayed culture of bacterial biopolymer-producing microorganisms 200 . In this case, a discontinuous (i.e. interrupted) bacterial biopolymer layer 4 can be obtained, thus providing a composite fabric 10 having a discontinuous (i.e. interrupted) bacterial biopolymer layer 4 ; in other words, a woven fabric 1 with regions that are covered by the bacterial biopolymer layer 4 , and other regions which are not covered by the bacterial biopolymer layer 4 can be obtained.
[0189] Specifically, the regions of the woven fabric 1 contacted by the culture of biopolymer-producing microorganisms 200 are those regions of the woven fabric 1 which are in correspondence of the mesh wire windows 302 when the culture of bacterial biopolymer-producing microorganisms 200 is sprayed onto the woven fabric 1 ; such regions, after the culturing of the microorganism on the woven fabric 1 , result to be regions of the composite fabric 10 that are provided with the bacterial biopolymer layer 4 .
[0190] On the contrary, where the woven fabric 1 is hidden by the mesh wire structure 301 when the culture of bacterial biopolymer-producing microorganisms 200 is sprayed onto the woven fabric 1 , the culture of biopolymer-producing microorganisms 200 does not substantially contact the woven fabric 1 and, therefore, the bacterial biopolymer layer 4 is not produced, thus providing regions of the composite fabric 10 that are not provided with the bacterial biopolymer layer 4 . The mesh wire 300 may be removed before dyeing once the bacterial cellulose is grown on the fabric, which is about 10 to 23 hours, e.g. 14-18 hours.
[0191] FIG. 9 is a perspective view of a portion of an exemplary composite fabric 10 , having a discontinuous bacterial biopolymer layer 4 . The exemplary composite fabric 10 of FIG. 9 is obtained by spraying a culture of biopolymer-producing microorganisms 200 through a mesh wire 300 on a woven fabric 1 , and subsequently culturing the biopolymer-producing microorganisms directly on the woven fabric 1 , without removing the mesh wire 300 . The mesh wire 300 may be advantageously removed after the “growth” of the bacterial biopolymer layer 4 is completed to the desired degree, before the bacterial layer is removed at least in part from the fabric or the yarns.
[0192] The woven fabric 1 is thus coupled to a discontinuous bacterial biopolymer layer 4 , providing a composite fabric 10 . The exemplary embodiment of the composite fabric 10 of FIG. 9 , comprises a woven fabric 1 coupled to a discontinuous bacterial biopolymer layer 4 , on its front side 5 .
[0193] The back side 6 of the woven fabric 1 is also indicated in FIG. 9 . In this case, the back side 6 of the woven fabric 1 corresponds to the back side of the composite fabric 10 .
[0194] In the embodiment of FIG. 9 , the bacterial biopolymer layer 4 is schematically represented as a discontinuous uniform layer. Namely, bacterial biopolymer layer 4 of FIG. 9 is “discontinuous” because it covers the front side 5 of the woven fabric 1 with “interruptions”, i.e. leaving regions that are not provided with the bacterial biopolymer layer 4 . The bacterial biopolymer layer 4 of FIG. 9 is “uniform”, because it maintains the same thickness T over its entire extension.
[0195] In embodiments of the invention, the bacterial biopolymer layer 4 is a discontinuous non-uniform layer, i.e. it is an interrupted layer, and has a thickness T which is variable throughout the extension of the bacterial biopolymer layer 4 .
[0196] FIG. 9 shows an exemplary composite fabric 10 which is not dyed, i.e. which has not been subjected to a process of dyeing. FIG. 10 is a perspective view of a portion of an exemplary composite fabric 10 , having a discontinuous uniform bacterial biopolymer layer 4 . In particular, FIG. 10 shows the composite fabric 10 after dyeing. The exemplary embodiment of the composite fabric 10 of FIG. 10 , comprises a woven fabric 1 provided with a discontinuous uniform bacterial biopolymer layer 4 , having thickness T, on its front side 5 .
[0197] The back side 6 of the woven fabric 1 is also indicated in FIG. 10 . In this case, the back side 6 of the woven fabric 1 corresponds to the back side of the composite fabric 10 .
[0198] According to the embodiment of FIG. 10 , the bacterial biopolymer layer 4 is a discontinuous bacterial biopolymer layer 4 , and the regions of the woven fabric 1 which are not coupled with (namely “not covered by”) the bacterial biopolymer layer 4 are dyed, as well as the bacterial biopolymer layer 4 .
[0199] FIG. 11 shows a perspective views of an exemplary embodiment of a treated fabric 100 as obtainable by the process of the invention, i.e. after that at least part of the bacterial biopolymer layer 4 is removed from the composite fabric 10 . FIG. 11 shows a treated fabric 100 , having warp yarns 2 and weft yarns 3 and having a front side 5 and a back side 6 .
[0200] FIG. 11 shows an embodiment wherein the bacterial biopolymer layer 4 has been completely removed from the woven fabric 1 , and that is obtainable when the bacterial biopolymer layer 4 of the composite fabric 10 is a discontinuous layer, such as, for example, in the composite fabric 10 illustrated in FIG. 10 and FIG. 9 .
[0201] The treated fabric 100 of FIG. 11 presents, on its front side 5 , first regions 7 that are intensely colored, second regions 8 that are slightly colored (i.e., dyed with a lighter shade of color than the first regions 7 ), and third regions 9 that are substantially not colored, i.e. not dyed.
[0202] FIG. 11 shows an embodiment of the treated fabric 100 wherein first regions 7 correspond to those regions that were not coupled with the bacterial biopolymer layer 4 , i.e. those regions where the thickness T of the bacterial biopolymer layer 4 was zero. The treated fabric 100 of FIG. 11 further presents second regions 8 which are colored with a lighter shade of dye than the first regions 7 , and third regions 9 which are substantially not dyed.
[0203] Third regions 9 are obtained, for example, when the dye that is applied to the composite fabric 10 is completely absorbed by the bacterial biopolymer layer 4 and, therefore, does not reach the woven fabric 1 , which remains undyed.
[0204] Second regions 8 are obtained, for example, when part of the dye that is applied to the composite fabric 10 reaches the woven fabric 1 , thus providing the treated fabric 100 with second regions 8 which are colored with a lighter shade of dye than the first regions 7 , when the bacterial biopolymer layer 4 is removed. First regions 7 are obtained, for example, when the majority of the dye that is applied to the composite fabric 10 reaches the woven fabric 1 .
[0205] FIG. 11 is a schematic representation of a treated fabric 100 according to the invention; in fact, the treated fabric 100 of the invention have a shaded appearance, i.e. the treated fabric 100 presents numerous different color shades, due to the different penetration of the dye, throughout the bacterial biopolymer layer 4 , namely through the thickness T of the bacterial biopolymer layer 4 .
[0206] As above discussed, this is particularly true in the embodiments of the invention, where the bacterial biopolymer layer 4 has a thickness T that is not the same throughout the extension of the bacterial biopolymer layer 4 , i.e. thickness T can assume different values (e.g. T 1 , T 2 , T 3 ) in different regions of the bacterial biopolymer layer 4 , i.e. the bacterial biopolymer layer 4 is non-uniform.
[0207] The number of the shades of color is further increased in those embodiments wherein the bacterial biopolymer layer 4 is discontinuous. In fact, the dye uptake of the composite fabric 10 is substantially determined by the thickness T of the bacterial biopolymer layer 4 . In particular, it has been observed that, the higher is the thickness T, the higher is the dye uptake. In other words, when a composite fabric 10 presents a bacterial biopolymer layer 4 having variable thickness T, different amounts of dye reach the surface (i.e., for example, the front side 5 ) of the woven fabric 1 .
[0208] For example, if the thickness T of the bacterial biopolymer layer 4 is high, a little, or none, dye reaches the surface (i.e., for example, the front side 5 ) of the woven fabric 1 , thus providing the treated fabric 100 with second regions 8 that are slightly colored and/or third regions 9 that are substantially not colored, i.e. not dyed.
[0209] On the contrary, for example, if the thickness T of the bacterial biopolymer layer 4 is low, or the bacterial biopolymer layer 4 is absent (e.g. when the bacterial biopolymer layer 4 is discontinuous) a great amount of dye reaches the surface (i.e., for example, the front side 5 ) of the woven fabric 1 , thus providing the treated fabric 100 with first regions 7 , that are intensely colored.
EXAMPLES
[0210] The following examples illustrate a process for the production of a treated fabric according to various embodiments of the disclosure.
[0211] The following examples are to be interpreted as merely illustrative and they do not limit the scope of the invention.
Example 1
[0212] 25 ml of a culture of Gluconacetobacter hansenii having a concentration of 2×10 4 cells/ml, is sprayed culture on the front side of a sample woven fabric according to the invention. The culture used is a culture of Gluconacetobacter hansenii , in in Hestrin-Schramm (HS) medium containing 2% (w/v) glucose, 0.5% (w/v) peptone, 0.5% (w/v) yeast extract, 0.27% (w/v) Na2HPO4 and 1.15 g/L citric acid.
[0213] Illustrative examples of woven fabrics according to the invention, which were used according to the present “Examples” are the following:
[0214] 1. “Rigid”—12 oz 100% cotton:
[0215] Warp yarns are Ne 7/1-10/1
[0216] Weft yarns are Ne 8/1-10/1
[0217] Warp density of the fabric is 25-28 threads/cm
[0218] Weft density of the fabric is 17-20 picks/cm
[0219] The weight of the woven fabric is 640-670 g/m
[0220] The front side of the woven fabric has a surface density of 407-423 g/m 2
[0221] Materials that can be used for the woven fabric, in particular for warp yarns, are cotton, cotton and other staple fibers blend, or staple fibers apart from cotton (CottoniTencel, Cotton/Modal, Cotton/PES, Cotton/Bamboo, 100%PES, 100% Tencel, Modal or Tencel/Modal blends).
[0222] 2. “Comfort”—12 oz cotton/elastane (18%-25% elasticity):
[0223] Warp yarns are Ne 7/1-10/1
[0224] Weft yarns are Ne 10/1-12/1
[0225] Warp density of the fabric is 27-31 threads/cm
[0226] Weft density of the fabric is 17-21 picks/cm
[0227] The weight of the woven fabric is 500-550 g/m
[0228] The front side of the woven fabric has a surface density of 407-423 g/m 2
[0229] Materials that can be used for the woven fabric, in particular for warp yarns, are cotton, cotton and other staple fibers blend, or staple fibers apart from cotton (Cotton/Tencel, Cotton/Modal, Cotton/PES, Cotton/Bamboo, 100% PES, 100% Tencel, Modal or Tencel/Modal blends).
[0230] 3. “Super stretch”—12 oz cotton/elastane (40%-65% elasticity):
[0231] Warp yarns are Ne 9/1-12/1
[0232] Weft yarns are Ne 15/1-18/1
[0233] Warp density of the fabric is 29-32 threads/cm
[0234] Weft density of the fabric is 20-24 picks/cm
[0235] The weight of the woven fabric is 464-490 g/m
[0236] The front side of the woven fabric has a surface density of 407-423 g/m 2
[0237] Materials that can be used for the woven fabric, in particular for warp yarns, are cotton, cotton and other staple fibers blend, or staple fibers apart from cotton (Cotton/Tencel, Cotton/Modal, Cotton/PES, Cotton/Bamboo, 100% PES, 100% Tencel, Modal or Tencel/Modal blends).
Example 2
[0238] After the application (spraying) of the bacterial culture of Example 1 on the woven fabric, the woven fabric is incubated for 16 hours, at temperature 28° C. After 16 hours, at temperature 28° C., a layer of bacterial cellulose having a thickness ranging from 0.5 mm to 1 mm, with an average value of 0.75 mm is obtained on the front side of the woven fabric, i.e. a composite fabric is obtained.
Example 3
[0239] After the bacterial cellulose layer growth is completed, the composite fabric obtained in Example 2 is washed with 0.1 M NaOH at 80° C. temperature to remove the residual bacteria and all the impurities coming from the growth medium including the bacteria, and in NaOCI, for 20 minutes to remove the residual bacteria from the composite fabric.
[0240] After the removal of residual bacteria and all the impurities coming from the growth medium including the bacteria, the composite fabric is print-dyed, with a dye selected from indigo, pigments, reactive and sulphur dyes. The composite fabric may be print-dyed with indigo on its front side, i.e. on the side wherein the bacterial cellulose layer is present.
[0241] Alternatively, the composite fabric may be VAT dyed with conventional indigo dyeing (i.e. on both sides of the fabric).
Example 4
[0242] The dyed composite fabric obtained in Example 3 is finished through one or more finishing techniques.
[0243] For example, the dyed composite obtained in Example 3 may be rinsed with water 20 minutes at 40° C. Additionally or alternatively, the dyed composite fabric obtained in Example 3 may be or stone washed (i.e. washed in the presence of pumice stone) 20 minutes at 40° C., followed by enzyme wash for 10 minutes at 50° C. to remove small hair (pilling) created by the stone wash.
[0244] Additionally or alternatively, the dyed composite obtained in Example 3 may undergo stone bleaching, for 20 minutes at 40° C. Additionally or alternatively, the dyed composite fabric obtained in Example 3 may undergo laser treatments. One or more of the above-mentioned techniques are used to remove the bacterial cellulose layer, thus obtaining a treated fabric according to the invention.
[0245] As used herein, “exemplary” means “as an example” and therefore an “exemplary embodiment” should not be considered to refer to a preferred or superior embodiment, but rather to “an example.” As such, an “exemplary embodiment” is used to mean “as one example, an embodiment of the disclosure.”
[0246] Although the invention has been described in terms of various embodiments, it is not limited thereto. Rather, the appended claims should be construed broadly, to include other variants and embodiments of the invention, which may be made by those skilled in the art without departing from the scope and range of equivalents of the invention.
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The present invention provides a process for the production of a fabric having a unique appearance and the fabric so obtained. Also provided is the clothing articles, i.e. garments, including the fabric. More particularly, the present invention relates to a process for producing a woven fabric having a unique, e.g. “used” (i.e. worn-out) or “multi-shaded” appearance and the process includes a step of providing a woven fabric with a layer of bacterial biopolymer, dyeing at least part of the fabric together with the biopolymer layer, and then removing at least part of the bacterial biopolymer layer from the fabric.
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BACKGROUND OF INVENTION
1. Field of the Invention
The present invention relates generally to the field of streaming. More specifically, the present invention is related to analyzing streaming data in packetized form.
2. Discussion of Prior Art
Many electronic networks such as local area networks (LANs), metropolitan area networks (MANs), and wide area networks (WANs) are increasingly being used to transport streaming media whose real-time data transport requirements exhibit high sensitivity to data loss and delivery time distortion. The technical literature is replete with various schemes to implement Quality of Service (QOS) on such networks to address the requirements of streaming media, especially when intermixed with conventional, time-insensitive, guaranteed delivery protocol stack data traffic. Furthermore, for efficiency reasons, the streaming media transport often uses a non-guaranteed delivery upper layer protocol stack such as UDP/IP making recovery of data in the presence of packet loss difficult. Regardless of whether QOS-enabled or non-QOS-enabled networks are employed, it is necessary to monitor the behavior of packet loss, delivery time distortion, and other real-time parameters of the network to assure satisfactory quality streaming media delivery.
There exists a variety of defined Management Information Bases (MIBs) which include definitions for a number of network parameters such as packet loss, inter-arrival times, errors, percentage of network utilization, etc., whose purpose is to indicate to a network manager the general operating conditions of the network. Such traditional forms of monitoring network behavior cannot easily indicate the effects that network performance has on a single or a group of individual streaming media streams. Data gathering from MIBs operating across a range of network layers combined with a highly skilled and experienced practitioner would be required to simply determine the jitter imposed on a single MPEG video stream, for instance, and would only be possible by post-processing data gathered while the network was in operation. Determining the cause of a fault in a streaming media stream may be possible through such analysis but lacks the real-time indication of a network fault that is required to maintain high-quality networks such as for video or audio delivery. It also does not address the need to monitor large numbers of streams in real-time such as streams of Video-on-Demand (VoD) networks using less technically skilled operations personnel, as would be necessary to enable implementation of continuous cost-effective quality control procedures for widely deployed networks such as for VoD.
Histograms are often used in prior art schemes to present the arrival time behavior of packets on a network, but such histograms only represent the aggregate behavior of packets arriving at the measurement node due to the need to combine MIB data from a range of network layers to extract sufficient information to track a particular stream's performance. Traditional histograms define the jitter between any two packets. Streaming media requires more in-depth knowledge, such as the time variation across many packets referred to as the “network jitter growth”. This network jitter growth affects the streaming media quality as experienced by the user due to intermediate buffer overflow/underflow between the media source and its destination.
Network jitter growth of a media stream due to traffic congestion can also be an indicator of an impending fault condition and can thus be used to avoid transport failures rather than simply to react to faults after they occur. Conventional post-processed MIB analysis is inadequate for these purposes as described above.
The concept of regulating stream flow in a network based on the leaky bucket paradigm describes a methodology that might be used to prevent intermediate buffer overflow and packet jitter by regulating the outflow of data based on a set of parameters configured to optimize a particular flow. This does not address the need to analyze and continuously monitor multiple streams as is required during the installation and operation of networks carrying streaming media, especially for those enterprises whose revenue is derived from the high quality delivery of streaming media, such as broadcast and cable television entities.
A common prior art scheme used to effectively monitor multiple video streams is to decode each stream's MPEG content (for the video example) and display the streams on a large group of television screens. Monitoring personnel then watch the screens looking for any anomalous indications and take appropriate corrective action. This is a highly subjective and error prone process, as there is a possibility that a transient fault might be missed. This is also a reactive process, as corrective action can only be taken after a fault has occurred. Furthermore, this is also an expensive process in terms of both equipment and personnel costs. It also provides little or no indications of the root cause of the fault, thus adding to the time required for implementing corrective action. This approach also does not easily scale to modern video delivery systems based upon emerging, cost-effective high-bandwidth, networks intended to transport thousands of independent video streams simultaneously. In addition, this approach cannot pinpoint the location of the fault. To do so, the personnel and equipment must be replicated at multiple points in the distribution network, greatly increasing the cost. For this to be effective, the personnel must monitor the same stream at exactly the same time for comparison.
Many types of network delivery impairments are transient in nature affecting a limited number of packets during a period of momentary traffic congestion, for example. Such impairments or impairment patterns can be missed using traditional monitoring personnel watching video monitors. By not recognizing possible repeating impairment patterns, faults can exist for much longer periods because after the fault has passed, there is no residual trace information available for analysis. The longer a fault persists, the worse the customer satisfaction levels, and the greater the potential for lost revenues.
Whatever the precise merits, features, and advantages of the above-mentioned prior art schemes, they fail to achieve or fulfill the purposes of the present invention.
SUMMARY OF INVENTION
The present invention provides for a system and method for analyzing packetized network traffic. In one embodiment, the system comprises: (a) one or more interfaces to forward a copy of the network traffic comprising one or more streams; (b) one or more filters to receive and filter the forwarded network traffic to isolate at least one stream; and (c) a native streaming interface to receive packetized data corresponding to the isolated stream(s), wherein the native streaming interface provides minimum time distortion to permit media stream analysis and monitoring to indicate the network's influence on the isolated stream(s) and measure each isolated stream's conformance to a pre-determined stream standard.
In one embodiment, the system for analyzing packetized network traffic comprises: (a) a compute engine to compute statistics associated with an isolated stream, wherein the statistics for each stream comprise at least a delay factor (DF) defining an instantaneous flow rate balance representing a virtual buffer delay that is needed to prevent data loss and absorb network jitter growth; and (b) one or more interfaces to forward the computed statistics for each streams of interest to a data consumer.
In another embodiment, the present invention provides for a system and method for analyzing packetized network traffic comprising one or more transportation streams. The system comprises: (a) one or more network interfaces to receive streaming network traffic associated with the transportation streams; (b) one or more filters to filter one or more streams of interest in the received transportation streams; (c) a compute engine comprising one or more finite state machines to compute index values associated with the streams of interest, wherein the index values for each stream comprising at least: a delay factor (DF) and a media loss rate (MLR); and (d) one or more interfaces to forward the computed index values for the streams of interest to a data consumer.
In another embodiment, the present invention's method comprises the steps of: (a) receiving network traffic comprising one or more transportation streams; (b) filtering the received traffic and isolating a transportation stream from the transportation streams; (c) computing statistics associated with the isolated transportation stream, wherein the statistics comprise at least a delay factor (DF) and a media loss rate (MLR); and (d) forwarding the computed statistics to a data consumer.
The DF value defines an instantaneous flow rate balance representing a virtual buffer delay that is needed to prevent data loss and absorb network jitter growth, and the MLR value represents the number of media packets lost or corrupted.
BRIEF DESCRIPTION OF DRAWINGS
FIGS. 1 a - c illustrate several methods of tapping an existing network traffic flow via the present invention's computing element.
FIG. 2 illustrates one embodiment of the present invention's computing element which analyzes network traffic.
FIG. 3 illustrates an extended embodiment of the present invention wherein a controller is used for controlling the computing element.
FIG. 4 illustrates another extended embodiment of the present invention wherein an encoder is used to encode the statistics calculated by the computing engine.
FIG. 5 illustrates an internal block diagram of the computing element and its interconnection with the control and logging system.
FIG. 6 illustrates an adder and a counter that form a part of the compute engine.
FIG. 7 illustrates a method associated with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
While this invention is illustrated and described in a preferred embodiment, the invention may be produced in many different configurations. There is depicted in the drawings, and will herein be described in detail, a preferred embodiment of the invention, with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and the associated functional specifications for its construction and is not intended to limit the invention to the embodiment illustrated. Those skilled in the art will envision many other possible variations within the scope of the present invention.
Many streaming media systems, such as VoD, broadcast television control centers, or satellite-based video distribution operations utilize packetized data networks for their low-cost and omnipresence in modern data systems. The present invention monitors these existing network conduits by sampling the data contained therein with minimal alteration of its characteristics.
FIGS. 1 a - c illustrate several methods of tapping an existing network traffic flow via the present invention's computing element 105 . FIG. 1 a illustrates a setup wherein an ordinary network switch or router 103 , which, while performing packet switching or routing on the traffic from its many ports, such as 101 and 102 , also provides for a “mirror” or “monitor” port 104 . Port 104 makes all data from a desired port available to the present invention's computing element 105 . Alternatively, as shown in FIG. 1 b , a passive network tap 108 diverts a portion of the network traffic flow energy from one network port 106 to the other network port 107 and transmits that portion via a port 109 to the present invention's computing element 105 . FIG. 1 c illustrates yet another method to tap the existing network flow via inserting the present invention's computing element 105 directly in-line with the network link to be observed via network ports 110 and 111 .
In the examples of FIGS. 1 a - b , the computing elements 105 used in each case are identical. In the example of FIG. 1 c , the computing element 105 also actively forwards all traffic from network connection 110 to network connection 111 and vice versa, while simultaneously providing all traffic to the equivalent internal functionality of the computing elements designated 105 .
FIG. 2 illustrates one embodiment of the present invention's computing element 105 which analyzes network traffic 202 . Computing element 105 comprises at least one network interface 204 to receive network traffic, one or more filters 206 to filter the received network traffic, at least one computing engine 208 to compute network statistics associated with the filtered network traffic via one or more finite state machines 210 , and at least one network interface 212 to accept control instructions and transmit the computed statistics to a data consumer. Network interface 204 interfaces with the network link to be monitored via network connections 203 . Network link protocols that support such packet-based transmission include, but are not limited to, 802.3 (Ethernet), 802.4, 802.5, USB, ATM, SONET, 802.11, Fibre-channel, Firewire or 1394, Infiniband, Bluetooth, 802.11, 802.15, 802.16, 802.17, ZigBee, or a native streaming video interface such as DVB-ASI.
The streaming media traffic of interest, which may consist of many individual streams of traffic, is filtered (via one or more filters 206 ) from the incoming network traffic 202 and processed by the finite state machines 210 of computing engine 208 to reduce its measured transmission characteristics to a set of statistics or critical parameters known as an “Index”. The Index can be communicated to a logging system with alarm values set for convenient human monitoring. For example, warnings can be forwarded to a data consumer when the computed statistics exceeds a predetermined threshold or rate-of-change. It should be noted that one computing engine can be used to track several streams of interest. Similarly, one or more computing engines can be used to track several streams of interest. Hence, the number of computing engines or the number of streams to be tracked should not be used to limit the scope of the present invention.
In one preferred embodiment, the Index, known as the Media Delivery Index (MDI) consists of two parts: the Delay Factor (DF) and the Media Loss Rate (MLR). This embodiment is especially valuable for constant bit rate MPEG-2 Transport Streams carried over a network such as a packetized network. The DF represents the Instantaneous Flow Rate Balance (IFRB) and is derived in the computing element. The MLR represents the number of lost or corrupted media packets and is readily derived from tracking the Continuity Counter (CC) for the MPEG-2 transport stream application or from a sequence counter or the like for protocols, such as RTP, which support the same. The MDI (DF:MLR) then represents the two key factors which describe the dynamic behavior of streaming media over packetized networks: packet jitter growth and packet loss. This Index provides at-a-glance determination of traffic impairment as well as an indication of the operating margin of a network. By modifying the calculation of the IFRB, the DF may also be used with variable bit rate streaming media transport over packetized networks.
FIG. 3 illustrates an extended embodiment of the present invention wherein a controller 302 is used for controlling the computing element 105 . Controller 302 transmits, via an interface, control instructions from a management system to modify system-level state-based logic data associated with the computing element 105 , and receives, via the interface, the analysis results generated by the computing element 105 .
FIG. 4 illustrates another extended embodiment of the present invention wherein encoder 402 is used to encode the statistics calculated by computing engine 208 . Then, the encoded statistics 404 is transmitted to a data consumer via one or more interfaces 212 . Some examples of encoding include (but are not limited to) encryption (such as for security), compression, or code format conversion (e.g., convert data in an ASCII format for readability).
It should be noted that more than one network interface can be used to receive network traffic. For example, FIG. 5 illustrates computing element 105 (as used in FIG. 1 c ) with two network interfaces 516 and 517 , wherein computing element 105 is used for analyzing one or more streaming media flows. The two network interfaces 516 and 517 interface with the network link to be monitored via network connections 514 and 515 . As in FIG. 2 , network link protocols that support such packet-based transmission include, but are not limited to, 802.3 (Ethernet), 802.4, 802.5, USB, ATM, SONET, 802.11, Fibrechannel, Firewire or 1394, Infiniband, Bluetooth, 802.11, 802.15, 802.16, 802.17, ZigBee, or DVB-ASI. In operation, data received from network connection 515 is decoded via network interface 517 and the resulting data is forwarded to the filter and compute engine 520 and to the other network interface 516 . Then, network interface 516 forwards the data to the network connection 514 , thus completing the connection from network interface 515 . Thus, all data received from network interface 515 is forwarded to network interface 514 with a minimum of distortion while making all the same data available for analysis by other components of the computing element. Likewise, all data from network connection 514 is forwarded to network connection 515 while also being forwarded to the filter and compute engine 520 . The result is a continuous full duplex connection between network connections 514 and 515 providing an uninterrupted network traffic flow while simultaneously providing all network data to the filter and compute engine 520 . Alternatively, as per FIG. 1 a and FIG. 1 b , the computing element 105 may require only a single network interface, but otherwise performs as described above, with network data being forwarded to the filter and compute engine 520 .
The filter and compute engine 520 is configured via interface 521 such that it can filter the desired streaming media flows from other network traffic types for further analysis. For example, to analyze MPEG-2 streaming video over UDP/IP protocols, the filter can be configured to accept only layer-2 packets with the IP protocol type and only IP frames with UDP protocol types and only UDP datagrams that encapsulate MPEG-2 transport streams. After performing the appropriate filtering function, the compute engine calculates the components that comprise the Index value for a given streaming media flow. The Index values, and other statistics regarding the flow, are forwarded to the network interface 522 via interface 521 . Then, interface 523 is used to convey the Index values to a data consumer such as an application running, for example, in a workstation consisting of control software and a logging system 524 , collectively referred to as a “management” system. Network Interface 522 need not be the same type as 516 or 517 (i.e., a RS-232 serial port). Its bandwidth via the choice of physical and link layer protocols may be scaled or sized to match the amount of data expected to be handled. It should be noted that network interface 522 , interface 523 , and workstation (management system) 524 may be physically co-located with the computing element 105 and need not be external.
In one embodiment, the compute engine comprises at least one finite state machine counter as shown in FIG. 6 . The finite state machine counter is used to compute an Instantaneous Flow Rate Balance (IFRB). Counter 628 is loaded when a packet has been received via 627 . The counter is loaded with the sum of the current count and the number of bits received in this packet 625 from the adder 626 . Counter 628 decrements its count at each clock input pulse 629 whose rate is set to the nominal streaming media rate. Further, counter 628 is cleared at any time via the 632 clear signal. The counter output 630 indicates the number of bits that have been received at the point of test but not yet consumed, assuming that a virtual terminal device which consumes or “uses” the streaming media flow (such as a video decoder for a streaming video media case) drains the data received at a nominal media rate at this network location. Thus, the counter output 630 represents the size of a buffer that would be needed to prevent data loss and absorb the network jitter growth due to data arriving via a packetized network. It should be noted that counter 628 may also result in negative numbers during periods between a burst of data thus representing the size of a virtual terminal's buffer needed to be prefilled to avoid underflow. Adder 626 and counter 628 may also be combined into a single entity to simply track the net difference between bits received on the packetized network side and the bits out based upon an expected drain rate. The actual quantity being tracked may be bits or any derivative thereof (bytes, words, etc.). It is important to note that the bits counted are only those subject to the drain rate. Typically, this is the payload of the packet (i.e., no headers or overhead.) For example, in the case of an MPEG-2 transport stream sent via Ethernet IP/UDP, the bits tracked would typically be the MPEG-2 transport stream packets contained within the Ethernet frame, excluding the IP/UDP headers and Ethernet CRC. The present invention further extends to using streaming media streams that are variable bit rate in nature. Variations in media bit rate may be accommodated by monitoring and updating the expected drain rate used in IFRB calculation along with the stream. Since this finite state machine is simple, it can operate at common media rate speeds and can be replicated easily and compactly if implemented in hardware such as an FPGA, ASIC, or discrete logic, making possible an array of such machines such that one may be dedicated to each streaming media flow. Furthermore, the filter and compute engine can also be configured to capture and track other streaming media flow parameters of interest such as an MPEG-2 transport steam's continuity counters to detect dropped or corrupted packets, stream identifiers, etc.
It should be noted that computing the Instantaneous Flow Rate Balance (IFRB), and thus DF, requires knowledge of the expected media drain rate either by prior knowledge or by measurement. The expected drain rate, and thus stream bitrate, may also be referred to as the media consumption rate, as this is the rate at which the receiver of the media stream must consume that stream. It is possible that the local estimation of the drain rate may drift or be offset with respect to the actual media streams' bitrate due to frequency drift or offset between the source of the media streams' clock and our local processing clock. This drift or offset causes monotonically increasing or decreasing IFRB and virtual buffer calculations, and may be mitigated by periodically clearing the current state of the IFRB and virtual buffer. Another approach utilizes a well known method entailing Phase Locked Loops (PLL) or Delay Locked Loops (DLL) to remove the drift or offset.
Returning to the discussion of FIG. 5 , streaming media flow parameters as described above can be forwarded via a network Interface 521 , and network connection 522 , and external network 523 , or via any type data interface as they are captured or buffered in a memory in the filter and compute engine for later retrieval by a workstation 524 . In some instances, the streaming media content itself may be presented to the workstation 524 via the same path for additional analysis. They may be combined with a time stamp at either the filter and compute engine 520 or the workstation 524 . Long term logs may be maintained by 524 for trend analysis, coincident analysis with other network events, the start and end of particular streaming media flows, etc. Alternatively, workstation 524 can show an instantaneous view of streaming media parameters for human monitoring. High and low watermark values may be set in the computing element 105 or in the workstation 524 for the Index parameter or any measured parameter, such that if exceeded, will be logged or trigger an alarm; this functionality may be used to warn of possible impending faults such as deviations from nominal in the flow rates that could cause a network or terminal device buffer to overflow or underflow. The Index value indicates the network's instantaneous operating jitter margin. Additionally, the rate of sampling of such parameters can be reduced to decrease the load on interface 523 during benign network conditions or increased to provide a more detailed analysis of an identified fault. Either the computing element or workstation 524 may produce long term analysis as well by performing additional computational operation on the IFRB.
In some instances, workstation 524 functionality may be integrated with the filter and compute engine for a direct display of information to the user.
It should be noted that a pure hardware, a pure software, and a hybrid hardware/software implementation of the filter and compute engine components is envisioned and should not be used to limit the scope of the present invention.
It should be noted that various kinds of interfaces can be used for establishing a packet-based communication session between the external interfaces ( 514 or 515 or 523 ) and the computing element, such as (but not limited to) a gigabit Ethernet network controller or a 10/100 Mbit/s Ethernet network interface card. Moreover, one skilled in the art can envision using various current and future interfaces and, hence, the type of packetized network interface used should not be used to limit the scope for the present invention.
In one embodiment, bandwidth for the transportation of network parameters via interface 523 as discussed above is allocated in an “on-demand” fashion, wherein full channel (network conduit) bandwidth is allocated and available to the data consumer. Compute engine 520 can track nearly any set of parameters or events, such as the last N-packets received or statistics acquired, storing it in a circular buffer. Thus, when a critical event occurs such as streaming media data loss, bandwidth would be allocated “on-demand” to report the tracking information leading up to the critical event to the workstation analysis device 524 through the interface 523 . Having pertinent information about what traffic the network was handling (not only at the time of the critical event but leading up to it as well) presented “on-demand” at the time of the critical event is very powerful. Having this information greatly reduces the “hunting” time required to identify the cause of the critical event. This information could be gathered remotely as well, given a suitable network type for 523 . Expanding on the “on-demand” possibilities for parameter reporting, bandwidth may also be allocated “on-demand” on either network interfaces 514 or 515 in an in-band reporting fashion, facilitating the monitoring by equipment on the same distribution network as the streaming media.
If the network Interface 523 is an ASI (Asynchronous Serial Interface, as in DVB-ASI) type and the streaming media content itself is presented to the Interface in such a way as to minimize instrument timing distortions, a conventional streaming media specific analyzer or monitor may be utilized to not only measure the stream's conformance to expected stream standards but also to indicate the influence of network behavior. In this configuration, the computing element may be thought of as a protocol converter as well.
The present invention's system can be used in debugging various embedded systems within the streaming media's transport network. Various equipment utilized in the transportation or creation of the streaming media may allow debugging and/or parameter manipulation via the transport network as well as provide its own statistical operational information (i.e., its own system “health”). This makes possible the cross-correlation of the system's overall state/health. The invention acquires such control information via a network channel and may use its filter and compute engine capabilities to provide either the raw or processed data to a Workstation Monitor/Logger as described for Index data above.
The present invention allows the implementer the ability to scale the amount of in-band or out-of-band measured or sampled data to pass through the system up to the maximum supported by the network conduit and down to nothing. Additionally, the present invention provides the ability to scale with improvements in network conduit technology. For example, the faster the network conduit, the more measurements or sampled data can pass. Moreover, as high-speed systems continue to evolve, their network conduit's bandwidth is usually increased proportionately to facilitate the use of the high-speed system itself (i.e., a faster network conduit is part of the main feature-set of the system; bandwidth is thereby increased by necessity). The present invention accommodates such increases in bandwidth associated with the network conduit and utilizes such high-speed systems to extract measurements or sampled data at a faster rate.
FIG. 7 illustrates a method 700 associated with an embodiment of the present invention. In step 702 , network traffic is received by a network interface, wherein the traffic comprises one or more streams of packetized data. Next, in step 704 , the received traffic is filtered to isolate at least one stream of packetized data. In step 706 , an Index is computed for the filtered stream of packetized data. In one preferred embodiment, the Index, known as the Media Delivery Index (MDI), consists of two parts: the Delay Factor (DF) and the Media Loss Rate (MLR). The DF represents the Instantaneous Flow Rate Balance (IFRB) and is derived in the computing element as described earlier. The MLR represents the number of lost or corrupted media packets and is readily derived from tracking the Continuity Counter (CC) for the MPEG-2 transport stream application or from a sequence counter or the like for protocols, such as RTP, which support the same. The MDI (DF:MLR) then represents the two key factors which describe the dynamic behavior of streaming media over packetized networks: packet jitter growth and packet loss. This Index provides at-a-glance determination of traffic impairment as well as an indication of the operating margin of a network. Then, in step 708 , the computed statistics are forwarded to a data consumer, such as one running in a workstation. In one embodiment, a quality of service (QOS) metering scheme is implemented based upon adjusting traffic priority between the forwarded computed network statistics and the streaming network traffic.
Furthermore, the present invention includes a computer program code-based product, which is a storage medium having program code stored therein which can be used to instruct a computer to perform any of the methods associated with the present invention. The computer storage medium includes any of, but not limited to, the following: CD-ROM, DVD, magnetic tape, optical disc, hard drive, floppy disk, ferroelectric memory, flash memory, ferromagnetic memory, optical storage, charge coupled devices, magnetic or optical cards, smart cards, EEPROM, EPROM, RAM, ROM, DRAM, SRAM, SDRAM, and/or any other appropriate static or dynamic memory or data storage devices.
Implemented in computer program code-based products are: (a) receiving network traffic comprising one or more transportation streams; (b) filtering the received traffic and isolating a transportation stream from the transportation streams; (c) computing statistics associated with the isolated transportation stream comprising at least a delay factor (DF) and a media loss rate (MLR), wherein DF defines an instantaneous flow rate balance representing a buffer size that is needed to prevent data loss and absorb network jitter growth, and MLR represents the number of media packets lost or corrupted; and (d) forwarding the computed statistics to a data consumer.
CONCLUSION
A system and method has been shown in the above embodiments for the effective implementation of a system and method for measuring and exposing the dynamic behavior of streaming media over a packet-based network. While various preferred embodiments have been shown and described, it will be understood that there is no intent to limit the invention by such disclosure but, rather, it is intended to cover all modifications and alternate constructions falling within the spirit and scope of the invention as defined in the appended claims. For example, the present invention should not be limited by the number of network interfaces, number of filters, number of streams handled by the compute engine, type of packetized network conduit, location of control software, choice of hardware or software implementation of bandwidth provisioning or filter or compute engine, type of streaming media data, choice of hardware or software implementation of the “on-demand” embodiment, computing environment, or specific hardware associated with the network interfaces, filter device, or compute engine system.
The above systems are implemented in various computing environments. For example, the present invention may be implemented on a conventional IBM PC or equivalent, multi-nodal system (e.g., LAN) or networking system (e.g., Internet, WWW, wireless web). All programming and data related thereto are stored in computer memory, static or dynamic or non-volatile, and may be retrieved by the user in any of: conventional computer storage, display (i.e., CRT) and/or hardcopy (i.e., printed) formats. The programming of the present invention may be implemented by one skilled in the art of computer systems and/or software design.
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A packetized streaming media delivery network carries many “streams” of differing media content. They often are from multiple sources and of different media types. The invention consists of a scalable hardware and/or software computing element resolving the network traffic into its individual streams for focused, simultaneous, and continuous real-time monitoring and analysis. The monitoring and analysis consists of delay factor and media loss rate which measure the cumulative jitter of the streaming media within the delivery network and the condition of the media payload. These measurements form a powerful picture of network problem awareness and resolution. The delay factor objectively indicates the contribution of the network devices in the streams' path, allowing for both problem prediction and indication. In one example, tapping a packetized network at various locations allows for correlation of the same-stream performance at various network points to pinpoint the source(s) of the impairment(s).
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is related to Japanese Patent Application No. 2002-149588 filed on May 23, 2002, whose priority is claimed under 35 USC § 119, the disclosure of which is incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a manufacturing method of a semiconductor substrate. In particular, the present invention relates to a manufacturing method of a semiconductor substrate that is effective in gaining a high quality silicon substrate wherein distortion of silicon is utilized.
[0004] 2. Description of Related Art
[0005] In recent years extensive research has been carried out concerning the manufacture of a high mobility transistor wherein a hetero structure is fabricated using a material having a lattice constant that is different from that of Si, that is to say, a film of a material having a lattice constant different from that of silicon substrate is grown on a silicon substrate in an epitaxial manner and, thereby, distortion due to compression or stretching in the horizontal direction is provided in the film so that the distortion is utilized in order to achieve an increase in the speed of a MOSFET (Metal Oxide Semiconductor Field Effect Transistor), in place of a conventional technology wherein a MOS interface of Si—SiO 2 is used as a channel.
[0006] The technology shown in FIGS. 3 ( a ) to 3 ( e ) is cited as an example of a manufacturing technology for a MOSFET wherein distortion is utilized.
[0007] First, as shown in FIG. 3( a ), a SiGe layer 2 is grown in an epitaxial manner to have a thickness of approximately 300 nm and to have a concentration of Ge of 20 atom % on a silicon substrate 1 and a Si layer 3 is sequentially grown in an epitaxial manner to have a thickness of approximately 20 nm on the SiGe layer.
[0008] Next, as shown in FIG. 3( b ), hydrogen ions are implanted into the entirety of the surface of the gained silicon substrate 1 and, after that, a heat treatment is carried out at approximately 800° C. As a result of this heat treatment, stacking faults 5 extending from micro voids 4 of hydrogen that have occurred in the vicinity of the hydrogen implantation peak reach to the interface between SiGe layer 2 and silicon substrate 1 and, furthermore, cause threading dislocations 6 in the direction of the interface. Distortion in SiGe layer 2 is relaxed due to the occurrence of these threading dislocations 6 in the direction of the interface. At this time, distortion due to stretching is generated in Si layer 3 on SiGe layer 2 , wherein the distortion is relaxed and the mobility is increased in Si layer 3 .
[0009] After that, as shown in FIGS. 3 ( c ) and 3 ( d ), the procedure passes through a conventional STI (Shallow Trench Isolation) process so that element isolation regions 11 are formed and, furthermore, as shown in FIG. 3( e ), a gate insulating film 12 , a gate electrode 13 and source/drain regions 14 are formed according to a general manufacturing process so that a MOSFET is completed.
[0010] According to the above described manufacturing method, however, in the case wherein the amount of implantation of hydrogen ions is sufficient to complete the relaxation of SiGe layer 2 in the step of implantation of hydrogen ions as shown in FIG. 3( b ), excessive micro voids 4 of hydrogen are formed due to the subsequent heat treatment and excessive stacking faults are formed. These excessive stacking faults do not stop at the interface between SiGe layer 2 and silicon substrate 1 but cause threading dislocations 6 that reach to the surface of Si layer 3 . These threading dislocations 6 caused by micro voids 4 of hydrogen are fixed by micro voids 4 of hydrogen and, therefore, it is difficult to remove threading dislocations 6 in the subsequent steps.
[0011] Thus, the amount of implantation of hydrogen ions is set at an amount of implantation lower than the amount that completely relaxes SiGe layer 2 and, thereby, prevention of the occurrence of threading dislocations 6 due to micro voids 4 of hydrogen in the subsequent heat treatment is attempted.
[0012] However, even in the case wherein the amount of implantation of hydrogen ions is set at an amount of implantation lower than the amount that completely relaxes SiGe layer 2 , new occurrences of threading dislocations 6 from the interface between SiGe layer 2 and silicon substrate 1 in the subsequent heat treatment as shown in FIG. 3( b ) cannot be avoided. Accordingly, the procedure passes through a conventional STI process as shown in FIGS. 3 ( c ) and 3 ( d ) under such conditions so that a MOSFET is fabricated and, then, many threading dislocations 6 are found beneath source/drain regions 14 as shown in FIG. 3( e ) wherein the leakage current increases at the time when a reverse voltage is applied to these junctions and, therefore, there is a problem wherein a manufacturing technology for a high quality MOSFET cannot be established.
SUMMARY OF THE INVENTION
[0013] The present invention is provided in view of the above described problem and a purpose thereof is to provide a manufacturing method of a semiconductor device wherein threading dislocations 6 can be relaxed so that the junction leakage current can be restricted to the minimum even in the case wherein threading dislocations 6 occur starting from the interface between SiGe layer 2 and silicon substrate 1 .
[0014] The present invention provides a manufacturing method of a semiconductor substrate comprising the steps of: (a) forming a SiGe layer on a substrate of which the surface is made of silicon; (b) further forming a semiconductor layer on the SiGe layer; and (c) implanting ions into regions of the SiGe layer in the substrate that become element isolation formation regions, and carrying out a heat treatment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIGS. 1 ( a ) to 1 ( e ) are schematic cross sectional views showing the main portion of a semiconductor substrate in the respective steps of a manufacturing method of a semiconductor substrate for describing an embodiment of the present invention;
[0016] [0016]FIG. 2 is a schematic cross sectional view showing the main portion of a semiconductor device that utilizes a semiconductor substrate gained according to the methods of FIGS. 1 ( a ) to 1 ( e ); and
[0017] FIGS. 3 ( a ) to 3 ( e ) are schematic cross sectional views showing the main portion of a semiconductor device in the respective steps for describing a manufacturing method of a semiconductor device according to a prior art.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] According to the manufacturing method of a semiconductor substrate of the present invention, first, in Step (a), a SiGe layer is formed on a substrate of which the surface is made of silicon.
[0019] The substrate of which the surface is made of silicon may be a silicon substrate made of amorphous silicon, microcrystal silicon, single crystal silicon, polycrystal silicon or silicon wherein two, or more, of these crystal conditions are mixed or may be a so-called SOI substrate having such a silicon layer on the surface. In particular, a single crystal silicon substrate is preferable.
[0020] The SiGe layer can be formed according to a variety of conventional methods such as, for example, a CVD method, a sputter method, a vacuum deposition method or an MEB method. In particular, it is preferable to form the SiGe layer according to an epitaxial growth method by means of a CVD method. The film formation conditions in this case can be selected from the conditions known in the field of the art and, in particular, a film formation temperature of, for example, from 400° C. to 900° C., preferably from approximately 400° C. to 650° C., is appropriate. Concretely, it is preferable for the film formation temperature to be 500° C., or below, in the case wherein a SiGe layer is grown to have a concentration of Ge in the range described below, for example, a SiGe layer is grown to have a concentration of Ge of 30 atom %. The concentration of Ge in this SiGe layer is not specifically limited and, for example, a concentration of from approximately 10 atom % to 50 atom %, preferably, from 10 atom % to 40 atom %, more preferably, from 20 atom % to 30 atom %, can be cited. It is preferable for the SiGe layer to be a thick film so that shift dislocations at the interface between the SiGe layer and the silicon substrate that occur in a subsequent annealing step for relaxation of distortion do not negatively affect a semiconductor device, for example a MOSFET, that may be formed on top of the above. In general, the lowering of the growth temperature is effective as a technique for increasing film thickness. On the other hand, it is preferable for the film to have a film thickness that is thinner than the film thickness wherein relaxation of lattice distortion in an SiGe layer occurs when the SiGe layer is deposited on the substrate, that is to say, to have a film thickness that is thinner than the critical film thickness. Concretely, a thickness of from approximately 50 nm to 500 nm can be cited and, furthermore, a thickness of from approximately 100 nm to 500 nm is appropriate. In particular, it is preferable for the SiGe layer to have a film thickness of 300 nm, or greater, taking into consideration the formation of a PN junction in a subsequent step.
[0021] Next, in Step (b), a semiconductor layer is formed on the gained substrate. The semiconductor layer is not specifically limited as long as it has a diamond structure in the same manner as silicon. Si, Si to which C has been added or a SiGe layer having a concentration of Ge that is lower than that in the above described SiGe layer, for example, can be cited as the semiconductor layer. In particular, a silicon (Si) layer is preferable. The concentration of C in SiC is not specifically limited and a concentration of from approximately 0.1 atom % to 2 atom %, for example, can be cited. In addition, it is appropriate for the concentration of Ge in the SiGe to be approximately 10 atom %, or less. The semiconductor layer can be formed according to the same method as is the SiGe layer and it is preferable for the semiconductor layer to be formed within the same device after the formation of the SiGe layer by, for example, switching the growth gases. Thereby, oxygen pollution, or the like, on the surface of the SiGe layer can be reduced. It is preferable for the temperature of the substrate in this case to be from approximately 400° C. to 650° C. It is preferable for the film thickness of the semiconductor layer to be a thick film, taking into consideration the reduction in the film thickness in subsequent manufacturing steps for the semiconductor device as well as diffusion of Ge from the SiGe layer, and the like, while it is preferable for the semiconductor layer to be formed so as to have a film thickness less than the critical film thickness in order to suppress the occurrence of defects on the Si layer caused by distortion due to stretching after the step of relaxation of distortion of the SiGe layer. Here, it is preferable wherein the higher is the concentration of germanium in the SiGe layer, the thinner is the semiconductor layer, and wherein the higher is the heat treatment temperature in the manufacturing process for the semiconductor device subsequently carried out, the thinner is the semiconductor layer. Concretely, the film thickness is from approximately 1 nm to 100 nm and, more preferably, from approximately 5 nm to 30 nm, and, in particular, it is appropriate for the film thickness to be approximately 20 nm, or less, in the case wherein the semiconductor layer is formed on a SiGe layer having a concentration of Ge of 30 atom % and it is appropriate for the film thickness to be approximately 50 nm, or less, in the case of a concentration of Ge of 20 atom %.
[0022] Here, it is preferable to implant ions into the gained substrate and to carry out a heat treatment after the formation of the SiGe layer and after the formation of the semiconductor layer. It is appropriate to carry out ion implantation using elements that can introduce lattice defects in the surface of the utilized silicon substrate as well as elements that can create micro cavities in the silicon substrate as a result of annealing after ion implantation, or the like, and such elements can be selected from the group consisting of hydrogen, inert gases and elements of group IV. Concretely, hydrogen, helium, neon, silicon, carbon, germanium, and the like can be cited as such elements and, in particular, hydrogen is preferable. The acceleration energy for ion implantation can be appropriately adjusted depending on the type of used ions, the film thickness of the SiGe layer, the material and film thickness of the semiconductor layer, and the like. It is desirable to set the acceleration energy at a value, for example, wherein the implantation peak is located at a position in the silicon substrate in the vicinity of the interface between the SiGe layer and the substrate and, more concretely, wherein the peak is located at a depth of approximately 20 nm, or greater, (preferably at a depth of from approximately 30 nm to 70 nm) in the substrate from the interface in order to prevent defects in the SiGe layer and in order to prevent the SiGe layer from becoming a thin film. A value of from approximately 20 keV to 150 keV, preferably from approximately 30 keV to 35 keV, can be cited as the implantation energy and, more concretely, a value of from approximately 18 keV to 25 keV can be cited as the implantation energy in the case wherein the SiGe layer has a film thickness of approximately 200 nm and wherein hydrogen is used. A dose value of approximately 2×10 16 cm −2 , or less, can be cited.
[0023] Furnace annealing, lamp annealing, RTA, and the like, for example, can be cited as types of annealing that can be carried out in an inert gas atmosphere, in a standard atmosphere, in a nitrogen gas atmosphere, in an oxygen gas atmosphere, in a hydrogen gas atmosphere, or the like, at a temperature in a range of from 600° C. to 900° C. for from approximately 10 minutes to 30 minutes.
[0024] Furthermore, in Step (c), ions are implanted into regions of the SiGe layer on the substrate that become element isolation formation regions and a heat treatment is carried out. Here, the implanted ions can be selected, for example, from the group comprising of hydrogen, inert gases and elements of groups II to V. Concretely, ions of hydrogen, helium, neon, silicon, carbon, germanium, arsenic, phosphorous, boron, and the like, can be cited and, in particular, silicon ions, germanium ions, arsenic ions, and the like, are preferable wherein silicon ions are more preferable. The acceleration energy for ion implantation can be appropriately adjusted depending on the type of used ions, the film thickness of the SiGe layer, the material and film thickness of the semiconductor layer, and the like. It is preferable to set the acceleration energy, for example, at a value wherein the implantation peak is located in an upper portion of the SiGe layer and, more concretely, wherein the peak is located at a position of the SiGe layer approximately 20 nm above the interface. A value of from approximately 20 keV to 150 keV, for example, can be cited as the implantation energy. A dose value of approximately 1×10 15 cm −2 , or greater, for example, can be cited.
[0025] Here, it is preferable to create trenches, of which the bottoms are located in the SiGe layer, in regions that become element isolation formation regions before the ion implantation in the above step so that ions are implanted into the bottoms of these trenches. Trenches can be created according to a well-known photolithographic and etching process. Here, etching may be by anisotropic or isotropic etching or by dry or wet etching, and anisotropic etching is preferable. The size and form of trenches are not specifically limited and can be appropriately adjusted in accordance with the design of the semiconductor device that is desired to be gained. The depth of trenches can be appropriately adjusted depending on the film thickness, or the like, of the SiGe layer and a depth of from approximately 200 nm to 450 nm can be cited. Here, in the case of creation of trenches, it is preferable to carry out ion implantation so that the implantation peak of ions is located in the vicinity of the bottoms of the trenches and, therefore, it is necessary to set the acceleration energy for ion implantation at a value of from approximately 20 keV to 60 keV.
[0026] The heat treatment can be carried out according to the same method as described above. In particular, it is preferable for the temperature to be set at from approximately 550° C. to 650° C.
[0027] In the following, a manufacturing method of a semiconductor device according to the present invention is described in detail in reference to FIGS. 1 ( a ) to 1 ( e ).
[0028] According to the manufacturing method of a semiconductor device of the present invention, first, as shown in FIG. 1( a ), SiGe layer 2 is grown in an epitaxial manner to have a thickness of approximately 300 nm and to have a concentration of Ge of 30 atom % using a well-known CVD (Chemical Vapor Deposition) method at a temperature of from 400° C. to 900° C. in an atmosphere of a mixed gas of SiH 4 and GeH 4 diluted with a hydrogen gas on the surface of a p type Si single crystal substrate (hereinafter referred to as silicon substrate 1 ) in the plane direction (100) having a concentration of doped boron of approximately 1×10 15 cm −3 that is used in a conventional Si manufacturing process. Then, Si semiconductor layer 3 is grown in an epitaxial manner to have a thickness of approximately 20 nm on SiGe layer 2 using a CVD method at a temperature of from 400° C. to 900° C. wherein the growth gas is switched to a SiH 4 gas diluted with a hydrogen gas utilizing the same manufacturing unit.
[0029] Next, as shown in FIG. 1( b ), a dose of hydrogen ions of 2×10 16 cm −2 , or less, is implanted using an implantation energy of from 30 keV to 35 keV and, after that, a heat treatment is carried out at a temperature of 600° C., or higher.
[0030] As a result of this heat treatment the implanted hydrogen ions grow to become micro voids 4 and stacking faults (dislocations) 5 grow around the voids, which serve as nuclei, so as to cause a shift at the interface between SiGe layer 2 and silicon substrate 1 and, thereby, distortion of SiGe layer 2 is relaxed. Here, the positions wherein micro voids 4 of the hydrogen ions are created correspond to the position of the implantation peak and threading dislocations 6 , which have reached to the inner surfaces of the stacking faults that have occurred due to a factor other than the hydrogen at this time, are thermodynamically stable and remain until the final step, in the case wherein there are no elimination sites, so as to cause leakage from a PN junction and, therefore, it is necessary to reduce such threading dislocations.
[0031] Then, as shown in FIG. 1( c ), a well-known photolithographic technology is used to form a resist pattern 7 for the formation of element isolation regions and this resist pattern (resist as an etching mask) 7 is used to etch SiGe layer 2 and Si layer 3 to a depth of 350 nm by means of a well-known RIE (Reactive Ion Etching) method using a SF 6 gas and, thereby, trenches 8 for element isolation are created. After that, a dose of Si ions of 1×10 15 cm −2 is implanted into the bottoms of trenches 8 for element isolation using an implantation energy of 40 KeV by means of a well-known ion implantation method. After that, a heat treatment is carried out at the comparatively low temperature of approximately 600° C. and, thereby, stacking faults 9 are created in the bottoms of trenches 8 for element isolation.
[0032] Here, it is necessary for the amount of the implantation of the Si ions to be 1×10 15 cm −2 , or greater, in order to convert SiGe layer 2 into an amorphous layer and the conditions concerning the implantation energy are selected so that the implantation peak is 20 nm, or greater, in order to form nuclei of stacking faults. The annealing temperature is set at 600° C. in the case of utilization of SiGe so that recovery from damage can progress and nuclei can be formed.
[0033] After that, as shown in FIG. 1( d ), trenches 8 for element isolation are filled in with SiO 2 , which is formed of a SiH 4 gas and an O 2 gas by means of a well-known CVD method and, then, flattening is carried out by removing the SiO 2 film from regions other than the element isolation regions by means of a well-known CMP (Chemical Mechanical Polishing) method so that element isolation regions 11 are formed.
[0034] A SiO 2 film may be formed by means of the well-known CVD method and, next, a SiN film may be formed in an atmosphere of SiH 4 and NH 3 by means of the well-known CVD method after the step of FIG. 1( b ) in order to increase the process margin for the etching of the SiO 2 according to the above described CMP method. The SiN film is used to stop the etching at the time of the CMP.
[0035] Next, a heat treatment is carried out at a temperature of from 800° C. to 1000° C. Thereby, the threading dislocations 6 in the active regions in FIG. 1( c ) can be shifted towards stacking faults 9 created in FIG. 1( d ) so as to be trapped in stacking faults 9 . These trapped dislocations 10 are thermally stable and are not released again as a result of the heat treatment at a temperature of 1000° C., or below, that is subsequently carried out in the Si manufacturing process.
[0036] Next, as shown in FIG. 1( e ), a gate insulating film 12 , a gate electrode made of an N type polycrystal Si film and N type source/drain regions 14 are formed according to a well-known MOSFET manufacturing technology so that the MOSFET is completed.
[0037] SiGe layer 2 , which has a thickness of 300 nm, and Si layer 3 , which has a thickness of 20 nm, are formed on silicon substrate 1 , into which a p type impurity of approximately 1×10 15 cm −2 has been doped, and gate electrode 13 is formed above the Si layer with gate insulating film 12 intervened in the semiconductor device manufactured in the above described manner, as shown in FIG. 2. Source/drain regions 14 are formed on both sides of gate electrode 13 and a channel region is formed in SiGe layer 2 directly beneath gate electrode 13 between source/drain regions 14 . This semiconductor device is isolated from other elements by means of trench-type element isolation regions 11 .
[0038] In addition, micro voids 4 are created at a depth of approximately 50 nm from the interface between SiGe layer 2 and silicon substrate 1 and stacking faults (dislocations) 5 that develop from these micro voids 4 extend to the interface between SiGe layer 2 and silicon substrate 1 so as to relax the majority of the distortion in SiGe layer 2 .
[0039] Furthermore, stacking faults 9 are created beneath element isolation regions 11 wherein dislocations 10 occurring due to the relaxation of the distortion in SiGe layer 2 are captured by these stacking faults 9 .
[0040] Thereby, threading dislocations 6 , which have occurred in a region of SiGe layer 2 wherein the MOS transistor is formed, are shifted toward stacking faults 9 so as to be captured by stacking faults 9 and, as a result, almost no defects are found in the region wherein the MOS transistor is formed. That is to say, the number defects in the active region of SiGe layer 2 can be reduced by utilizing the stacking faults created by means of ion implantation into SiGe layer 2 beneath element isolation regions 11 .
[0041] As described above according to the present invention, relaxation of the distortion at the interface between the silicon substrate and the SiGe layer is promoted and, at the same time, stacking faults that occur due to shift at the SiGe/Si interface can be prevented by utilizing the stacking faults that develop from microscopic defects by means of a heat treatment after the relaxation of distortion due to hydrogen ion implantation.
[0042] However, in the case wherein an excessive number of stacking faults have developed from microscopic defects, created due to hydrogen ion implantation, these stacking faults become the cause of the occurrence of defects in the SiGe layer. It is necessary to create an excessive number of microscopic defects, due to ion implantation, in order to completely relax the distortion in the SiGe layer and, thereby, dislocations occur in the SiGe layer.
[0043] Thus, an amount of ions smaller than an amount that will completely relax the SiGe layer is implanted and a heat treatment is carried out so that stacking faults that have developed from the interface between the SiGe layer and the silicon layer also partially relax the SiGe layer. In this case, the stacking faults that have developed from the interface between the SiGe layer and the silicon layer and that have reached the surface shift in a thermally random manner in the direction perpendicular to the surface of the substrate when the temperature is raised. Therefore, according to the present invention, the stacking faults are shifted toward the element isolation regions that cover the periphery of a normally active region so that dislocations are erased therein.
[0044] Therefore, an excessive amount of silicon ions is introduced into the silicon substrate by means of an ion implantation method so that stacking faults that occur at the time when a device is formed at a comparatively low temperature are utilized. The dislocations that have once been captured by these stacking faults are converted to a stable condition with respect to energy and, therefore, most of these dislocations do not shift toward the active region during heat treatment in a conventional manufacturing process for a transistor and, therefore, no problems are caused.
[0045] Accordingly, defects that may lead to junction leakage during the electrical operation of a MOS transistor are eliminated and a MOS transistor with excellent characteristics can be implemented.
[0046] According to the present invention, dislocations in an active region, which cause problems in the case wherein a high speed MOSFET is formed using a provisional substrate including SiGe, are trapped beneath element isolation regions so that the active region is not negatively affected and, thereby, a semiconductor substrate can be manufactured wherein junction leakage, which has conventionally been problematic, can be greatly reduced. It becomes possible by utilizing such a semiconductor substrate to implement a high speed LSI that requires a low consumption of power and that cannot conventionally be manufactured using distorted Si.
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A manufacturing method of a semiconductor substrate comprising the steps of: (a) forming a SiGe layer on a substrate of which the surface is made of silicon; (b) further forming a semiconductor layer on the SiGe layer; and (c) implanting ions into regions of the SiGe layer in the substrate that become element isolation formation regions, and carrying out a heat treatment.
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BACKGROUND OF THE INVENTION
Field of the Invention
[0001] A compound having Formula (I):
[0000]
[0000] or pharmaceutically acceptable salts thereof; wherein
W is
[0000]
A 1 and A 4 are independently C or N;
each A 2 and A 3 is C, or one of A 2 and A 3 is N when R 6 and R 7 form a ring;
B and C are independently an optionally substituted 5-7 membered carbocyclic ring, aryl, heteroaryl or heterocyclic ring containing N, O or S;
Z 1 , Z 2 and Z 3 are independently NR 11 , C═O, CR—OR, (CR 2 ) 1-2 or ═C—R 12 ;
R 1 and R 2 are independently halo, OR 12 , NR(R 12 ), SR 12 , or an optionally substituted C 1-6 alkyl, C 2-6 alkenyl or C 2-6 alkynyl; or one of R 1 and R 2 is H;
R 3 is (CR 2 ) 0-2 SO 2 R 12 , (CR 2 ) 0-2 SO 2 NRR 12 , (CR 2 ) 0-2 CO 1 - 2 R 12 , (CR 2 ) 0-2 CONRR 12 or cyano;
R 4 , R 6 , R 7 and R 10 are independently an optionally substituted C 1-6 alkyl, C 2-6 alkenyl or C 2-6 alkynyl; OR 12 , NR(R 12 ), halo, nitro, SO 2 R 12 , (CR 2 ) p R 13 or X; or R 4 , R 7 and R 10 are independently H;
R, R 5 and R 5 ′ are independently H or C 1-6 alkyl;
R 8 and R 9 are independently C 1-6 alkyl, C 2-6 alkenyl, C 2-6 alkynyl, halo or X, or one of R 8 and R 9 is H when R 1 and R 2 form a ring; and provided one of R 8 and R 9 is X;
alternatively, R 1 and R 2 , or R 6 and R 7 , R 7 and R 8 , or R 9 and R 10 , when attached to a carbon atom may form an optionally substituted 5-7 membered monocyclic or fused carbocyclic ring, aryl, or heteroaryl or heterocyclic ring comprising N, O and/or S; or R 7 , R 8 , R 9 and R 10 are absent when attached to N;
R 11 is H, C 1-6 alkyl, C 2-6 alkenyl, (CR 2 ) p CO 1-2 R 1 (CR 2 ) p OR 1 (CR 2 ) p R 13 , (CR 2 ) p NRR 12 , (CR 2 ) p CONRR 12 or (CR 2 ) p SO 1-2 R 12 ;
R 12 and R 13 are independently an optionally substituted 3-7 membered saturated or partially unsaturated carbocyclic ring, or a 5-7 membered heterocyclic ring comprising N, O and/or S; aryl or heteroaryl; or R 12 is H, C 1-6 alkyl;
X is (CR 2 ) q Y, cyano, CO 1-2 R 12 , CONR(R 12 ), CONR(CR 2 ) p NR(R 12 ), CONR(CR 2 ) p OR 12 , CONR(CR 2 ) p SR 12 , CONR(CR 2 ) p S(O) 1-2 R 12 or (CR 2 ) 1-6 NR(CR 2 ) p OR 12 ;
Y is an optionally substituted 3-12 membered carbocyclic ring, a 5-12 membered aryl, or a 5-12 membered heteroaryl or heterocyclic ring comprising N, O and/or S and attached to A 2 or A 3 or both via a carbon atom of said heteroaryl or heterocyclic ring when q in (CR 2 ) q Y is 0; and
n, p and q are independently 0-4;
were originally described in WO2008/073687 A1.
[0019] Further, heat shock protein 90 (Hsp90) is recognized as an anti-cancer target. Hsp90 is a highly abundant and essential protein which functions as a molecular chaperone to ensure the conformational stability, shape and function of client proteins. The Hsp90 family of chaperones is comprised of four members: Hsp90α and Hsp90β both located in the cytosol, GRP94 in the endoplasmic reticulum, and TRAP1 in the mitochondria. Hsp90 is an abundant cellular chaperone constituting about 1% -2% of total protein.
[0020] Among the stress proteins, Hsp90 is unique because it is not required for the biogenesis of most polypeptides. Hsp90 forms complexes with oncogenic proteins, called “client proteins”, which are conformationally labile signal transducers playing a critical role in growth control, cell survival and tissue development. Such binding prevents the degradation of these client proteins. A subset of Hsp90 client proteins, such as Raf, AKT, phospho-AKT, CDK4 and the EGFR family including ErbB2, are oncogenic signaling molecules critically involved in cell growth, differentiation and apoptosis, which are all processes important in cancer cells. Inhibition of the intrinsic ATPase activity of Hsp90 disrupts the Hsp90-client protein interaction resulting in their degradation via the ubiquitin proteasome pathway.
[0021] Hsp90 chaperones, which possess a conserved ATP-binding site at their N-terminal domain belong to a small ATPase sub-family known as the DNA Gyrase, Hsp90, Histidine Kinase and MutL (GHKL) sub-family. The chaperoning (folding) activity of Hsp90 depends on its ATPase activity which is weak for the isolated enzyme. However, it has been shown that the ATPase activity of Hsp90 is enhanced upon its association with proteins known as co-chaperones. Therefore, in vivo, Hsp90 proteins work as subunits of large, dynamic protein complexes. Hsp90 is essential for eukaryotic cell survival and is overexpressed in many tumors.
[0022] In spite of numerous treatment options for proliferative disease patients, there remains a need for effective and safe therapeutic agents and a need for their preferential use in combination therapy. Surprisingly, it has been found that the compounds of formula (l), which have been described in WO2008/073687, provoke strong anti-proliferative activity and an in vivo antitumor response in combination with Hsp90 inhibitors. An additional benefit of Hsp90 inhibition may arise from its effect on other signaling components within the Pl3K/Akt/mTOR pathway, as for example on AKT and pAKT, and its broad effects on many client proteins.
SUMMARY OF THE INVENTION
[0000]
The present invention relates to a pharmaceutical combination comprising (a) a compound of formula (I),
[0000]
[0000] or pharmaceutically acceptable salts thereof; wherein
W is
[0000]
[0000] A 1 and A 4 are independently C or N;
each A 2 and A 3 is C, or one of A 2 and A 3 is N when R 6 and R 7 form a ring; B and C are independently an optionally substituted 5-7 membered carbocyclic ring, aryl, heteroaryl or heterocyclic ring containing N, O or S; Z 1 , Z 2 and Z 3 are independently NR 11 , C═O, CR—OR, (CR 2 ) 1-2 or ═C—R 12 ; R 1 and R 2 are independently halo, OR 12 , NR(R 12 ), SR 12 , or an optionally substituted C 1-6 alkyl, C 2-6 alkenyl or C 2-6 alkynyl; or one of R 1 and R 2 is H; R 3 is (CR 2 ) 0-2 SO 2 R 12 , (CR 2 ) 0-2 SO 2 NRR 12 , (CR 2 ) 0-2 CO 1-2 R 12 , (CR 2 ) 0-2 CONRR 12 or cyano; R 4 , R 8 , R 7 and R 10 are independently an optionally substituted C 1-6 alkyl, C 2-6 alkenyl or C 2-6 alkynyl; OR 12 , NR(R 12 ), halo, nitro, SO 2 R 12 , (CR 2 ) p R 13 or X; or R 4 , R 7 and R 10 are independently H; R, R 5 and R 5 ′ are independently H or C 1-6 alkyl; R 8 and R 9 are independently C 1-6 alkyl, C 2-6 alkenyl, C 2-6 alkynyl, halo or X, or one of R 8 and R 9 is H when R 1 and R 2 form a ring; and provided one of R 8 and R 9 is X; alternatively, R 1 and R 2 , or R 6 and R 7 , R 7 and R 8 , or R 9 and R 10 , when attached to a carbon atom may form an optionally substituted 5-7 membered monocyclic or fused carbocyclic ring, aryl, or heteroaryl or heterocyclic ring comprising N, O and/or S; or R 7 , R 8 , R 9 and R 10 are absent when attached to N; R 11 is H, C 1-6 alkyl, C 2-6 aIkenyl, (CR 2 ) p CO 1-2 R, (CR 2 ) p OR, (CR 2 ) p R 13 , (CR 2 ) p NRR 12 , (CR 2 ) p CONRR 12 or (CR 2 ) p SO 1-2 R 12 ; R 12 and R 13 are independently an optionally substituted 3-7 membered saturated or partially unsaturated carbocyclic ring, or a 5-7 membered heterocyclic ring comprising N, O and/or S; aryl or heteroaryl; or R 12 is H, C 1-6 alkyl; X is (CR 2 ) q Y, cyano, CO 1-2 R 12 , CONR(R 12 ), CONR(CR 2 ) p NR(R 12 ), CONR(CR 2 ) p OR 12 , CONR(CR 2 ) p SR 12 , CONR(CR 2 ) p SR 12 , CONR(CR 2 ) p S(O) 1 - 2 R 12 or (CR 2 ) 1-6 NR(CR 2 ) p OR 12 ; Y is an optionally substituted 3-12 membered carbocyclic ring, a 5-12 membered aryl, or a 5-12 membered heteroaryl or heterocyclic ring comprising N, O and/or S and attached to A 2 or A 3 or both via a carbon atom of said heteroaryl or heterocyclic ring when q in (CR 2 ) q Y is 0; and
[0038] (b) at least one compound targeting, decreasing or inhibiting the intrinsic ATPase activity of Hsp90 and/or degrading, targeting, decreasing or inhibiting the Hsp90 client proteins via the ubiquitin proteosome pathway. Such compounds will be referred to as “Heat shock protein 90 inhibitors” or “Hsp90 inhibitors. Examples of Hsp90 inhibitors suitable for use in the present invention include, but are not limited to, the geldanamycin derivative, Tanespimycin (17-allylamino-17-demethoxygeldanamycin)(also known as KOS-953 and 17-AAG); Radicicol; 6-Chloro-9-(4-methoxy-3,5-dimethylpyridin-2-ylmethyl)-9H-purin-2-amine methanesulfonate (also known as CNF2024); IPI504; SNX5422; 5-(2,4-Dihydroxy-5-isopropyl-phenyl)-4-(4-morpholin-4-ylmethyl-phenyl)-isoxazole-3-carboxylic acid ethylamide (AUY922); and (R)-2-amino-7-[4fluoro-2-(6-methyoxy-pyridin-2-yl)-phenyl]-4-methyl-7,8-dihydro-6H-pyrido[4,3-d]pyrimidin-5-one (HSP990).
[0039] In the above Formula (1), R 1 may be halo or C 1-6 alkyl; R 2 is H or NH 2 ; or R 1 and R 2 together form an optionally substituted 5-6 membered aryl, or heteroaryl or heterocyclic ring comprising 1-3 nitrogen atoms, In other examples, R 3 in Formula (1) may be SO 2 R 12 , SO 2 NH 2 , SO 2 NRR 12 , CO 2 NH 2 , CONRR 12 , CO 1-2 R 12 , or cyano; and R 12 is C 1-6 alkyl, an optionally substituted C 3-7 cycloalkyl, C 3-7 cycloalkenyl, pyrrolidinyl, piperazinyl, piperidinyl, morpholinyl or azetidinyl In yet other examples, R 5 , R 5′ , R 7 and R 10 in Formula (1) are independently H, and n is 0, In other examples, R 6 in Formula (1) may be halo or OR 12 , and R 12 is C 1-6 alkyl.
[0040] In a preferred embodiment, the compound of Formula (1) is
[0000]
[0041] The present invention further relates to a pharmaceutical composition comprising a compound of formula (I) or a pharmaceutically acceptable salt thereof and at least one Hsp90 inhibitor or a pharmaceutically acceptable salt thereof. In one embodiment, this pharmaceutical composition of the present invention is for use in the treatment of a proliferative disease.
[0042] The present invention further relates to the use of a pharmaceutical combination comprising a compound of formula (I) or a pharmaceutically acceptable salt thereof and at least one Hsp90 inhibitor or a pharmaceutically acceptable salt thereof, for the preparation of a medicament for the treatment of a proliferative disease.
[0043] The present invention further relates to a method for treating a proliferative disease in a subject in need thereof, comprising administering to said subject a therapeutically effective amount of a compound of formula (I) or a pharmaceutically acceptable salt thereof, and at least one Hsp90 inhibitor or a pharmaceutically acceptable salt thereof. In accordance with the present invention, the compound of formula (I) and the Hsp90 inhibitor may be administered either as a single pharmaceutical composition, as separate compositions, or sequentially.
[0044] The present invention further relates to a kit comprising a compound of formula (I) according to claim 1 or a pharmaceutically acceptable salt thereof, and at least one Hsp90 inhibitor or a pharmaceutically acceptable salt thereof.
[0045] In one embodiment of the present invention, the compound of formula (I) is selected from 5-chloro-N2-(2-isopropoxy-5-methyl-4-(piperidin-4-yl)phenyl)-N4-[2-(propane-2-sulfonyl)-phenyl]-pyrimidine-2,4-diamine (Compound A) having the following structure
[0000]
[0000] or pharmaceutically acceptable salts thereof.
[0046] In one embodiment of the present invention, the HSP inhibitor is 5-(2,4-Dihydroxy-5-isopropyl-phenyl)-4-(4-morpholin-4-ylmethyl-phenyl)-isoxazole-3-carboxylic acid ethylamide (AUY922).
[0047] In one embodiment of the present invention, the compound of formula (I) is 5-chloro-N2-(2-isopropoxy-5-methyl-4-(piperidin-4-yl)phenyl)-N4-[2-(propane-2-sulfonyl)-phenyl]-pyrimidine-2,4-diamine (Compound A) and the HSP inhibitor is 5-(2,4-Dihydroxy-5-isopropyl-phenyl)-4-(4-morpholin-4-ylmethyl-phenyl)-isoxazole-3-carboxylic acid ethylamide (AUY922).
DESCRIPTION OF THE FIGURES
[0048] FIG. 1 shows the antitumor activity of AUY922 50 mg/kg, 5-chloro-N2-(2-isopropoxy-5-methyl-4-(piperldin-4-yl)phenyl)-N4-[2-(propane-2-sulfonyl)-phenyl]-pyrimidine-2,4-diamine (Compound A) 10 mg/kg, or combination of AUY922 50 mg/kg and Compound A 10 mg/kg in mice bearing HLUX-1787 lung primary tumor xenografts which harbor an EML4-ALK variant 2 translocation (TRP-0318).
[0049] FIG. 2 shows the percent change in body weight of AUY922 50 mg/kg, Compound A 10 mg/kg, or combination of AUY922 50 mg/kg and Compound A 10 mg/kg in mice bearing HLUX-1787 lung primary tumor xenografts which harbor an EML4-ALK variant 2 translocation (TRP-0318).
[0050] For the in vivo testing in FIGS. 1 and 2 , female nude (nu/nu) harlan mice bearing HLUX-1787 lung primary tumor xenografts were treated with AUY922, Compound A, a combination of AUY922 and Compound A, or vehicle at the indicated doses and schedules. Treatments started 24 days post tumor cells implantation and lasted 20 consecutive days. Statistics on change in tumor volumes and were performed with a one-way ANOVA, post hoc Tukey (*p<0.05 vs. vehicle controls).
[0051] FIG. 3 shows the antitumor activity of AUY922 50 mg/kg, Compound A 10 mg/kg, or combination of AUY922 50 mg/kg and Compound A 10 mg/kg in mice bearing HLUX-1787 lung primary tumor xenografts which harbor an EML4-ALK variant 2 translocation (TRP-0335).
[0052] FIG. 4 shows the percent change in body weight of AUY922 50 mg/kg, Compound A 10 mg/kg, or combination of AUY922 50 mg/kg and Compound A 10 mg/kg in mice bearing HLUX-1787 lung primary tumor xenografts which harbor an EML4-ALK variant 2 translocation (TRP-0318).
[0053] For the in vivo testing in FIGS. 3 and 4 , female nude (nu/nu) harlan mice bearing HLUX-1787 lung primary tumor xenografts were treated with AUY922, Compound A, a combination of AUY922 and Compound A, or vehicle at the indicated doses and schedules. Treatments started 27 days post tumor cells implantation and lasted 13 consecutive days. Statistics on change in tumor volumes and were performed with a one-way ANOVA, post hoc Tukey (*p<0.05 vs. vehicle controls).
[0054] FIG. 5 shows the mean body weight of vehicle, Compound A25 mg/kg, Compound A 50 mg/kg, Compound A 100 mg/kg, AUY922 50 mg/kg, and combination AUY922 50 mg/kg and Compound A 25 mg/kg treated groups in mice bearing the subcutaneous primary human lung cancer LUF1656 (treatment phase, n=8) by day 21.
[0055] FIG. 6 shows the mean body weight of vehicle, Compound A 25 mg/kg, Compound A 50 mg/kg, Compound A 100 mg/kg, AUY922 50 mg/kg, and combination AUY922 50 mg/kg and
[0056] Compound A 25 mg/kg treated groups in mice bearing the subcutaneous primary human lung cancer LUF1656 (re-growth phase, n=4) from day 22 to day 34 .
[0057] FIG. 7 shows the antitumor activity of Compound A 25 mg/kg, Compound A 50 mg/kg, Compound A 100 mg/kg, AUY922 50 mg/kg, and combination AUY922 50 mg/kg and Compound A 25 mg/kg treated groups in mice bearing the subcutaneous primary human lung cancer LUF1656 (treatment phase, n=8) by day 21.
[0058] FIG. 8 shows the antitumor activity of Compound A 25 mg/kg, Compound A 50 mg/kg, Compound A 100 mg/kg, AUY922 50 mg/kg, and combination AUY922 50 mg/kg and Compound A 25 mg/kg treated groups in mice bearing the subcutaneous primary human lung cancer LUF1656 (re-growth phase, n=4) from day 22 to day 34.
[0059] For the in vivo testing in FIGS. 5, 6, 7 and 8 , female nude (nu/nu) mice bearing LUF1656 lung primary tumor xenografts were treated with AUY922, Compound A, a combination of AUY922 and Compound A, or vehicle at the indicated doses and schedules. The treatments were started when mean tumor size reached approximately 140 mm 3 (range 86.8-245 mm 3 ). Statistics on change in tumor volumes and were performed with a one-way ANOVA, post hoc Tukey (*p<0.05 vs. vehicle controls).
DETAILED DESCRIPTION OF THE INVENTION
[0060] The following general definitions are provided to better understand the invention:
Definitions
[0061] “Alkyl” refers to a moiety and as a structural element of other groups, for example halo-substituted-alkyl and alkoxy, and may be straight-chained or branched. An optionally substituted alkyl, alkenyl or alkynyl as used herein may be optionally halogenated (e.g., CF 3 ), or may have one or more carbons that is substituted or replaced with a heteroatom, such as NR, O or S (e.g., —OCH 2 CH 2 O—, alkylthiols, thioalkoxy, alkylamines, etc).
[0062] “Aryl” refers to a monocyclic or fused bicyclic aromatic ring containing carbon atoms. “Arylene” means a divalent radical derived from an aryl group. For example, an aryl group may be phenyl, indenyl, indanyl, naphthyl, or 1,2,3,4-tetrahydronaphthalenyl, which may be optionally substituted in the ortho, meta or para position.
[0063] “Heteroaryl” as used herein is as defined for aryl above, where one or more of the ring members is a heteroatom. Examples of heteroaryls include but are not limited to pyridyl, pyrazinyl, indolyl, indazolyl, quinoxalinyl, quinolinyl, benzofuranyl, benzopyranyl, benzothiopyranyl, benzo[1,3]dioxole, imidazolyl, benzo-imidazolyl, pyrimidinyl: furanyl, oxazolyl, isoxazolyl, triazolyl, benzotriazolyl, tetrazolyl, pyrazolyl, thienyl, pyrrolyl, isoquinolinyl, purinyl, thiazolyl, tetrazinyl, benzothiazolyl, oxadiazolyi, benzoxadiazolyl, etc.
[0064] A “carbocyclic ring” as used herein refers to a saturated or partially unsaturated, monocyclic, fused bicyclic or bridged polycyclic ring containing carbon atoms, which may optionally be substituted, for example, with ═O. Examples of carbocyclic rings include but are not limited to cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cyclopropylene, cyclohexanone, etc.
[0065] A “heterocyclic ring” as used herein is as defined for a carbocyclic ring above, wherein . one or more ring carbons is a heteroatom. For example, a heterocyclic ring may contain N, O, S, —N═,—S—, —S(O), —S(O) 2 -, or —NR— wherein R may be hydrogen, C 1-4 alkyl or a protecting group. Examples of heterocyclic rings include but are not limited to morpholino, pyrrolidinyl, pyrrolidinyl-2-one, piperazinyl, piperidinyl, piperidinylone, 1,4-dioxa-8-aza-spiro[4.5]dec-8-yl, 1,2,3,4-tetrahydroquinolinyl, etc. Heterocyclic rings as used herein may encompass bicyclic amines and bicyclic diamines.
[0066] “Salts” (which, what is meant by “or salts thereof” or “or a salt thereof”), can be present alone or in mixture with free compound, e.g. the compound of the formula (I), and are preferably pharmaceutically acceptable salts. Such salts of the compounds of formula (I) are formed, for example, as acid addition salts, preferably with organic or inorganic acids, from compounds of formula (I) with a basic nitrogen atom. Suitable inorganic acids are, for example, halogen acids, such as hydrochloric acid, sulfuric acid, or phosphoric acid. Suitable organic acids are, e.g., carboxylic acids or sulfonic acids, such as fumaric acid or methansulfonic acid. For isolation or purification purposes it is also possible to use pharmaceutically unacceptable salts, for example picrates or perchiorates. For therapeutic use, only pharmaceutically acceptable salts or free compounds are employed (where applicable in the form of pharmaceutical preparations), and these are therefore preferred. In view of the close relationship between the novel compounds in free form and those in the form of their salts, including those salts that can be used as intermediates, for example in the purification or identification of the novel compounds, any reference to the free compounds hereinbefore and hereinafter is to be understood as referring also to the corresponding salts, as appropriate and expedient. The salts of compounds of formula (I) are preferably pharmaceutically acceptable salts; suitable counter-ions forming pharmaceutically acceptable salts are known in the field.
[0067] “Combination” refers to either a fixed combination in one dosage unit form, or a non-fixed combination (or kit of parts) for the combined administration where a compound of the formula (I) and a combination partner (e.g. another drug as explained below, also referred to as “therapeutic agent” or “co-agent”) may be administered independently at the same time or separately within time intervals, especially where these time intervals allow that the combination partners show a cooperative, e.g. synergistic effect. The term “combined administration” or the like as utilized herein are meant to encompass administration of the selected combination partner to a single subject in need thereof (e.g. a patient), and are intended to include treatment regimens in which the agents are not necessarily administered by the same route of administration or at the same time. The term “fixed combination” means that the active ingredients, e.g. a compound of formula (I) and a combination partner, are both administered to a patient simultaneously in the form of a single entity or dosage. The terms “non-fixed combination” or “kit of parts” mean that the active ingredients, e.g. a compound of formula (I) and a combination partner, are both administered to a patient as separate entities either simultaneously, concurrently or sequentially with no specific time limits, wherein such administration provides therapeutically effective levels of the two compounds in the body of the patient. The latter also applies to cocktail therapy, e.g. the administration of three or more active ingredients.
[0068] “Treatment” includes prophylactic (preventive) and therapeutic treatment as well as the delay of progression of a disease or disorder. The term “prophylactic” means the prevention of the onset or recurrence of diseases involving proliferative diseases. The term “delay of progression” as used herein means administration of the combination to patients being in a pre-stage or in an early phase of the proliferative disease to be treated, in which patients for example a pre-form of the corresponding disease is diagnosed or which patients are in a condition, e.g. during a medical treatment or a condition resulting from an accident, under which it is likely that a corresponding disease will develop.
[0069] “Subject” is intended to include animals. Examples of subjects include mammals, e.g., humans, dogs, cows, horses, pigs, sheep, goats, cats, mice, rabbits, rats, and transgenic non-human animals. In certain embodiments, the subject is a human, e.g., a human suffering from, at risk of suffering from, or potentially capable of suffering from a brain tumor disease. Particularly preferred, the subject is human.
[0070] “Pharmaceutical preparation” or “pharmaceutical composition” refer to a mixture or solution containing at least one therapeutic compound to be administered to a mammal, e.g., a human in order to prevent, treat or control a particular disease or condition affecting the mammal.
[0071] “Co-administer”, “co-administration” or “combined administration” or the like are meant to encompass administration of the selected therapeutic agents to a single patient, and are intended to include treatment regimens in which the agents are not necessarily administered by the same route of administration or at the same time.
[0072] “Pharmaceutically acceptable” refers to those compounds, materials, compositions and/or dosage forms, which are, within the scope of sound medical judgment, suitable for contact with the tissues of mammals, especially humans, without excessive toxicity, irritation, allergic response and other problem complications commensurate with a reasonable benefit/risk ratio.
[0073] “Therapeutically effective” preferably relates to an amount that is therapeutically or in a broader sense also prophylactically effective against the progression of a proliferative disease.
[0074] “Single pharmaceutical composition” refers to a single carrier or vehicle formulated to deliver effective amounts of both therapeutic agents to a patient. The single vehicle is designed to deliver an effective amount of each of the agents, along with any pharmaceutically acceptable carriers or excipients. In some embodiments, the vehicle is a tablet, capsule, pill, or a patch. In other embodiments, the vehicle is a solution or a suspension.
[0075] “Dose range” refers to an upper and a lower limit of an acceptable variation of the amount of agent specified. Typically, a dose of the agent in any amount within the specified range can be administered to patients undergoing treatment.
[0076] The terms “about” or “approximately” usually means within 20%, more preferably within 10%, and most preferably still within 5% of a given value or range. Alternatively, especially in biological systems, the term “about” means within about a log (i.e., an order of magnitude) preferably within a factor of two of a given value.
[0077] The present invention relates to a pharmaceutical combination comprising (a) a compound of formula (I), as defined HEREIN, or a pharmaceutically acceptable salt thereof; and (b) at least one Hsp90 inhibitor or a pharmaceutically acceptable salt thereof. Such combination may be for simultaneous, separate or sequential use for the treatment of a proliferative disease.
[0078] Suitable Hsp90 inhibitors include, but are not limited to,
(a) the geldanamycin derivative, Tanespimycin (17-allylamino-17-demethoxygeldanamycin)(also known as KOS-953 and 17-AAG), which is available from Sigma-Aldrich Co, LLC (St. Louis, Miss.), and disclosed in U.S. Pat. No. 4,261,989, dated Apr. 14, 1981, which is hereby incorporated into the present application by reference, and other geldanamycin-related compounds; (b) Radicicol, which is available from Sigma-Aldrich Co, LLC (St. Louis, Miss.); (c) 6-Chloro-9-(4-methoxy-3,5-dimethylpyridin-2-ylmethyl)-9H-purin-2-amine methanesulfonate (also known as CN F2024)(Confomia Therapeutics Corp.); (d) IPI504; (e) SNX5422; (f) 5-(2,4-Dihydroxy-5-isopropyl-phenyl)-4-(4-morpholin-4-ylmethyl-phenyl)-isoxazole-3-carboxylic acid ethylamide (AUY922), which is disclosed in structure and with the process for its manufacture in PCT Application No. WO04/072051, published on Aug. 26, 2004, which is hereby incorporated into the present application by reference; and (g) (R)-2-amino-7-[4-fluoro-2-(6-methyoxy-pyridin-2-yl)-phenyl]-4-methyl-7,8-dihydro-6H-pyrido[4,3-d]pyrimidin-5-one (HSP990), which is disclosed in structure and with the process for its manufacture in U.S. Patent Application Publication No. 2007-0123546, published on May 31, 2007, which is hereby incorporated into the present application by reference;
[0086] and pharmaceutically acceptable salts thereof.
[0087] Preferred Hsp90 inhibitors for the present invention are 5-(2,4-Dihydroxy-5-isopropyl-phenyl)-4-(4-morpholin-4-ylmethyl-phenyl)-isoxazole-3-carboxylic acid ethylamide (AUY922) and (R)-2-amino-7-[4-fluoro-2-(6-methyoxy-pyridin-2-yl)-phenyl]-4-methyl-7,8-dihydro-6H-pyrido[4,3-d]pyrimidin-5-one (HSP990) or pharmaceutically acceptable salts thereof.
[0088] Comprised are likewise the pharmaceutically acceptable salts thereof, the corresponding racemates, diastereoisomers, enantiomers, tautomers, as well as the corresponding crystal modifications of above disclosed compounds where present, e.g. solvates, hydrates and polymorphs, which are disclosed therein. The compounds used as active ingredients in the combinations of the present invention can be prepared and administered as described in the cited documents, respectively. Also within the scope of this invention is the combination of more than two separate active ingredients as set forth above, i.e., a pharmaceutical combination within the scope of this invention could include three active ingredients or more.
[0089] In one embodiment of the present invention, the pharmaceutical combination comprises the compound of formula (I) that is
[0000]
[0090] or a pharmaceutically acceptable salt thereof, and at least one Hsp90 inhibitor selected from 5-(2,4-Dihydroxy-5-isopropyl-phenyl)-4-(4-morpholin-4-ylmethyl-phenyl)-isoxazole-3-carboxylic acid ethylamide (AUY922), (R)-2-amino-7[4-fluoro-2-(6-methyoxy-pyridin-2-yl)-phenyl]-4-methyl-7,8-dihydro-6H-pyrido[4,3-d]pyrimidin-5-one (HSP990), or pharmaceutically acceptable salts thereof.
[0091] In one embodiment of the present invention, the pharmaceutical combination comprises the compound of formula (I) that is 5-chloro-N2-(2-isopropoxy-5-methyl-4-(piperidin-4-yl)phenyl)-N4-[2-(propane-2-sulfonyl)-phenyl]-pyrimidine-2,4-diamine or pharmaceutically acceptable salts thereof, and at least one Hsp90 inhibitor 5-(2,4-Dihydroxy-5-isopropyl-phenyl)-4-(4-morpholin-4-ylmethyl-phenyl)-isoxazole-3-carboxylic acid ethylamide (AUY922) or a pharmaceutically acceptable salt thereof.
[0092] In one embodiment of the present invention, the pharmaceutical combination comprises the compound of formula (I) that is 5-chloro-N2-(2-isopropoxy-5-methyl-4-(piperidin-4-yl)phenyl)-N4-[2-(propane-2-sulfonyl)-phenyl]-pyrimidine-2,4-diamine (Compound A) having the following structure
[0000]
[0000] or pharmaceutically acceptable salts thereof and the HSP inhibitor is 5-(2,4-Dihydroxy-5-isopropyl-phenyl)-4-(4-morpholin-4-ylmethyl-phenyl)-isoxazole-3-carboxylic acid ethylamide (AUY922).
[0093] In a further embodiment, the compound of formula (1) is 5-chloro-N2-(2-isopropoxy-5-methyl-4-(piperidin-4-yl)phenyl)-N4-[2-(propane-2-sulfonyl)-phenyl]-pyrimidine-2,4-diamine (Compound A) and the HSP inhibitor is 5-(2,4-Dihydroxy-5-isopropyl-phenyl)-4-(4-morpholin-4-ylmethyl-phenyl)-isoxazole-3-carboxylic acid ethylamide (AUY922).
[0094] It has now been surprisingly found that the combination of a compound of formula (I), and at least one Hsp90 inhibitor possess beneficial therapeutic properties, which render it particularly useful for the treatment of proliferative diseases, particularly cancer.
[0095] In one aspect, the present invention provides a pharmaceutical combination comprising (a) a compound of formula (I), and (b) at least one Hsp90 inhibitor or a pharmaceutically acceptable salt thereof, for use in the treatment of a proliferative disease, particularly cancer.
[0096] In one aspect, the present invention provides the use of a pharmaceutical combination comprising a compound of formula (I) or a pharmaceutically acceptable salt thereof and at least one Hsp90 inhibitor or a pharmaceutically acceptable salt thereof, for the preparation of a medicament for the treatment of a proliferative disease.
[0097] In one aspect, the present invention further relates to a method for treating a proliferative disease in a subject in need thereof, comprising administering to said subject a therapeutically effective amount of a compound of formula (I) or a pharmaceutically acceptable salt thereof, and at least one Hsp90 inhibitor or a pharmaceutically acceptable salt thereof. In accordance with the present invention, the compound of formula (I) and the Hsp90 inhibitor may be administered either as a single pharmaceutical composition, as separate compositions, or sequentially.
[0098] Preferably, the present invention is useful for the treating a mammal, especially humans, suffering from a proliferative disease such as cancer.
[0099] To demonstrate that the combination of a compound of formula (I) and at least one Hsp90 inhibitor is particularly suitable for the effective treatment of proliferative diseases with good therapeutic margin and other advantages, clinical trials can be carried out in a manner known to the skilled person.
[0100] Suitable clinical studies are, e.g., open label, dose escalation studies in patients with proliferative diseases. Such studies prove in particular the synergism of the active ingredients of the combination of the invention. The beneficial effects can be determined directly through the results of these studies which are known as such to a person skilled in the art. Such studies are, in particular, suitable to compare the effects of a monotherapy using the active ingredients and a combination of the invention. Preferably, the dose of agent (a) is escalated until the Maximum Tolerated Dosage is reached, and agent (b) is administered with a fixed dose. Alternatively, the agent (a) is administered in a fixed dose and the dose of agent (b) is escalated. Each patient receives doses of the agent (a) either daily or intermittent. The efficacy of the treatment can be determined in such studies, e.g., after 12, 18 or 24 weeks by evaluation of symptom scores every 6 weeks.
[0101] The administration of a pharmaceutical combination of the invention results not only in a beneficial effect, e.g., a synergistic therapeutic effect, e.g., with regard to alleviating, delaying progression of or inhibiting the symptoms, but also in further surprising beneficial effects, e.g., fewer side effects, an improved quality of life or a decreased morbidity, compared with a monotherapy applying only one of agents (a) or agents (b) used in the combination of the invention.
[0102] A further benefit is that lower doses of the active ingredients of the combination of the invention can be used, e.g., that the dosages need not only often be smaller but are also applied less frequently, which may diminish the incidence or severity of side effects. This is in accordance with the desires and requirements of the patients to be treated.
[0103] It is one objective of this invention to provide a pharmaceutical composition comprising a quantity, which is jointly therapeutically effective at targeting or preventing proliferative diseases, of each combination partner agent (a) and (b) of the invention. In one aspect, the present invention relates to a pharmaceutical composition comprising a compound of formula (I) or a pharmaceutically acceptable salt thereof and at least one Hsp90 inhibitor or a pharmaceutically acceptable salt thereof. In one embodiment, such pharmaceutical composition of the present invention is for use in the treatment of a proliferative disease. In accordance with the present invention, agent (a) and agent (b) may be administered together in a single pharmaceutical composition, separately in one combined unit dosage form or in two separate unit dosage forms, or sequentially. The unit dosage form may also be a fixed combination.
[0104] The pharmaceutical compositions for separate administration of agent (a) and agent (b) or for the administration in a fixed combination (i.e., a single galenical composition comprising at least two combination partners (a) and (b)) according to the invention may be prepared in a manner known per se and are those suitable for enteral, such as oral or rectal, topical, and parenteral administration to subjects, including mammals (warm-blooded animals) such as humans, comprising a therapeutically effective amount of at least one pharmacologically active combination partner alone, e.g., as indicated above, or in combination with one or more pharmaceutically acceptable carriers or diluents, especially suitable for enteral or parenteral application. Suitable pharmaceutical compositions contain, e.g., from about 0.1% to about 99.9%, preferably from about 1% to about 60%, of the active ingredient(s).
[0105] Pharmaceutical compositions for the combination therapy for enteral or parenteral administration are, e.g., those in unit dosage forms, such as sugar-coated tablets, tablets, capsules or suppositories, ampoules, injectable solutions or injectable suspensions. Topical administration is e.g. to the skin or the eye, e.g. in the form of lotions, gels, ointments or creams, or in a nasal or a suppository form. If not indicated otherwise, these are prepared in a manner known per se, e.g., by means of conventional mixing, granulating, sugar-coating, dissolving or lyophilizing processes. It will be appreciated that the unit content of agent (a) or agent (b) contained in an individual dose of each dosage form need not in itself constitute an effective amount since the necessary effective amount can be reached by administration of a plurality of dosage units.
[0106] Pharmaceutical compositions may comprise one or more pharmaceutical acceptable carriers or diluents and may be manufactured in conventional manner by mixing one or both combination partners with a pharmaceutically acceptable carrier or diluent. Examples of pharmaceutically acceptable diluents include, but are not limited to, lactose, dextrose, mannitol, and/or glycerol, and/or lubricants and/or polyethylene glycol. Examples of pharmaceutically acceptable binders include, but are not limited to, magnesium aluminum silicate, starches, such as corn, wheat or rice starch, gelatin, methylcellulose, sodium carboxymethylcellulose and/or polyvinylpyrrolidone, and, if desired, pharmaceutically acceptable disintegrators include, but are not limited to, starches, agar, alginic acid or a salt thereof, such as sodium alginate, and/or effervescent mixtures, or adsorbents, dyes, flavorings and sweeteners. It is also possible to use the compounds of the present invention in the form of parenterally administrable compositions or in the form of infusion solutions. The pharmaceutical compositions may be sterilized and/or may comprise excipients, for example preservatives, stabilizers, wetting compounds and/or emulsifiers, solubilisers, salts for regulating the osmotic pressure and/or buffers.
[0107] In particular, a therapeutically effective amount of each of the combination partner of the combination of the invention may be administered simultaneously or sequentially and in any order, and the components may be administered separately or as a fixed combination. For example, the method of preventing or treating proliferative diseases according to the invention may comprise: (i) administration of the first agent (a) in free or pharmaceutically acceptable salt form; and (ii) administration of an agent (b) in free or pharmaceutically acceptable salt form, simultaneously or sequentially in any order, in jointly therapeutically effective amounts, preferably in synergistically effective amounts, e.g., in daily or intermittently dosages corresponding to the amounts described herein. The individual combination partners of the combination of the invention may be administered separately at different times during the course of therapy or concurrently in divided or single combination forms. Furthermore, the term administering also encompasses the use of a pro-drug of a combination partner that convert in vivo to the combination partner as such. The instant invention is therefore to be understood as embracing all such regimens of simultaneous or alternating treatment and the term “administering” is to be interpreted accordingly.
[0108] The effective dosage of each of combination partner agent (a) or agent (b) employed in the combination of the invention may vary depending on the particular compound or pharmaceutical composition employed, the mode of administration, the condition being treated, the severity of the condition being treated. Thus, the dosage regimen of the combination of the invention is selected in accordance with a variety of factors including type, species, age, weight, sex and medical condition of the patient; the severity of the condition to be treated; the route of administration; the renal and hepatic function of the patient; and the particular compound employed. A physician, clinician or veterinarian of ordinary skill can readily determine and prescribe the effective amount of the drug required to prevent, counter or arrest the progress of the condition. Optimal precision in achieving concentration of drug within the range that yields efficacy requires a regimen based on the kinetics of the drug's availability to target sites. This involves a consideration of the distribution, equilibrium, and elimination of a drug.
[0109] For purposes of the present invention, a therapeutically effective dose will generally be a total daily dose administered to a host in single or divided doses. The compound of formula (I) may be administered to a host in a daily dosage range of, for example, from about 0.05 to about 50 mg/kg body weight of the recipient, preferably about 0.1-25 mg/kg body weight of the recipient, more preferably from about 0.5 to 10 mg/kg body weight of the recipient. Agent (b) may be administered to a host in a daily dosage range of, for example, from about 0.001 to 1000 mg/kg body weight of the recipient, preferably from 1.0 to 100 mg/kg body weight of the recipient, and most preferably from 1.0 to 50 mg/kg body weight of the recipient. Dosage unit compositions may contain such amounts of submultiples thereof to make up the daily dose.
[0110] A further benefit is that lower doses of the active ingredients of the combination of the invention can be used, e.g., that the dosages need not only often be smaller but are also applied less frequently, or can be used in order to diminish the incidence of side effects. This is in accordance with the desires and requirements of the patients to be treated.
[0111] The combination of the compound of formula (I) and an HSP90 inhibitor can be used alone or combined with at least one other pharmaceutically active compound for use in these pathologies. These active compounds can be combined in the same pharmaceutical preparation or in the form of combined preparations “kit of parts” in the sense that the combination partners can be dosed independently or by use of different fixed combinations with distinguished amounts of the combination partners, i.e., simultaneously or at different time points. The parts of the kit of parts can then, e.g., be administered simultaneously or chronologically staggered, that is at different time points and with equal or different time intervals for any part of the kit of parts. Non-limiting examples of compounds which can be cited for use in combination with the combination of a compound of formula (I) and at least one HSP90 inhibitor are cytotoxic chemotherapy drugs, such as anastrozole, doxorubicin hydrochloride, flutamide, dexamethaxone, docetaxel, cisplatin, paclitaxel, etc. Further, the combination of a pyrimidylaminobenzamide compound and an HSP90 inhibitor could be combined with other inhibitors of signal transduction or other oncogene-targeted drugs with the expectation that significant synergy would result.
[0112] The combination of the present invention is particularly useful for the treatment of proliferative diseases. The term “proliferative disease” includes, but not restricted to, cancer, tumor, hyperplasia, restenosis, cardiac hypertrophy, immune disorder and inflammation.
[0113] Examples for a proliferative disease the can be treated with the combination of the present invention are for instance cancers, including, for example, sarcoma; lung; bronchus; prostate; breast (including sporadic breast cancers and sufferers of Cowden disease); pancreas; gastrointestinal cancer or gastric; colon; rectum; colorectal adenoma; thyroid; liver; intrahepatic bile duct; hepatocellular, adrenal gland; stomach; glioma; glioblastoma; endometrial; kidney; renal pelvis; urinary bladder; uterine corpus; uterine cervix; vagina; ovary; multiple myeloma; esophagus; a leukaemia; acute myelogenous leukemia; chronic myelogenous leukemia; lymphocytic leukemia; myeloid leukemia; brain; oral cavity and pharynx; larynx; small intestine; non-Hodgkin lymphoma; melanoma; villous colon adenoma; a neoplasia; a neoplasia of epithelial character; lymphomas; a mammary carcinoma; basal cell carcinoma; squamous cell carcinoma; actinic keratosis; a tumor of the neck or head; polycythemia vera; essential thrombocythemia; myelofibrosis with myeloid metaplasia; and Walden stroem disease.
[0114] Further examples include, polycythemia vera, essential thrombocythemia, myelofibrosis with myeloid metaplasia, asthma, COPD, ARDS, Loffler's syndrome, eosinophilic pneumonia, parasitic (in particular metazoan) infestation (including tropical eosinophilia), bronchopulmonary aspergillosis, polyarteritis nodosa (including Churg-Strauss syndrome), eosinophilic granuloma, eosinophil-related disorders affecting the airways occasioned by drug-reaction, psoriasis, contact dermatitis, atopic dermatitis, alopecia areata, erythema multiforme, dermatitis herpetiformis, scleroderma, vitiligo, hypersensitivity angiitis, urticaria, bullous pemphigoid, lupus erythematosus, pemphisus, epidermolysis bullosa acquisita, autoimmune haematogical disorders (e.g. haemolytic anaemia, aplastic anaemia, pure red cell anaemia and idiopathic thrombocytopenia), systemic lupus erythematosus, polychondritis, scleroderma, Wegener granulomatosis, dermatomyositis, chronic active hepatitis, myasthenia gravis, Steven-Johnson syndrome, idiopathic sprue, autoimmune inflammatory bowel disease (e.g. ulcerative colitis and Crohn's disease), endocrine opthalmopathy, Grave's disease, sarcoidosis, alveolitis, chronic hypersensitivity pneumonitis, multiple sclerosis, primary biliary cirrhosis, uveitis (anterior and posterior), interstitial lung fibrosis, psoriatic arthritis, glomerulonephritis, cardiovascular diseases, atherosclerosis, hypertension, deep venous thrombosis, stroke, myocardial infarction, unstable angina, thromboembolism, pulmonary embolism, thrombolytic diseases, acute arterial ischemia, peripheral thrombotic occlusions, and coronary artery disease, reperfusion injuries, retinopathy, such as diabetic retinopathy or hyperbaric oxygen-induced retinopathy, and conditions characterized by elevated intraocular pressure or secretion of ocular aqueous humor, such as glaucoma.
[0115] In one embodiment, the proliferative disease treated by the combination of the present invention is a cancer that can be beneficially treated by the inhibition of HSP90 and/or ALK including, for example, gastric, lung and bronchus; prostate; breast; pancreas; colon; rectum; thyroid; liver and intrahepatic bile duct; kidney and renal pelvis; urinary bladder; uterine corpus; uterine cervix; ovary; multiple myeloma; esophagus; acute myelogenous leukemia; chronic myelogenous leukemia; lymphocytic leukemia; myeloid leukemia; brain; oral cavity and pharynx; larynx; small intestine; non-Hodgkin lymphoma; melanoma; and villous colon adenoma.
[0116] In one embodiment, the proliferative disease treated by the combination of the present invention is a cancer of the esophagus, gastrointestinal cancer or gastric.
[0117] Where a tumor, a tumor disease, sarcoma, a carcinoma or a cancer are mentioned, also metastasis in the original organ or tissue and/or in any other location are implied alternatively or in addition, whatever the location of the tumor and/or metastasis.
[0118] The combination of the present invention is particularly useful for the treatment of proliferative diseases, particularly cancers and other malignancies, mediated by anaplastic lymphoma kinase (ALK). Proliferative diseases may include those showing overexpression or amplification of ALK, including lymphoma, osteosarcoma, melanoma, or a tumor of breast, renal, prostate, colorectal, thyroid, ovarian, pancreatic, neuronal, lung (non-small cell lung cancer and small cell lung cancer), uterine or gastrointestinal tumor, cancer of the bowel (colon and rectum), stomach cancer, cancer of liver, melanoma, bladder tumor, and cancer of head and neck. Hematological and neoplastic diseases, for example in anaplastic large-cell lymphoma (ALCL) and non-Hodgkin's lymphomas (NHL), specifically in ALK+NHL or Alkomas in inflammatory myofibroblastic tumors (IMT) and neuroblastomas.
[0119] In one embodiment, the present invention relates to a method for treating a proliferative disorder comprising administering to said subject a therapeutically effective amount of a compound of formula (I) and at least one Hsp90 inhibitor selected from the geldanamycin derivative, Tanespimycin (17-allylamino-17-demethoxygeldanamycin) (also known as KOS-953 and 17-AAG); Radicicol; 6-Chloro-9-(4-methoxy-3,5-dimethylpyridin-2-ylmethyl)-9H-purin-2-amine methanesulfonate (also known as CNF2024); IP1504; SNX5422; 5-(2,4-Dihydroxy-5-isopropyl-phenyl)-4-(4-morpholin-4-ylmethyl-phenyl)-isoxazole-3-carboxylic acid ethylamide (AUY922); and (R)-2-amino-7-[4-fluoro-2-(6-methyoxy-pyridin-2-yl)-phenyl]-4-methyl-7,8-dihydro-6H-pyrido[4,3-d]pyrimidin-5-one (HSP990) or a pharmaceutically acceptable salt thereof.
[0120] The present invention further relates to a kit comprising a compound of formula (I), or a pharmaceutically acceptable salt thereof, and at least one Hsp90 inhibitor or a pharmaceutically acceptable salt thereof, and a package insert or other labeling including directions for treating a proliferative disease.
[0121] The present invention further relates to a kit comprising a compound of formula (I), or a pharmaceutically acceptable salt thereof, and a package insert or other labeling including directions for treating a proliferative disease by co-administering at least one Hsp90 inhibitor or a pharmaceutically acceptable salt thereof.
[0122] Following is a description by way of example only.
EXAMPLE 1
Antitumor effect of 5-(2,4-Dihydroxy-5-isopropyl-phersyS)-4-{4-morpholin-4-ylmethyl-phenyl)˜isoxazole-3-carboxylic acid ethylamide (AUY922) and 5-chloro-N2-(2-isopropoxy-5-methyl-4-(piperidin-4-yl)phenyl)-N4-[2-(propane-2-sulfonyl)-phenyl]-pyrimidine-2,4-diamine (Compound A) in the Human Lung Primary Tumor Xenograft Model HLUX1787
[0123] The subcutaneous human lung primary tumor xenograft model HLUX1787 harbors an EML4-ALK variant 2 translocation and has high levels of phospho-cMET. The primary tumor sample HLUX-1787 is a human primary tumor xenograft that is obtained from Oncology Research at Novartis Institute for Biomedical Research at Cambridge, Mass. The xenograft model was established by direct subcutaneous (sc) implantation of minced surgical material into the subcutaneous area of nude adult female mice. The tumors were then serially passaged in mice to enable studies in this report. HLUX-1787 primary tumors were harvested and cut into 3×3×3 mm 3 size and implanted into nude mice. The tumors reached approximately 200 mm 3 at 24-27 days post implantation. On Day 24 (TRP-0318) or Day 27 (TRP-0335), tumors were measured and mice were randomized into treatment groups based on tumor volume.
[0124] Compound A was dissolved in 0.5° A, MC/0.5% Tween 80. It is stable for at least one week at room temperature. The dosing volume was 10 ml/kg.
[0125] AUY922 (mesylate salt) was dissolved in 5% Dextrose in water (D5W), and prepared fresh before dosing. It was administered at 60.5 mg/kg (equivalent to 50 mg/kg free base), iv, twice a week (2qw) or once a week (qw).
[0126] Efficacy Study Design
[0127] The designs for study TRP0318 and TRP0335 are summarized in Tables 1-1 and 1-2. Treatment dose was body weight adjusted. Tumor dimensions and body weights were collected at the time of randomization and twice weekly thereafter for the study duration. The following data were provided after each day of data collection: incidence of mortality, individual and group average body weight, and individual and group average tumor volume.
[0000]
TABLE 1-1
Dose and Schedule for Study TRP0318
Number
Treatment
Dose
Schedule
of mice
D5W
5 ml/kg
2qw iv
4
0.5% MC/
10 ml/kg
qd po
0.5% Tween 80
Compound A
10 mg/kg
qd, po
4
AUY922
50 mg/kg
2qw, iv
4
Compound A
10 mg/kg
qd, po
4
AUY922
50 mg/kg
2qw, iv
[0128] For study TRP0318, treatments were initiated on day 27 following tumor fragment implantation, when the average tumor volume was 240 mm 3 . Treatments continued for 20 days.
[0000]
TABLE 1-2
Dose and Schedule for Study TRP0335
Number of
Treatment
Dose
Schedule
mice
D5W
5 ml/kg
2qw iv
5
0.5% MC/
10 ml/kg
qd po
0.5% Tween 80
Compound A
25 mg/kg
qd, po
5
AUY922
50 mg/kg
qw, iv
5
AUY922
50 mg/kg
2qw, iv
5
Compound A
25 mg/kg
qd, po
5
AUY922
50 mg/kg
qw, iv
Compound A
25 mg/kg
qd, po
5
AUY922
50 mg/kg
2qw, iv
[0129] For study TRP0335, treatments were initiated on day 24 following tumor fragment implantation, when the average tumor volume was 240 mm 3 . Treatments continued for 13 days.
[0130] Data Analysis
[0131] Body Weight
[0132] The % change in body weight was calculated as (BW current −BW initial )/(BW initial )×100%. Data is presented as percent body weight change from the day of treatment initiation.
[0133] Tumor Volume
[0134] Percent treatment/control (TIC) values were calculated using the following formula:
[0000] % T/C= 100×Δ T/ΔC if Δ T> 0
[0000] % Regression=100×Δ T/T initial if Δ T< 0
[0135] where:
[0136] T=mean tumor volume of the drug-treated group on the final day of the study;
[0137] ΔT=mean tumor volume of the drug-treated group on the final day of the study−mean tumor volume of the drug-treated group on initial day of dosing;
[0138] T initial =mean tumor volume of the drug-treated group on initial day of dosing;
[0139] C=mean tumor volume of the control group on the final day of the study; and
[0140] ΔC=mean tumor volume of the control group on the final day of the study−mean tumor volume of the control group on initial day of dosing.
[0141] Statistical Analysis
[0142] Tumor volume and percent body weight change were expressed as mean±standard error of the mean (SEM). Plasma concentration of compound was expressed as mean±standard deviation. Delta tumor volume was used for statistical analysis. Between group comparisons were carried out using the one way analysis of variance (ANOVA) followed by a post hoc Tukey test. For all statistical evaluations, the level of significance was set at p<0.05. Significance compared to the vehicle control group is reported unless otherwise stated.
[0143] Results
[0144] Tolerability
[0145] The initial mean body weight and percentage of body weight change at termination are summarized in Table 1-3 and shown in FIGS. 1 and 2 (TRP-0318), and summarized in Table 1-4 (TRP-0335) and shown in FIGS. 3 and 4 .
[0000]
TABLE 1-3
Mean initial body weight and percentage of
body weight change (TRP-0318)
% BW changes
Treatment
Dose/schedule
Initial BW (g)
on day 47
D5W
5 ml/kg, 2qw iv
25.8 ± 0.7
4.1 ± 1.3
0.5%
10 ml/kg, qd po
MC/0.5%
Tween 80
Compound A
10 mg/kg, qd po
26.0 ± 0.3
3.5 ± 2.4
AUY922
50 mg/kg, 2qw iv
24.9 ± 0.5
−6.8 ± 3.1
AUY922
50 mg/kg, 2qw iv
25.1 ± 0.7
−5.2 ± 4.5
Compound A
10 mg/kg, qd po
[0000]
TABLE 1-4
Mean initial body weight and percentage of
body weight change (TRP-0335)
% BW changes
Treatment
Dose/schedule
Initial BW (g)
on day 37
05W
5 ml/kg, 2qw iv
25.2 ± 0.6
1.5 ± 3.2
0.5%
10 ml/kg, qd po
MC/0.5%
Tween 80
Compound A
25 mg/kg, qd po
25.1 ± 0.2
3.0 ± 2.2
AUY922
50 mg/kg, qw iv
24.2 ± 0.4
5.0 ± 0.8
AUY922
50 mg/kg, 2qw iv
24.6 ± 0.6
−2.2 ± 1.4
AUY922
50 mg/kg, qw iv
25.3 ± 0.7
1.1 ± 0.7
Compound A
25 mg/kg, qd po
AUY922
50 mg/kg, 2qw iv
26.0 ± 0.3
−0.1 ± 1.6
Compound A
25 mg/kg, qd po
[0146] In TRP-0318, Compound A was well tolerated at 10 mg/kg, with percent body weight change as 3.5%. The percent body weight change for the vehicle-treated group was 4.1% and the AUY922 50 mg/kg treated group was −6.8%. Compound A at 10 mg/kg in combination of AUY922 at 50 mg/kg twice a week resulted in −5.2% body weight losses.
[0147] Similarly, in TRP-0335, Compound A was well tolerated at 25 mg/kg with 3.0% body weight change, compared to vehicle-treated group with 1.5% body weight change, and AUY922 50 mg/kg once a week and twice a week treated group exhibit 5.0% and −2.2% body weight changes respectively. Compound A at 25 mg/kg in combination with AUY922 at 50 mg/kg once a week or AUY922 at 50 mg/kg twice a week, were also tolerated well with mean body weight change at 1.1% and -0.1% respectively.
[0148] In Vivo efficacy
[0149] Tumor growth and percent TIC are summarized in Table 1-5 (TRP-0318) and Table 1-6 (TRP-0335) and illustrated in FIGS. 1 and 2 (TRP-0318) to FIGS. 3 and 4 (TRP-0335).
[0000]
TABLE 1-5
Mean anti-tumor effect and body weight change summary
on day 47 (TRP-0318)
Tumor
Host
Response
Response
T/C
T/T0
% BW
Treatment
Dose
Schedule
(%)
(%)
change
Survival
D5W
5 ml/kg
2qw iv
4.1%
4
0.5%
10 ml/kg
qd po
MC/0.5%
Tween 80
Com-
10 mg/kg
qd, po
50.9%
3.5%
4
pound A
AUY922
50 mg/kg
2qw, iv
19.2%*
−6.8%
4
Com-
10 mg/kg
qd, po
−6.8%*
−5.2%
4
pound A
AUY922
50 mg/kg
2qw, iv
*p < 0.05 compared to Vehicle by one way ANOVA post hoc Tukey test.
[0000]
TABLE 1-6
Mean anti-tumor effect and body weight change summary
on day 37 (TRP-0335)
Tumor
Host
Response
Response
T/C
T/T0
% BW
Treatment
Dose
Schedule
(%)
(%)
change
Survival
D5W
5 ml/kg
2qw iv
1.5%
5
0.5%
10 ml/kg
qd po
MC/0.5%
Tween 80
Com-
25 mg/kg
qd, po
45.3%
3.0%
5
pound A
AUY922
50 mg/kg
qw, iv
19.3%*
5.0%
5
AUY922
50 mg/kg
2qw, iv
20.0%*
−2.2%
5
Com-
25 mg/kg
qd, po
16.0%*
1.1%
5
pound A
AUY922
50 mg/kg
qw, iv
Com-
25 mg/kg
qd, po
−34%**
−0.1%
5
pound A
AUY922
50 mg/kg
2qw, iv
*p < 0.05 compared to Vehicle by one way ANOVA post hoc Tukey test.
**p < 0.001 compared to Vehicle by one way ANOVA post hoc Tukey test.
[0150] In TRP-0318, Compound A at 10 mg/kg produced statistically non-significant anti-tumor effects with T/C 50.9%. AUY922 at 50 mg/kg resulted in TIC 19.2% (p<0.05 vs vehicle treated group), Compound A at 10 mg/kg in combination of AUY922 at 50 mg/kg twice a week resulted in tumor stasis with T/TO −6.8% (p<0.05 vs vehicle treated group) (See Table 1-5, FIG. 1 ).
[0151] In TRP-0335, Compound A at 25 mg/kg resulted in statistically non-significant effects with TIC 45.3%. AUY922 at 50 mg/kg once a week and twice a week resulted in T/C 19.3% and 20.0%, respectively (p<0.05 vs vehicle treated group). Compound A at 25 mg/kg in combination of AUY922 at 50 mg/kg once a week resulted in T/C 16.0% (p<0.05 vs vehicle treated group); Compound A at 25 mg/kg in combination of AUY922 at 50 mg/kg twice a week resulted in tumor regression with T/TO -34% (p<0.001 vs vehicle-treated group) (See Table 1-6, FIG. 3 ).
[0152] Results
[0153] In the HLUX1787 model, Compound A at 10 mg/kg and 25 mg/kg yielded 50.9% T/C and 45.3% T/C respectively; AUY922 at 50 mg/kg (free base) twice weekly resulted in 20%T/C; combinations of Compound A at 10 mg/kg or 25 mg/kg with AUY922 at 50 mg/kg resulted in tumor stasis (T/TO:−6.8%) and tumor regression (T/TO:−34%) respectively. Increased antitumor effect was observed in the HLUX-1787 model when Compound A and the HSP90 inhibitor AUY922 were combined. The combination of Compound A with AUY922 is more potent than either single agent in a lung cancer model which harbors EML4-ALK variant 2 translocation.
EXAMPLE 2
Antitumor effect of 5-{(2,4-Dihydroxy-5-isopropyl-phersyS)-4-(4-morpholin-4-ylmethyl-phenyl)˜isoxazole-3-carboxylic acid ethylamide (AUY922) and 5-chloro-N2-(2-isopropoxy-5-methyl-4-(piperidin-4-yl)phenyl)-N4-12-(propane-2-sulfonyl)-phenyl]-pyrimidine-2,4-diamine (Compound A) in the Human Lung Primary Tumor Xenograft Model LUF1656
[0154] The subcutaneous human lung primary tumor xenograft model LUF1656 harbors an EML4-ALK variant 1 translocation and has high levels of EGFR expression. EGFR, cMET and other RTK signaling pathways are also likely to be activated in these models.
[0155] Experimental Design
[0000]
TABLE 2-1
Dose and Schedule
Compound 1
Compound 2
Number
Dose and
Dose and
Group
of mice*
Drug
schedule
Drug
schedule
Endpoints
1
8
Vehicle 1
10 ml/kg po
Vehicle 2
5 ml/kg iv
Among the 8 mice in
(0.5% MC/0.5%
qd × 21 days
(D5W)
2qw × 3 wks
each group, 4 mice
Tween 80)
had tumor samples
2
8
Compound A
25 mg/kg po
taken at 4 hrs after
qd × 21 days
the last dose of
3
8
Compound A
50 mg/kg po
Compound A or
qd × 21 days
Vehicle 1. The rest of
4
8
Compound A
100 mg/kg po
mice in each group
qd × 21 days
were kept under
5
8
AUY922
50 mg/kg iv
observation for 2
2qw × 3 wks
weeks.
6
8
Compound A
25 mg/kg po
AUY922
50 mg/kg iv
qd × 21 days
2qw × 3 wks
[0156] Methods
[0157] Tumor Inoculation
[0158] Tumor fragments from stock mice inoculated with selected primary human lung cancer (LUF1656) were harvested and used for inoculation into nu/nu mice. Each mouse was inoculated subcutaneously at the right flank with one tumor fragment (3×3×3 mm 3 ) for tumor development. The treatments were started when mean tumor size reached approximately 140 mm 3 (range 86.8-245 mm 3 ). The test articles administration and the animal numbers in each group are shown in the experiment design Table 2-1.
[0000]
TABLE 2-2
Testing Article Formulation Preparation
Dose
Concentration
Compounds
(mg/kg)
Preparation
(mg/ml)
Storage
Vehicle 1 for
—
0.5% MC/0.5% Tween 80
—
Stored at
Compound A
4° C.
Vehicle 2 for
D5W
—
Stored at
AUY922
RT
Compound A
100
Suspended 370 mg Compound A in 37 ml
10
Stored at
(1)
0.5% methylcellulose/0.5% Tween 80,
RT for 1
vortexed to mix well.
week
Compound A
50
Diluted 18 ml Compound A (1) in 18 ml 0.5%
5
Stored at
(2)
methylcellulose/0.5% Tween 80.
RT for 1
week
Compound A
25
Diluted 17.5 ml Compound A (2) in 17.5 ml
2.5
Stored at
(3)
0.5% methylcellulose/0.5% Tween 80.
RT for 1
week
AUY922
50
Dissolved 33.9 mg AUY922-AG (equivalent
10
Prepared
to 28 mg AUY922-NX) in 2.8 ml of D5W,
fresh
sonicated until clear.
[0159] Tumor Measurements and the Endpoints
[0160] The major endpoint was to see if the tumor growth can be delayed or tumor bearing mice can be cured. Tumor size was measured twice weekly in two dimensions using a caliper, and the volume was expressed in mm 3 using the formula: V=0.5 a×b 2 where a and b are the long and short diameters of the tumor, respectively. The tumor size was then used for calculations of both T−C and T/C values. T−C was calculated with T as the time (in days) required for the mean tumor size of the treatment group to reach a predetermined size (e.g., 400 mm 3 ), and C was the time (in days) for the mean tumor size of the control group to reach the same size. Percent treatment/control (T/C) values were calculated using the following formula:
[0000] % T/C= 100×Δ T/ΔC if Δ T> 0
[0000] Regression=100×Δ T/T initial if Δ T< 0
[0161] where:
[0162] T=mean tumor volume of the drug-treated group on the final day of the study;
[0163] ΔT=mean tumor volume of the drug-treated group on the final day of the study−mean tumor volume of the drug-treated group on initial day of dosing;
[0164] T initial =mean tumor volume of the drug-treated group on initial day of dosing;
[0165] C=mean tumor volume of the control group on the final day of the study; and
[0166] ΔC=mean tumor volume of the control group on the final day of the study−mean tumor volume of the control group on initial day of dosing.
[0167] Statistical Analysis
[0168] Summary statistics, including mean and the standard error of the mean (SEM), are provided for the tumor volume of each group at each time point.
[0169] Statistical analysis of difference in tumor volume among the groups was conducted using a one-way ANOVA followed by multiple comparisons using Tukey HSD. Log transformation was performed for homogeneity of variances when necessary. All data were analyzed using SPSS (Statistical Package for the Social Sciences or Statistical Product and Service Solutions) 16.0. p<0.05 was considered to be statistically significant.
[0170] The standard protocols used in pharmacology studies are not pre-powered to demonstrate statistically significant superiority of a combination over the respective single agent treatment. The statistical power is often limited by potent single agent response and/or model variability. The p-values for combination vs single agent treatments are, however, provided.
[0171] Results
[0172] Body Weights
[0173] The results of the body weight changes in the tumor bearing mice are shown in FIG. 5 and FIG. 6 .
[0174] Tumor Volumes
[0175] The tumor sizes of the different groups at different time points are shown in Table 2-3 and Table 2-4.
[0000]
TABLE 2-3
Tumor Sizes in the Different Treatment Groups (treatment phase, n = 8)
Tumor Volume (mm 3 ) a
Cmpd A
25 mg/kg (QD ×
22 Days)
Days
Cmpd A 25 mg/kg
Cmpd A
Cmpd A
AUY922
AUY922
post
Vehicle 1 +
(QD × 22
50 mg/kg (QD ×
100 mg/kg
50 mg/kg
50 mg/kg
Treatment
Vehicle 2
Days)
22 Days)
(QD × 22 Days)
(2qw × 3 wks)
(2qw × 3 wks)
0
139.5 ± 17.0
139.8 ± 16.7
139.5 ± 17.0
139.4 ± 18.3
140.1 ± 17.3
139.5 ± 15.6
4
226.7 ± 45.2
171.5 ± 29.9
144.9 ± 23.5
110.8 ± 21.7
177.5 ± 22.9
112.7 ± 20.7
7
283.7 ± 54.6
205.4 ± 46.4
138.8 ± 30.8
107.7 ± 24.6*
194.9 ± 28.0
112.5 ± 26.5*
11
416.0 ± 78.5
248.0 ± 68.4
155.4 ± 38.8**
118.3 ± 29.9**
244.5 ± 32.2
121.2 ± 34.6**
14
552.0 ± 103.3
296.9 ± 93.9
175.1 ± 45.2**
133.2 ± 33.2**
282.1 ± 36.7
147.3 ± 48.4**
18
750.0 ± 141.1
356.1 ± 113.6
194.5 ± 53.6**
146.1 ± 36.4***
402.5 ± 51.9
209.5 ± 72.9**
21
983.2 ± 198.1
435.7 ± 155.6
231.5 ± 65.2**
155.8 ± 41.2***
466.8 ± 59.5
235.7 ± 86.8**
Note:
a Mean ± SEM;
n: animal number;
*P < 0.05, **P < 0.01, ***P < 0.001, compared with the vehicle control.
[0000]
TABLE 2-4
Tumor Sizes in the Different Treatment Groups (re-growth phase, n = 4)
Tumor Volume (mm 3 )
Compound A
Compound A
Compound A
Compound A
25 mg/kg (QD ×
Days
25 mg/kg
50 mg/kg
100 mg/kg
AUY922 50 mg/kg
22 Days)
post
Vehicle 1 +
(QD × 22
(QD × 22
(QD × 22
(2qw ×
AUY922 50 mg/kg
Treatment
Vehicle 2
Days)
Days)
Days)
3 wks)
(2qw × 3 wks)
23
1085.3 ± 310.8
434.4 ± 141.0
270.1 ± 109.0
186.4 ± 68.1
612.0 ± 80.7
254.6 ± 94.4
27
1324.6 ± 378.7
552.4 ± 159.3
300.2 ± 106.2
203.2 ± 77.3
904.7 ± 136.8
352.5 ± 126.0
30
1574.8 ± 432.7
671.6 ± 175.7
348.5 ± 124.4
235.0 ± 93.9
1136.2 ± 188.6
497.6 ± 173.6
34
1924.3 ± 499.2
949.9 ± 246.7
514.3 ± 163.8
304.0 ± 120.3
1508.9 ± 273.8
766.9 ± 275.5
[0176] Tumor Growth Inhibition
[0177] The tumor growth inhibition is summarized in Table 2-5.
[0000]
TABLE 2-5
Antitumor Activity of Compound A as a Single Agent and in
Combination with AUY922 in the Treatment of Primary Human
Lung Cancer LUF1656 Xenograft Model at Day 21.
Tumor Size (mm 3 ) a at
P
Treatment
Day 21 after Treatment
T/C (%)
value b
Vehicle 1 + Vehicle 2
983.2 ± 198.1
—
—
Compound A (25 mg/kg, PO, QD × 22 Days)
435.7 ± 155.6
35.1
0.098
Compound A (50 mg/kg, PO, QD × 22 Days)
231.5 ± 65.2
10.9
0.002
Compound A (100 mg/kg, PO, QD × 22 Days)
155.8 ± 41.2
1.9
<0.001
AUY922 (50 mg/kg, IV, 2QW × 3 wks)
466.8 ± 59.5
38.7
0.486
Compound A (25 mg/kg, PO, QD × 22 Days) +
235.7 ± 86.8
11.4
0.001
AUY922 (50 mg/kg, IV, 2QW × 3 wks)
Note:
a Mean ± SEM;
b vs. vehicle control.
[0178] Tumor Growth Curves
[0179] The tumor growth curves of different groups are shown in FIGS. 7 and 8 .
[0180] Result Summary and Discussion
[0181] In this efficacy study, the therapeutic efficacy of Compound A as a single agent and in combination with AUY922 in the treatment of subcutaneous primary human lung cancer LUF1656 xenograft model in nu/nu mice was evaluated. The results of tumor size in different groups at different time points after treatment are shown in the Tables 2-3 and 2-4 and in FIGS. 7 and 8 .
[0182] Treatment with Compound A as a single agent at 25 mg/kg (PO, QD×22 Days) showed moderate antitumor activity (T/C value=35.1% on Day 21 after treatment) (p>0.05 when compared to vehicle). Treatment with Compound A as a single agent at 50 and 100 mg/kg (PO, QD×22 Days) exhibited significant antitumor activity from Day 11 to Day 21 and Day 7 to Day 21 after treatment compared with vehicle control (T/C value=10.9%, p<0.01, at Day 21 after treatment of 50 mg/kg Compound A treatment group; and T/C value=1.9%, p<0.001, at Day 21 after treatment of 100 mg/kg Compound A treatment group). Treatment with AUY922 as a single agent at 50 mg/kg (IV, 2QW×3 wks) showed moderate antitumor activity (T/C value=38.7% at Day 21 after treatment when compared to vehicle). Treatment with 25 mg/kg Compound A (PO, QD×22 Days) plus 50 mg/kg AUY922 (IV, 2QW×3 wks) showed significant antitumor activity from Day 7 to Day 21 after treatment when compared to vehicle control (T/C value=11.4%, p<0.01, at Day 21 after treatment). The antitumor activity of the combination treatment (25 mg/kg Compound A+50 mg/kg AUY922) was better than that of each monotherapy.
[0183] Based on the body weight data as shown in FIGS. 5 and 6 , the test articles Compound A at dose levels of 25, 50 and 100 mg/kg, AUY922 at 50 mg/kg and combination of 25 mg/kg Compound A with 50 mg/kg AUY922 were all tolerated by the primary human lung cancer LUF1656 tumor-bearing mice in this study.
[0184] In summary, the test article Compound A at 50 and 100 mg/kg as single agent and 25 mg/kg Compound A in combination with 50 mg/kg AUY922 all demonstrated statistically significant antitumor activity against the primary human lung cancer LUF1656 xenograft model. Combination of Compound A and AUY922 produced increased anti-tumor activity compared to the corresponding monotherapies.
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A pharmaceutical combination comprising (a) a compound of formula (I),
or pharmaceutically acceptable salts thereof; and (b) one or more at least one compound targeting, decreasing or inhibiting the intrinsic ATPase activity of Hsp90 and/or degrading, targeting, decreasing or inhibiting the Hsp90 client proteins via the ubiquitin proteosome pathway; the uses of such combination in the treatment or prevention of proliferative diseases; and methods of treating a subject suffering.
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FIELD
[0001] The present disclosure relates to an apparatus and method of reducing undesirable emissions from a vehicle, and more particularly to an apparatus and method of producing airflow for use during a cold start to reduce undesirable emissions.
BACKGROUND
[0002] Vehicles today employ various methods to reduce undesirable components of emissions. A catalytic converter is one component found in most vehicles that assists in reducing undesirable components found in vehicle emissions. One of the biggest shortcomings of the catalytic converter, however, is that it generally provides its highest efficiency at fairly high temperatures. This does not present a problem during normal operation of a vehicle because the heat generated by the vehicle's engine heats the catalytic converter. During a cold start of a vehicle, however, the engine is not able to heat the catalytic converter for a short period. During this short period, the catalytic converter does not operate at a desirable efficiency to reduce undesirable components in the vehicle's exhaust.
[0003] In one configuration to reduce emissions during a cold start, the temperature of the catalytic converter can be quickly raised without using heat generated by the engine. To raise the temperature of the catalytic converter in these situations, many vehicles are equipped with a secondary air system. The secondary air system typically includes a compact air pump that compresses and forces air into an exhaust manifold that contains the catalytic converter. As emissions from the engine enter the exhaust manifold, they encounter the compressed air and oxidize. The oxidation of the emissions quickly raises the temperature of the catalytic converter. This allows the catalytic converter to operate efficiently and reduce the toxicity of emissions even during a cold start. This efficiency comes at a price, however, since the required air pump tends to be expensive and at times unreliable. What is needed is a better way to supply compressed air to the exhaust manifold during a cold start to enable efficient operation of the catalytic converter.
SUMMARY
[0004] The present disclosure provides an apparatus for moving air in a vehicle. The apparatus includes a cooling fan for the vehicle's engine that has a plurality of blades. The plurality of blades defines an outer perimeter of the fan. The apparatus also includes a housing surrounding at least a portion of the outer perimeter of the fan and a plurality of vanes between the housing and the fan. The vanes revolve around the outer perimeter of the fan to direct air into the housing.
[0005] The housing may have an outlet, wherein the air directed into the housing is directed out the outlet. The air in the housing may be compressed before being directed out the outlet. The housing may include a varying cross sectional area for compressing the air. Further, the outlet may be directed to a secondary air system of the vehicle.
[0006] The apparatus may also include a motor for revolving the vanes and revolving the fan. The vanes may also be hinged to allow rotation between an open position and a closed position. Revolving the vanes in a first direction rotates the vanes to the open position. Revolving the vanes in a second direction rotates the vanes to the closed position. Additionally, revolving the fan in the second direction directs air to assist in cooling the engine.
[0007] The present disclosure also provides a method of moving air in a vehicle. The method includes revolving a plurality of vanes around a perimeter of a cooling fan for the vehicle's engine. The revolving vanes direct air into a housing surrounding the vanes. The method may further include compressing the air that enters the housing and outputting the compressed air through an outlet in the housing. The compressed air may be directed to a secondary air system of the vehicle. Further, the housing may compress the air entering the housing by having a varying cross sectional area.
[0008] The method may also include revolving the vanes and the fan using a single motor. The vanes used in the method may be hinged to allow rotation between an open position and a closed position. Revolving the vanes in a first direction rotates the vanes to the open position. Revolving the vanes in a second direction rotates the vanes to the closed position. Additionally, revolving the fan in the second direction directs air to assist in cooling the engine.
[0009] Further areas of applicability of the present disclosure will become apparent from the detailed description, drawings and claims provided hereinafter. It should be understood that the detailed description, including disclosed embodiments and drawings, are merely exemplary in nature and intended for purposes of illustration only, and are not intended to limit the scope of the invention, its application, or use. Thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a front view of a exemplary fan with a surrounding vane system;
[0011] FIG. 2 is a side view of an exemplary air flow production system that incorporates the fan and vane support of FIG. 1 ;
[0012] FIG. 3 is a front view of the fan of FIG. 1 with a front vane support removed to show the vanes;
[0013] FIG. 4 a is an exemplary rotatable hinged vane;
[0014] FIG. 4 b is an exemplary fixed vane;
[0015] FIG. 5 is an exemplary cavity in a vane support that houses part of the vane of FIG. 4 a;
[0016] FIG. 6 is a front view of the air production system of FIG. 2 along the line 6 , with the vanes in the open position;
[0017] FIG. 7 is a side view of FIG. 1 with the vanes in the open position;
[0018] FIG. 8 is a front view of the air production system of FIG. 2 along the line 6 , with the vanes in the closed position;
[0019] FIG. 9 is a side view of FIG. 1 with the vanes in the closed position; and
[0020] FIG. 10 is the air production system of FIG. 2 within a vehicle.
DETAILED DESCRIPTION
[0021] FIGS. 1 and 2 illustrate various components of an exemplary airflow production system 100 used in a vehicle. The system 100 includes a fan 110 with a plurality of fan blades 112 coupled to a motor 114 . The motor 114 is in the center of the fan 110 and produces a force that revolves the blades 112 . The fan 110 may be a radiator fan used in a vehicle's cooling systems. Alternatively, the fan 110 may have other configurations. The system 100 also includes a vane system 130 that is circular and surrounds the outer periphery of the fan 110 . The vane system 130 has an open area and does not cover the face of the fan 110 . The vane system 130 includes a front vane support 132 , a back vane support 134 , and a plurality of vanes 140 as illustrated in FIG. 7 . The front vane support 132 and the back vane support 134 are both circular with open areas. Individual vanes 140 are coupled between the front and back vane supports 132 , 134 . The front and back vane supports 132 , 134 support and retain the vanes 140 in place. The vanes 140 are described below in more detail with respect to FIGS. 4 , 5 , and 6 .
[0022] The vane system 130 is coupled to the motor 114 . As the motor 114 spins to revolve the fan blades 112 , the motor 114 revolves the vane system 130 . Alternatively, the vane system 130 may be coupled to and revolved by another motor that is not part of the fan 110 . The vane system 130 may be coupled to the motor 114 by way of the fan blades 112 . Each fan blade 112 , at a point furthest from the fan motor 114 , may be coupled to the vane system 130 . Alternatively, supports may couple the vane system 130 to the motor 114 to allow the motor 114 to revolve the vane system 130 . It should be understood that the disclosure should not be limited to how the vane system 130 is revolved around its center axis.
[0023] FIG. 2 illustrates a side view of system 100 with the periphery of the fan blades 112 and the vane system 130 surrounded by a housing 120 . The motor 114 is shown in the middle of the housing 120 . The housing 120 has an open area to allow airflow produced by the fan 110 to pass through. Arrows 116 show one direction of airflow produced by the fan 110 passing through the area of the housing 120 .
[0024] FIG. 3 illustrates a view of the fan 110 surrounded by the vane system 130 with the front vane support 132 removed to expose the vanes 140 supported in the vane system 130 . FIG. 4 a illustrates an example of a rotatable vane 140 . The vane 140 includes a first arm 142 , a second arm 144 , a hinge 146 , and a flat 148 . The first and second arms 142 , 144 extend away from the circular hinge 146 , with the first arm 142 being longer than the second arm 144 . Each vane 140 has an axis of rotation around the hinge 146 . The axis of rotation is offset from the center of the each vane 140 because the first and second arms 142 , 144 are not the same length in this example. The flat 148 is coupled to the hinge 146 and has a rectangle shape.
[0025] The flat 148 and the hinge 146 of each vane 140 interact with a vane connector 136 ( FIG. 5 ) on both the front and back vane supports 132 , 134 . In an illustrated embodiment, the vane connector 136 is a cavity within the front and back vane supports 132 , 134 that has a bowtie shape with a circular middle 137 as illustrated in FIG. 5 . The hinge 146 of each vane 140 rests in the middle 137 of the vane connector 136 . This connection allows the vane 140 to rotate. The flat 148 also resides within the cavity of the vane connector 136 . The flat 148 limits the rotation of the vane 140 . As the vane 140 rotates around the hinge 146 , the flat 148 rotates and meets a flat section of the vane connector 136 , stopping the rotation of the vane 140 . The shape of the vane connector 136 and the flat 148 may be modified to control the amount of rotation of each vane 140 . It should be understood that the ability to control the rotation of a vane 140 is not limited to the vane 140 having a flat 148 . Alternatively, the rotation of a vane 140 may be controlled by the vane 140 coming into contact with another vane 140 or by other means.
[0026] Alternatively, the vane system 130 may include fixed vanes 240 illustrated in FIG. 4 b . Each fixed vane 240 has a shape similar to vanes 140 , but does not include a hinge or a flat. The fixed vane 240 is instead rigidly coupled to the front and back vane support 132 , 134 and does not rotate. The fixed vanes 240 are fixed in a position similar to the vanes 140 shown in FIG. 7 .
[0027] FIG. 6 illustrates a cross-sectional view of the front of the system 100 taken along the line 6 of FIG. 2 and illustrates the internal part of the housing 120 . The housing 120 is open next to the vane system 130 to receive airflow 160 directed, here pushed, by the vane system 130 into the housing 120 . The housing 120 has a varying internal height 122 and first and second outlets 124 , 126 . The outlets 124 , 126 are evenly spaced around the periphery of the housing 120 and are located in corresponding compression chambers 125 , 127 . The compression chambers 125 , 127 equally divide the housing 120 in half. The height 122 within each compression chamber 125 , 127 is at its peak at an end farthest from its respective outlet 124 , 126 . The height 122 of each compression chamber 125 , 127 gradually decreases until it reaches a minimum height 123 near its respectively outlet 124 , 126 .
[0028] The varying height 122 of each compression chamber 125 , 127 allow the compression chambers 125 , 127 to compress air that is directed into the chambers 125 , 127 by the vane system 130 . The varying height 122 also allows the compression chamber 125 , 127 to force the compressed air out the respective outlets 124 , 126 . It should be understood that system 100 is not limited to having two outlets 124 , 126 and two compression chambers 125 , 127 . Nor is the system 100 limited to having the chambers 125 , 127 and outlets 124 , 126 equally spaced around the housing 120 . Alternatively, the system 100 may have a single outlet and compression chamber. The system 100 may also have multiple outlets and chambers. Further, the chambers 125 , 127 and outlets 124 , 126 may be unevenly spaced around the housing 120 .
[0029] In operation, system 100 moves air and then compresses it. To begin, the vane system 130 is revolved by the motor 114 in a counter-clockwise direction. The vane system 130 draws air from the area, e.g. center area, of the system 100 and directs the air into the housing 120 as shown by the airflow 160 . Once inside the housing 120 , the airflow 160 within compression chamber 125 is directed toward the outlet 124 . As the airflow 160 flows along the compression chamber 125 , the volume of the compression chamber 125 decreases as the height 122 decreases, thereby compressing the airflow 160 . The compressed airflow 160 is then directed out of outlet 124 . The airflow 160 within the compression chamber 127 is compressed and directed out the outlet 126 in a similar manner.
[0030] FIG. 10 illustrates the system 100 used in a vehicle 220 to compress air and to cool an engine 222 of the vehicle 220 . The system 100 would be used on a cold start to provide compressed air to a secondary air system 224 . For example, as shown in FIG. 6 and described above, when the fan 110 and the vane system 130 are rotated in a counter-clockwise direction, air is pushed into the housing 120 , compressed and piped to the secondary air system 224 . Either the hinged vanes 140 or the fixed vanes 240 may be used to direct air into the housing 120 where the air is compressed. The compressed air is used by the secondary air system 224 to quickly raise the temperature of the catalytic converter to reduce emissions on a cold start. Air is also directed by the fan 110 away from the engine 222 of the vehicle 220 . After the catalytic converter's temperature is raised, the rotations of the fan 110 and vane system 130 are stopped.
[0031] After the engine 222 has been running, it may need to be cooled. The fan 110 of the system 100 is revolved in a clockwise direction to direct air to cool the engine 222 . As a result, the vane system 130 is also rotated in a clockwise direction. If the fixed vanes 240 are part of the system 100 , when the fan 110 rotates in a clockwise direction to direct air to cool the engine 222 , the fixed vanes 240 direct some air into the housing 120 . As a result, pressure builds and the pressure applies a force counter to the rotation of the fan motor 114 . The fan motor 114 must subsequently draw additional power from the engine 222 to overcome this force.
[0032] To eliminate the extra draw on the engine 222 , the hinged vanes 140 should be used. As discussed above, each vane 140 is able to rotate around their respective hinge 146 and the hinge 146 is offset from the center of each vane 140 so that each vane 140 has an offset center of inertia. As a result, as shown in FIGS. 6 and 7 , when the vane system 130 is rotated in the counter clockwise direction the centripetal force on each vane 140 rotates that vane 140 . The vane 140 is rotated until the flat 148 contacts a portion of the vane connector 136 . After being rotated, the vane 140 has its first arm 142 extending toward the motor 114 of the fan 110 and is in an open position. With the vanes 140 in the open position, the vane system 130 is able to direct air into the housing 120 where the air is compressed to aid in a cold start.
[0033] When the fan 110 is rotated in a clockwise direction to cool the engine 222 , the vanes 140 also rotate. When the vanes 140 are rotated in a clockwise direction, the centripetal force rotates the vanes 140 in a direction opposite from when the vanes 140 are rotated in the counter-clockwise direction. Again, each vane 140 is rotated until the flat 148 contacts a portion of the vane connector 136 . After being rotated, the first arm 142 of each vane 140 is folded up and in contact with another one of the vanes 140 , closing the housing 120 . FIGS. 8 and 9 illustrate the vanes 140 in the closed position. As a result, the vane system 130 does not direct air into the housing 120 and no additional force is placed on the motor 114 when the fan 110 is used to cool the engine 222 . It should be understood that system 100 may be designed to produce compressed air when the vanes 140 are rotated in either the clockwise or counter-clockwise direction.
[0034] The system 100 offers various advantageous because little additional space is required to generate the compressed air for a cold start because the system 100 utilizes many components from the vehicle's 220 existing cooling system, namely a fan 110 and a housing 120 . Further, the additional component costs are reduced compared to known systems. Moreover, the system 100 has higher reliability and requires less energy draw than existing systems.
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An apparatus and method for producing air flow in a vehicle that uses a cooling fan for an engine of the vehicle. The cooling fan has plurality of blades, which define an outer perimeter of the fan. The apparatus also includes a housing surrounding at least a portion of the outer perimeter of the fan and a plurality of vanes between the housing and the fan. The vanes are revolved around the outer perimeter of the fan to direct air into the housing.
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This application is a continuation of application Ser. No. 07/906,663, filed Jun. 30, 1992, now abandoned, which is a divisional of application Ser. No. 07/627,919, filed Dec. 17, 1990, now U.S. Pat. No. 5,322,376, which is a continuation of application Ser. No. 07/230,677, filed Aug. 8, 1988, now abandoned, which is a continuation of application Ser. No. 07/063,781, filed Jun. 22, 1987, now abandoned, which is a continuation of application Ser. No. 06/883,447, filed Jul. 10, 1986, now abandoned, which is a continuation of application Ser. No. 06/664,945, filed Oct. 26, 1984, now abandoned, which is a continuation of application Ser. No. 05/314,441, filed Oct. 23, 1981, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a serial printing apparatus in which the font wheel and the carriage are stopped before each printing action, and more particularly to such printing apparatus system provided with a plurality of interchangeable font wheels, more generally referred to as type units.
2. Description of the Prior Art
The conventional large word processor with a cathode ray tube display is bulky, expensive and requires expertise in use. Also there are known electronic typewriters which function as small word processors but they are still associated with various shortcomings requiring improvements and are complicated and expensive in structure.
SUMMARY OF THE INVENTION
The object of the present invention is to provide certain improvements on such apparatus.
BRIEF DESCRIPTION OF THE FIGURES
The attached Figures illustrate an embodiment of the electronic typewriter of the present invention, wherein:
FIG. 1 is a schematic perspective external view of the electronic typewriter;
FIG. 2 is a schematic perspective view showing the internal structure thereof;
FIGS. 3A and 3B are cross-sectional and lateral views respectively of a carriage unit shown in FIG. 2;
FIG. 4 is a perspective view showing the positional relationship between a ribbon cassette and a ribbon detector;
FIG. 5 is a lateral view showing the cassette position in a print action and in a stand-by state;
FIG. 6 shows the manner in which FIGS. 6-1 and 6-2 should be arranged;
FIGS. 6-1 and 6-2 are block diagrams of the entire control system grouped in various functions;
FIG. 7 is a detailed block diagram of the printer control unit shown in FIG. 6-1;
FIG. 8 is a circuit diagram of the paper feed pulse motor control unit shown in FIG. 7;
FIGS. 9 and 11 are circuit diagrams of the printing hammer control unit shown in FIG. 7;
FIGS. 10 and 12 are circuit diagrams of the ribbon feed motor control unit shown in FIG. 7;
FIGS. 13 and 14 are circuit diagrams respectively of the bail start motor drive unit and the carriage indicator unit shown in FIG. 7;
FIG. 15 is a circuit diagram of the alarm control unit shown in FIG. 6-2;
FIG. 16 is a circuit diagram of the type selecting motor control unit shown in FIG. 7;
FIG. 17 is a circuit diagram of the carriage driving motor control unit shown in FIG. 7;
FIG. 18 shows the manner in which FIGS. 18-1 and 18-2 should be arranged;
FIGS. 18-1 and 18-2 are circuit diagrams showing an example of a key input circuit;
FIG. 19B shows the manner in which FIGS. 19B-1 and 19B-2 should be arranged;
FIGS. 19A, 19B-1 and 19B-2 are waveform charts showing the function thereof;
FIG. 20 is a detailed plan view showing an example of the control panel of an electronic typewriter shown in FIG. 1;
FIG. 21 is a detailed view of the flag group shown in FIG. 6-2;
FIG. 22 is a detailed view of the register group shown in FIG. 6-2;
FIG. 23 is a detailed view of the line buffer shown in FIG. 6-2;
FIGS. 24 and 25 are control flow charts for said line buffer;
FIG. 26 is a control flow chart for key operations at the registration of characters or a sentence;
FIG. 27 is a flow chart showing the function thereof;
FIG. 28 shows the manner in which FIGS. 28-1 and 28-2 should be arranged;
FIGS. 28-1 and 28-2 are control flow charts for key operations at the reviewing of characters or a sentence;
FIG. 29 shows the manner in which FIGS. 29-1 and 29-2 should be arranged;
FIGS. 29-1 and 29-2 are flow charts showing the function thereof;
FIG. 30 is a schematic view showing an example of the printing sheet;
FIG. 31 is a control flow chart for key operations at the registration of page format;
FIG. 32 is a control flow chart for key operations at the recalling of page format;
FIG. 33 is a control flow chart for key operations at the registration of tabulator stop positions;
FIG. 34 is a control flow chart for key operations at the recalling of tabulator stop positions;
FIG. 35 shows the manner in which FIGS. 35-1 and 35-2 should be arranged;
FIGS. 35-1 and 35-2 are flow charts showing the functions of registration of page format and tabulator stop positions;
FIG. 36 is a flow chart showing the functions of recalling of page format and tabulator stop positions;
FIG. 37 is a schematic view showing an example of printing;
FIG. 38 is a block diagram of an embodiment for obtaining the contents of a line buffer as shown in FIGS. 39-1 and 39-2;
FIG. 39 shows the manner in which FIGS. 39-1 and 39-2 should be arranged;
FIGS. 39-1 and 39-2 are views showing an example of the content of line buffer;
FIG. 40 is a schematic view of an example of the printing head of the present embodiment;
FIGS. 41 and 42 are schematic views showing examples of printing;
FIG. 43 is a block diagram showing a circuit for conducting said printing;
FIG. 44 is a block diagram showing an embodiment of the invention;
FIG. 45 is a schematic view showing the thus obtained print;
FIGS. 46A and 46B are schematic views showing the changes in the display and print;
FIG. 47 shows the manner in which FIGS. 47-1 and 47-2 should be arranged;
FIGS. 47-1 and 47-2 are block diagrams showing another embodiment of the electronic typewriter; and
FIG. 48 is a view showing another embodiment of the keyboard.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Now the present invention and its various features will be clarified in detail by the following description to be taken in conjunction with the attached Figures.
At first reference is made to FIGS. 1 to 5 showing the basic structures of an electronic typewriter embodying the present invention, wherein a platen knob 1 is provided for manual loading of an unrepresented printing sheet or for fine adjustment of the print position in the vertical direction. Said knob 1, when pressed inwards, is disengaged from a stepping motor 14 (FIG. 2) to allow manual rotation of said knob 1. A paper support 2 guides the printing sheet in such a manner that the printed face of even a thin sheet is directed toward the operator. A page end indicator 3 is a scale indicating the length to the last line of the sheet and is manually adjusted in advance by the operator in the vertical direction indicated by the arrow, whereby the position of the last line can be known when the upper end of the printing sheet coming out from a platen 17 (FIG. 2) reaches a determined scale line on the indicator 3. A paper bail 250 (FIG. 2) maintains the printing sheet in contact with the platen 17. A release lever 4 (FIG. 1) releases pinch rollers 17a, 17b and 17c (FIG. 2) provided under the platen 17, thus allowing the inclination of the printing sheet to be manually corrected. A cover 5, made of transparent acrylic resin, reduces the noise of impact printing and still allows the operator to see the printed characters. An upper cover 6, 7 can be swung open to the back for replacement of a typefont wheel 30 or a ribbon cassette 36 mounted on a carriage 26 as shown in FIG. 2. The printing hammer 32, printing ribbon 34, correcting ribbon 33, winding spool 38, and stepping motor 39 are discussed later in connection with FIGS. 3A and 3B.
The illustrated electronic typewriter can achieve four printing pitches in the lateral direction, i.e. 10, 12 or 15 characters per inch or proportional spacing in which the printing pitch is variable according to the size of each type. A scale 8 has three gradations, represented on scales 8a, 8b and 8c, respectively for 10, 12 and 15 characters per inch. An indicator mount 11 mounted on the carriage 26 as shown in FIG. 2, holds a carriage indicator 12 which lights a light-emitting diode, 12a, 12b, or 12c, respectively, corresponding to a printing pitch instructed from a keyboard 10 to indicate the carriage position on said scale 8a, 8b, or 8c, respectively.
The keyboard 10 is composed of character keys 10a for entering characters, control keys 10b, 10c provided on both sides, mode keys 10d, 10g provided on both sides and locking slide keys 10e, 10f for selecting the print modes, and the entered key signals are identified by a keyboard control unit 24 (FIG. 2) and supplied to a main control unit 22 (FIG. 2) containing a microprocessor unit (MPU) which is shown in FIG. 6-1 as element 44. In case of key entries for printing, related data are supplied from the unit 22 to a printer control unit 16. A block diagram for the printer control circuit is shown in FIG. 6-1 and will be discussed later. In case of key entries for display, related data are supplied from the unit 22 to a display control unit 48 for display on a display unit 9. A block diagram for the display control circuit is shown in FIG. 6-2 and will be discussed later. Also in case of key entries for changing the LED (light emitting diode) display units L1, L2, L3, L4, and L5 on the keyboard 10, such as changing the printing pitch (indicated by L1), line spacing (indicated by L2), or character selection keys (indicated by L3), data for controlling LED's L1-L5 are supplied from the main control unit 22 to the keyboard control unit 24. A paper feed stepping motor 14 for advancing the printing sheet rotates platen 17 through a transmission belt 15 under the control of the printer control unit 16.
A servo motor 18 for carriage displacement causes the lateral displacement of the carriage 26 along guide rods 25 and 27 through gears 20 and a belt 21. A photoencoder 19 for detecting the rotation angle of said carriage driving motor 18 provides a feedback signal to the printer control unit 16, thus constituting a servo control loop. A back-up battery 23 for the memory 54 (FIG. 6-2) in the main control unit 22 prevents the loss of stored information when the power supply is cut off. A loud speaker 42 is provided for giving a sound alarm and is controlled by an alarm control unit 49. A power supply unit 13 positioned behind the printer supplies electric power to various units. A flexible conductor FL supplies signals to the stepping motor 39 etc. on the carriage 26.
FIGS. 3A and 3B show the structure of carriage 26 in cross-sectional and lateral views. In the cross-sectional view in FIG. 3A, there is shown a servo motor 29 for character selection, which is provided on an end thereof with a typefont wheel 30 and on the other end thereof with a photoencoder 35. A printing hammer 32 is composed of a linear motor 32a in which the driving direction of the hammer 32 is varied according to the direction of the energizing current in the coil 32b. In the movement towards the platen 17 said hammer 32 hits a selected type of the typefont wheel 30 against the printing sheet on the platen 17 through a printing ribbon 34 in the printing action or through a correcting ribbon 33 in a correcting action. In the lateral view in FIG. 3B, there is shown a printing ribbon cassette 36 in which is provided a printing ribbon 34 (as shown in FIGS. 2, 3A, and 4), which is advanced by a determined amount in each printing action by a stepping motor 39. On an arm portion 36a of the ribbon cassette 36, as shown in FIG. 4, is a reflecting plate 41 for indicating the species of the printing ribbon 34, and correspondingly the carriage 26 (FIG. 3A) is provided with a reflective photodetector 40. Under the ribbon cassette 36 is a frame 37 (FIG. 3B) for the correcting ribbon 33 on which is mounted a supply mechanism 33a for said ribbon 33 supporting a winding spool 38 (FIG. 3B). The mechanism 33a operates on said spool 38 to take up the correcting ribbon 33. Said ribbons 33 and 34 are moved to a desired position when required by energizing solenoids 28 (FIG. 3A) and 31 (FIG. 3B), respectively, to raise the print ribbon cassette 36 alone, and to raise both the correcting ribbon frame 37 and the print ribbon cassette 36 together.
FIGS. 4 and 5 show the positional relationship of the ribbon cassette 36 in the print action and in the stand-by state, and of the photodetector 40. In the stand-by state said detector 40 detects the presence or absence of the reflecting plate 41 in the arm portion 36a of the cassette 36. When the solenoid 31 is not energized and the photodetector 40 produces a signal indicating the presence of a reflecting plate 41, the printer control unit 16 invokes the proportional spacing process discussed more fully in connection with FIG. 12. When the detector 40 produces a signal indicating the presence of said reflecting plate 41, which means that the cassette 36 contains a single-use ribbon 34, the printer control unit 16 controls the pulses to the stepping motor 39 for winding the printing ribbon 34 in response to the signal from the detector 40 to modify the advancing amount of the ribbon 34 according to the width of the characters printed. Also in the absence of said signal from the detector 40, which means that the cassette 36 contains a multiple-use ribbon 34, the printer control unit 16 so controls said ribbon advancing stepping motor 39 as to advance the ribbon 34 by a constant amount. The rotating shaft 39a (FIG. 4) of the ribbon advancing stepping motor 39 is connected for example with a ribbon drive shaft 39b (FIG. 5) to control the advancing amount of the ribbon 34 according to the rotation of said motor 39. In a print action the solenoid 31 alone is energized to lift the print ribbon cassette 36 alone through connecting means 31a (FIG. 3B) as represented by broken lines in FIG. 5, whereby the printing ribbon 34 becomes positioned facing the uppermost typefont on the typefont wheel 30. The position of the printing hammer 32 and the platen 17 are also shown. In this state the detector 40 no longer faces the reflecting plate 41 but faces the printing ribbon 34 passing through the arm portion 36a of the cassette 36. Said ribbon 34 is provided at the end portion thereof with a reflecting member 34a such as aluminum foil, whereby the printer control unit 16 identifies the end of the printing ribbon 34 when a signal is obtained from the detector 40 while the solenoid 31 is energized.
In a correcting operation the solenoid 28 shown in FIG. 3A is energized to lift the correcting ribbon frame 37 together with the printing ribbon cassette 36 thereby bringing the correcting ribbon 33 in front of the uppermost font position of the typefont wheel 30. The printing hammer 32 is activated in the same manner as in the printing action to correct the already printed character by "lifting off" or "covering up".
The control for the printing and for the display of the above device is explained in the following. FIG. 6 shows the manner in which FIGS. 6-1 and 6-2 should be arranged.
FIGS. 6-1 and 6-2 show basic block diagrams around the main control unit 22 for printing control and display control, respectively. As shown in FIG. 6-1 a microprocessor unit (MPU) 44 identifies the key signals received from the keyboard 10 through data bus DB and performs control of the print unit 43, as well as of the display unit 9, sentence memory 54, and loud speaker 42 as shown in FIG. 6-2, according to the sequence control programs stored in a read-only memory (ROM) 53. An address decoder 45, under the control of the MPU 44 through an address bus AB as shown in FIG. 6-1, generates signals SELROM, SELBF, SELREG, SELM2, SELFF, SELM1, SELKEY, SELPRT, SELDISP, and SELBZ to respectively control the ROM 53, line buffer 52, register group 51, secondary memory 57, flag group 50, sentence memory 54, keyboard control unit 24, printer control unit 16, display control unit 48, and alarm control unit 49. The display control unit 48 can provide an interrruption signal INT to the MPU 44 when necessary, as explained more fully in connection with FIG. 18-1. The printer control unit 16 in turn provides signals to a motor M of the print unit 43 through a motor drive MD. The keyboard control unit 24 also provides signals to an LED matrix 89 through a cathode driver 64, the operation of which will be more fully explained in connection with FIG. 18-2. The keyboard 10, display unit 9, print unit 43, sentence memory 54, read-only memory (ROM) 53, etc. have respective addresses for processing by the MPU 44.
The function of the components shown in FIG. 6-2 will now be explained. The flag group 50 stores the designated state and various modes of the typewriter. The register group 51 is used for storing for example the intermediate results of the processing. The line buffer 52 stores the information of characters already printed and to be printed in the line-unit or word-unit printing mode. In the correcting operation the MPU 44 retrieves the already printed characters from said line buffer 52 and automatically performs the corrections. The sentence memory 54 stores sentences, characters, tabulator group information, etc. with or without title names entered by the operator according to a certain procedure (which is explained in connection with FIGS. 28-1 and 28-2), and is backed up by a battery 23 against information loss when the power supply unit 13 is cut off. Said battery 23 is inspected by a sensor 56 and an inspection unit 55 as long as the power supply unit 13 is turned on, and an alarm is given to the operator through alarm control unit 49 and loud speaker 42 in case of a voltage decrease for example due to the expiration of the service life of the battery 23. The secondary memory 57, similarly backed up by the battery 23, stores various modes immediately prior to the turning off of the power supply unit 13.
FIG. 7 shows the details of the printer control unit 16, wherein provided are a microprocessor unit (MPU') 110; an interface 111 for receiving instructions from the microprocessor unit 44 for the entire control and transmitting the information on the printer during the print function thereof to said microprocessor unit 44; a work memory 112 for storing intermediate data etc. generated by the MPU' 110; a read-only memory (ROM') 113 for storing the control programs for the MPU' 110; an address bus AB'; an address decoder 114 for generating various signals designating various control loads such as the motors and solenoids having addresses allotted thereto; a ribbon solenoid control unit 109 for controlling the solenoids 31 (FIG. 3B) and 28 (FIG. 3A) for displacing the printing ribbon 34 and correcting ribbon 33, respectively, a detecting unit 116 including the detector 40 shown in FIG. 4 for identifying the species of the printing ribbon 34 and the end point of said ribbon 34, said detecting unit 116 supplying data to the MPU' 110 through a bus driver 115 in response to a request from the MPU' 110; and control units 117, 118 for the type selecting motor 29 (FIG. 3A) and the carriage drive motor 18 (FIG. 2) respectively, which rotate said motors 29 and 18 by determined angles instructed by the MPU' 110 and transmit signals thereto through the bus driver 115 upon completion of said rotation.
There are also shown a paper feed pulse motor control unit 119 for driving the stepping motor 14 for sheet advancing according to the number of pulses supplied from the MPU' 110; a printing hammer control unit 120 for energizing the printing hammer 32 during a period instructed by the MPU' 110; a ribbon feed motor control unit 121 for driving the ribbon feed stepping motor 39 for advancing the ribbon 34 according to the number of pulses supplied from the MPU' 110; a DC bail start motor drive unit 122 to be actuated by the instruction from the MPU' 110 to liberate a paper bail 250 pressing the printing sheet; a latch circuit 123 for selectively lighting one of three light-emitting diodes 12a, 12b, and 12c constituting the carriage indicator 12 through a carriage indicator drive unit 124 in response to the data from the MPU' 110; a character position table 125 composed of a read-only memory for converting the key signal transferred from the MPU 44 to MPU' 110 into positional information of a Corresponding character on the typefont wheel 30 relative to a reference index position thereon; and a printing pitch table 126 which is utilized, in the proportional spacing mode, to determine the type spacing or the amount of lateral displacement of the carriage 26 according to the width of each type and has memory contents as shown in the following:
______________________________________Type A B . . . a i , . . .Type spacing 1 1 . . . 3/4 1/2 1/2 . . .______________________________________
Also in case the detector 40 identifies a single-use ribbon, the ribbon advancement is controlled to the width of each character in order to minimize the ribbon consumption, and said printing pitch table 126 is also utilized for determining the amount of ribbon advancement. Furthermore, in case the typefont wheel 30 is changed, the table 126 is utilized to enable variable ribbon advancement optimum for each character of each typefont wheel 30.
A printing pressure table 127 is utilized for controlling the energizing period of thee hammer 32 according to the size of characters in order to obtain a uniform print density, and stores a hammer energizing period such as 2 msec. or 1.5 msec. for each character in a manner similar to the aforementioned printing pitch table 126. Generally the typefont wheel 30 is changed according to the character size or the character pitch, and the content of said printing pressure table 127 should also be changed accordingly. However a memory of a large capacity will be required for providing the printing pressure tables for all the pitches. For this reason, in order to economize the memory, there is provided only one printing pressure table 127 for a particular typefont wheel 30, and other tables are obtained by multiplying coefficients in the MPU' 110 in response to the information of character pitch supplied from the MPU 44.
FIG. 8 shows the details of the paper advance pulse motor control unit 119 (FIG. 7) for the paper feeding stepping motor 14, wherein provided are an oscillator 170 oscillating at a frequency meeting the self-starting frequency of said stepping motor 14; an AND gate 171; a presettable subtracting counter 172; a circuit 173 (comprising three inverters 173' and a NAND gate 173") for detecting a count zero state of the counter 172, providing an L-level, that is LOW-level, output signal upon detecting said state; exclusive OR gates 174, 176; D-type flip-flops 175, 177 constituting a pulse generating circuit for 2-phase forward/reverse drive of the stepping motor 14; a stepping motor driver 178 (including four single-input AND gates 178'); and a 4-phase stepping motor 14.
In response to a sheet feed instruction including the amount of sheet feeding supplied from the keyboard 10 through the MPU 44, the MPU' 110 sets the feeding direction in the latch 123 and the feed amount in the counter 172. If the feed amount is not zero, the zero detecting circuit 173 releases an H-level, that is High-level, output signal to open the AND gate 171, whereby the counter 172 counts the output pulses of the oscillator 170 by subtraction until the count reaches zero. The output signals of the oscillator 170 transmitted through the AND gate 171 are supplied to a pulse generating circuit composed of elements 174, 175, 176, and 177 for driving the stepping motor 14 to generate pulses of a number stored in the counter 172, thereby rotating the stepping motor 14 by the instructed amount in a direction stored in the latch 123.
FIG. 9 shows the details of the printing hammer control unit 120 shown in FIG. 7, wherein provided are an oscillator 180; a subtracting counter 181; a zero detecting circuit 182 (comprising three inverters 182' and an AND gate 182") releasing an H-level signal in response to the zero count of the counter 181; a set-reset type flip-flop 183; AND gates 185, 186; an inverter 184; and a printing hammer 32. In response to the print instruction supplied from the MPU 44, the MPU' 110 controls the type selecting motor 29 in the aforementioned manner through the character position table 125 shown in FIG. 7, thereby stopping the typefont wheel 30 at a desired position. Then, for the printing action the MPU' 110 stores "1" in the latch 123, opens the gate 185, refers to the printing pressure table 127 and stores the hammer energizing period for each character obtained therefrom in the counter 181. Also the flip-flop 183 is set by the set signal to said counter 181. As the AND gate 185 is opened, a transistor 187 is activated to drive the printing hammer 32 for a period corresponding to each character, thus performing the printing action with optimum pressures. In the standby state between print instructions, a "0" signal is provided from the latch 123 to the AND gate 185, which is closed. The same "0" signal is received by the inverter 184, which supplies a "1" signal to the AND gate 186. As the AND gate 186 is opened, a transistor 188 is activated to retract the printing hammer 32 from the typefont wheel 30.
Mow FIG. 10 shows the details of the ribbon feed motor control unit 121 (FIG. 7) for the ribbon advancing stepping motor 39. Pulses of an instructed number are generated in the same manner as in the circuit of FIG. 8 for the sheet advancing motor 14, except that the D-type flip-flops 194, 195 are so arranged as to generate pulses for 2-phase drive in the forward direction alone.
In case the signal from the ribbon detector 40 indicates a multiple-use ribbon 34, the MPU' 110 sets a constant value in the subtracting counter 192 to perform a constant ribbon feeding. Also in case said signal indicates a single-use ribbon 34, the MPU' 110 detects the width of the printed character from the printing pitch table 126 shown in FIG. 7 and sets a corresponding pulse number for ribbon advancing in the counter 192. If the advancing amount is not zero, the zero detecting circuit 193 (comprising three inverters 193' and a NAND gate 193") provides an H-level signal to open the AND gate 191, whereby the counter 192 counts the output pulses from the oscillator 190 until the count zero state. In this manner the stepping motor 39 is driven through the flip-flops 194, 195 and a stepping motor driver 196 (including four single-input AND gates 196') by pulses of a number stored in the counter 192.
FIG. 11 shows an embodiment of the printer capable of providing uniform printing from various typefont wheels 30 (10K, 12K, 15K), by utilization of a printing pressure table 127 to regulate the printing hammer control unit 120.
The conventionally known apparatus of this sort, such as the electronic typewriter, utilizes typefont wheels with different character sizes for example for character pitches 10, 12, and 15 characters per inch, and even in each wheel there are types of different sizes, so that uneven density is unavoidable if the printing is performed with a constant pressure. On the other hand, in order to store the information of printing pressure there is required a memory of an extremely large capacity, leading to an elevated cost.
The present embodiment provides a printing apparatus not associated with such drawback and capable of providing uniform density from an arbitrary typefont wheel 10K, 12K, 15K, etc. by means of two read-only memories ROM1, ROM2, each of limited capacity
FIG. 11 shows said embodiment in a block diagram, wherein a printing hammer H, when activated by a hammer solenoid HS, performs the printing action in the known manner by hitting a type 12C of a typefont daisy wheel 12K, which is provided with types for printing 12 characters per inch and is replaceable for example by other typefont wheels 10K or 15K for printing 10 or 15 characters per inch.
Since each character has a different area in the typefont wheels 10K, 12K and 15K, as shown, for example, by type 10C on typefont wheel 10K, it is desirable to regulate the printing pressure of the hammer H accordingly in order to obtain uniform print quality.
It is also desirable for obtaining uniform print quality to use different pressures for example for a large type "A" and for a small type ",", even within the same typefont wheel.
For this purpose there can be provided a memory for setting a particular print pressure, for example a particular hammer energizing period for each character, but such memory has to be of a large capacity if the information for the printing pressure is stored for all thee types in all the typefont wheels 10K, 12K, 15K. It is however possible to avoid an excessive capacity by providing a read-only memory ROM1 for the typefont wheel 10K for printing 10 characters per inch and by calculating the hammer energizing times for other typefont wheels 12K, 15K, etc. from the information stored in said memory ROM1 for the wheel 10K.
Thus the memory ROM1 stores the hammer energizing times 2 msec., 1.8 msec., 1.5 msec., etc. in the coded forms for the types A, B, C, . . . , a, . . . as shown in FIG. 11.
Also another read-only memory ROM2 stores the coefficients 1, 0.9, 0.8, etc. in the coded forms respectively for the typefont wheels 10K, 12K, 15K, etc.
There are also provided a multiplier MLT, a subtracting counter DK, an oscillator OSC, and a flip-flop FH. Now, upon mounting for example of the typefont wheel 12K in the printing unit, a typefont wheel detector KS identifies said mounting by a code mark M12 on the wheel 12K and designates an address corresponding to 12K in the memory ROM2. When the typefont wheel 12K is rotated and a desired type 12C is brought to the position of the hammer H by the known character selecting operation, an address corresponding to said type 12C in the memory ROM1 is designated to supply the corresponding hammer energizing period, for example 2 msec., for "A" or 1.8 msec for "a", to the multiplier MLT. The multiplier MLT also receives the coefficient 0.9 corresponding to the typefont wheel 12K from the memory ROM2 to effect a multiplication such as 2×0.9 or 1.8×0.9, and the result is stored in the subtraction counter DK in synchronization with a print instruction PO.
Simultaneously the flip-flop FH is set by said print instruction PO to energize the solenoid HS, thereby initiating the motion of the printing hammer H.
The subtracting counter DK step reduces the content thereof in response to each output signal from the oscillator OSC, and releases an output signal upon reaching zero count state to reset the flip-flop FH, thereby terminating the function of the printing hammer H. In this manner the set period of the flip-flop FH is changed according to the result of multiplication to regulate the energizing period of the printing hammer H thereby differentiating the printing pressure for each typefont wheel, 10K, 12K, or 15K. Also the characters within a typefont wheel can be printed uniformly as the hammer energizing period is regulated for each character, 10C for example, in the typefont wheel, 10K for example.
The instruction for the typefont wheels 10K, 12K, and 15K can also be supplied from the keyboard (not shown).
As explained in the foregoing, the present embodiment allows obtaining beautiful printing with a uniform printing pressure for all the types and in all the typefont wheels of different character sizes with a limited amount of stored information, by storing the information of printing pressures for the types of a determined typefont wheel and by multiplying a suitable coefficient corresponding to the selected typefont wheel thereby obtaining optimum pressures matching the type sizes and thus effecting the pressure control in the printing operation.
Now reference is made to FIG. 12 showing an embodiment of the printer capable of varying the type spacing corresponding to the size of different characters on a typefont wheel 30, by utilization of a printing pitch table 126 to regulate the carriage driving motor control unit 118.
The conventional apparatus of this sort utilizing a single-use printing ribbon is inevitably associated with the waste of printing ribbon since the advancing amount thereof is determined to a type of largest width, which is usually " -- ".
The present embodiment provides a printer capable of achieving maximum economy in the printing ribbon, particularly the single-use printing ribbon, with a simple structure.
The type spacing information, utilized for controlling the lateral displacement of the carriage 26 in the proportional spacing mode in which the type spacing is made variable according to the character size, in fact represents the width of types and is utilized in the present embodiment for controlling the advancing amount of the printing ribbon 34, thereby reducing the consumption thereof. In the use of the typefont wheels 12K or 15K with smaller types for printing 12 or 15 characters per inch respectively, the above-mentioned information is multiplied by the coefficient of each typefont wheel 12K, 15K to further reduce the ribbon consumption.
FIG. 12 shows said embodiment in a block diagram, wherein shown are the printing ribbon IR; a feed roller FR therefor; a stepping motor PM for advancing said ribbon IR; typefont wheels 10K, 12K, and 15K respectively for printing 10, 12, and 15 characters per inch; a typefont wheel detector KS; a read-only memory ROM1' storing the character width information for the types on the typefont wheel 10K for example in the form of numbers of steps 6, 5, 3, etc. of the stepping motor PM; a read-only memory ROM2 storing coefficients 1, 0.9, 0.8, etc. for the typefont wheels 10K, 12K, 15K, etc. having code marks M10, M12, M15, etc., respectively to be multiplied by the character width information stored in the memory ROM1'; a multiplier MLT for multiplying the character width information stored in ROM1' by the coefficients stored in ROM2; a subtracting counter DK; an oscillator GSC for generating subtracting pulses; a flip-flop FP for controlling a gate G; and a motor driving pulse generator PG.
In case the wheel 10K is mounted on the printing unit, the detector KS identifies the code mark M10 of said wheel 10K and designates an address for said wheel 10K in the memory ROM2 thereby supplying a coefficient "1" to the multiplier MLT. Then the typefont wheel 10K is rotated to perform the character selecting operation in the known manner, and the printing hammer H is activated when a desired type 10C or 12C (FIG. 11) is brought to the printing position to perform the print action. Subsequently an address in the memory ROM1' corresponding to the printed character is designated, and the character width information in said address, for example "6" for a character "A" or "5" for "a" is supplied to the multiplier MLT for conducting a multiplication such as 6×1 or 5×1. Then the result of said multiplication is stored in the subtracting counter DK in synchronization with the ribbon advancing instruction IRF. Simultaneously the flip-flop FP is set to open the gate G, whereby the stepping motor PM initiates rotation by the pulses from the pulse generator PG to advance the printing ribbon IR. The subtracting counter DK step reduces the content thereof in response to each output pulse from the oscillator OSC, and releases an output signal upon reaching zero count state to reset the flip-flop FP, whereby the gate G is closed to terminate the rotation of the stepping motor PM, thus stopping the advancement of the printing ribbon IR. In this manner the set period of the flip-flop FP is changed according to the result of said multiplication, thus regulating the functioning period of the stepping motor PM and thereby controlling the advancing amount of the printing ribbon IR corresponding to the pitch of each type.
Also in case the typefont wheel is changed to 12K, a coefficient 0.9 in the memory ROM2 is supplied to the multiplier MLT to multiply said coefficient by the character width information supplied from the memory ROM1', thus reducing the advancing amount of the printing ribbon IR compared to the case of wheel 10K.
In this manner a memory of a large capacity can be dispensed with by storing the information for a determined wheel, for example 10K, alone in the memory ROM1' and by employing a memory ROM2 for storing coefficients for different wheels 12K, 15K, etc. and a multiplier MLT.
As explained in the foregoing, the present embodiment, utilizing the information of printing pitch obtained from means for proportional spacing mode, allows reduction of the consumption of the single-use printing ribbon IR thus achieving maximum economy in the utilization of ribbon IR.
FIG. 13 shows part of the bail start motor drive unit 122 and the carriage indicator drive unit 124 shown in FIG. 7. Upon actuation of the pitch selecting key 10d provided in the keyboard 10 in FIG. 2, the corresponding data are supplied through the keyboard control unit 24 to the MPU 44, thereby storing a signal for activating one of the light-emitting diodes 12a-12c in the latch 123 under the control of the address decoder 45. As an example, the key 10d is actuated once for the mode of 10 characters per inch to light the LED 12a through the inverter 200 thereby indicating the gradation 8a, then is actuated again to light the LED 12b through the inverter 201 thereby indicating the gradation 8b for 12 characters per inch, and is actuated once again to light the LED 12c through the inverter 202 thereby indicating the gradation 8c for 15 characters per inch. Also the printer control unit 16 controls the carriage driving motor 18 so as to cause the displacement of the carriage 26 according to the thus selected printing pitch. The lighted LED, being mounted on said carriage 26, also serves to indicate the carriage position. Also in response to each actuation of the key 10d, one of light-emitting diodes La, Lb, or Lc is lighted in a display unit L1 in the keyboard 10 to indicate which printing pitch is selected, 10 characters, 12 characters, or 15 characters per inch, respectively.
As explained in the foregoing, the present embodiment, being provided with plural indicating means La, Lb, Lc for different printing pitches, activates one of said indicating means La, Lb, Lc corresponding to the selected print pitch, thereby allowing the operator to easily confirm the printing pitch on a scale indicated by said indicating means La, Lb, Lc, as well as the print position or the number of characters that can be printed.
FIG. 14 shows part of the detecting unit 116 and part of the bail start motor drive unit 122 shown in FIG. 7. A transistor 206 is provided to drive a paper bail start DC motor 207 to which a paper bail 250 (FIG. 2) and a microswitch 208 (FIG. 14) are linked. Thus, in response to an instruction for the automatic loading of the printing sheet from the keyboard 10, the transistor 206 is activated through the latch 123 to drive the DC motor 207, which releases the paper bail 250 from the platen 17 and subsequently closes the microswitch 208. A bus driver 115 receives a signal when the microswitch 208 is closed and also receives a signal through a single-input AND gate 210 from the detector 40 in the presence of a reflecting plate 41. In response to the microswitch function detected through the bus driver 115, the MPU' 110 sets a number determined by the MPU 44 in the counter 172 in FIG. 8 and drives the paper feeding stepping motor 14 until the counter 172 reaches the zero count state. Thereafter the paper bail 250 again comes into contact with the printing sheet, and microswitch 208 is opened. In response to said opening the MPU' 110 turns off the transistor 206 through the latch 123 thereby stopping the DC motor 207.
FIG. 15 shows the details of the alarm control unit 49 shown in FIG. 6-2 wherein provided are oscillators 220, 221 oscillating at mutually different frequencies f1 and f2; a monostable multivibrator 222 for determining the duration of he sound alarm in response to the signal SELBZ; a latch 229 for supplying the output signal of the oscillator 220 or 221 to the loud speaker 42 through AND gates 223, 224 and OR gate 225 under the control of the MPU 44; an inverter 226 to ensure that at most one AND gate 223, 224 is open; and a filter 227 for modulating the square waves from the gate 225 to a pleasant waveform for supply to said loud speaker 42 through an amplifier 228.
As explained in the foregoing, the present embodiment is provided with counting means in various control units for controlling the printing pressure, amount of ribbon advancement, amount of sheet feeding, etc. according to the characters to be printed, and, the digital control of the apparatus is facilitated in this manner.
How reference is made to FIG. 16 showing the details of the type selecting motor control unit 117 (FIG. 7) for the type selecting motor 29, wherein provided are a latch 130 for storing key information supplied from the MPU 44 to the MPU' 110 and converted into the positional information on the typefont wheel 30 by the aforementioned character position table 125; adder/subtracters 131, 133; a zero detecting circuit 132; a digital-to-analog (D/A) converter 134 for converting the digital result of calculation by adder/subtracter 133 into a voltage; a power amplifier 135; a type selecting motor 29 of which the shaft 29a is directly connected to the typefont wheel 30 (not shown) and a slitted disk 137 constituting an encoder 35. Across said disk 137 there are provided LEDs 147 and phototransistors 138, 139, and 140, in which the phototransistors 138 and 139 are so positioned as to provide signals of a phase difference of 90° while the phototransistor 140 is so positioned as to provide an index output signal for each turn of the motor 29. Based on the signals from said phototransistors 138, 139 a pulse generating circuit 141 generates a signal I for identifying the rotating direction and a signal H' giving a pulse for each rotation corresponding to a character.
An adding and subtracting counter 144 adds or subtracts, according to the signal I, the count for each signal H, and the counter is reset upon receipt of a signal F. In this manner the count of the counter 144 indicates the rotation angle of the slitted disk 137 or the typefont wheel 30 with respect to a determined position of said disk 137.
An interval counter 142 counts the time interval of the pulses H' from the circuit 141, and the obtained count, being inversely proportional to the rotating speed of the motor 29, is converted by an inverse number table 143 to a value proportional to the speed.
A servo control is obtained by calculating the positional error in the adder/subtracter 131, then subtracting the speed obtained from the inverse number table 143 from the above-mentioned positional error, and driving the motor 29 according to the thus obtained difference. The circuit 132 for detecting zero positional error transmits the zero detection to the MPU' 110 through the bus driver 115 and simultaneously changes over a switch 146 from the side of the D/A converter 134 to the side of a circuit 145 for forming a signal in the interval between slits. Said circuit 145 is composed of a resistor RA for passing the substantially sinusoidal signal from the phototransistor 138 in parallel with a serial circuit comprising a condenser C and a resistor R for passing said sinusoidal signal and a second resistor RD in parallel with an amplifier A. Thus, after the MPU' 110 detects the zero error signal detected by the zero detecting circuit 132, the wheel 30 is stopped by the circuit 145 and the printing hammer 32 is activated to perform the printing. In this manner it is rendered possible to provide a preferable servo control process in which the wheel 30 can be stopped exactly and rapidly at the destination with the extremely simple and inexpensive structure explained above.
FIG. 17 shows the details of the carriage driving motor control unit 118 for the carriage driving motor 18 shown in FIG. 7, having a servo control structure similar to that employed in the type selecting motor 29.
The MPU 44 transfers, to the MPU' 110, the instruction on the relative amount of displacement and direction from the present location of the carriage 26. The MPU' 110 adds or subtracts the relative amount to or from the present location according to the direction of displacement and transfers the obtained destination to a latch 151. The latched value and the output from an adding and subtracting counter 164 obtained according to the signal from a pulse generating circuit 161 are subjected to the addition or subtraction in an adder/subtracter 152 to obtain a positional error An adder/subtracter 154 subtracts the speed of the carriage driving motor 18 obtained through a counter 162 and an inverse number table 163 from said positional error, thus achieving a servo control of the motor 18 through a D/A converter 155 and an amplifier 156. Upon zero detection by the zero detecting circuit 153, a switch 166 is changed over to stop the carriage displacement in a similar manner as explained in the foregoing. Signals similar to the foregoing are obtained from LEDs 167 and phototransistors 159, 160 positioned across a slitted disk 158 mounted on the shaft 18a of said motor 18. In this case, however, a counter 164 receives a limit signal obtained from an element 168 comprising an LED and a phototransistor indicating the left-hand end of the carriage displacement, instead of the index signal F generated at each turn in the case of the type selecting motor 29. Also a circuit 165 similar to the circuit 145 is provided.
FIG. 18 shows the manner in which FIGS. 18-1 and 18-2 should be arranged. Now reference is made to FIGS. 18-1 and 18-2 showing key input devices allowing rapid and secure key entries and adapted for use in an electronic typewriter.
In the conventional key input device there is generally employed a method of accepting the key input information only after the key signal is stablized or plural readings of the key signal have resulted in a same result. For this reason a rapid key information entry is difficult.
Also in case a key signal during the course of stabilization is interrupted for some reason, the apparatus may regard that the key has been actuated twice despite the fact that the key was actuated only once.
The embodiment shown in FIGS. 18-1 and 18-2 provides key input devices not associated with the above-mentioned drawbacks and allowing rapid and accurate key entries with a simple structure.
In FIGS. 18-1 and 18-2 groups of addressable latches 60 are provided with memory cells or latches L11-Lnn respectively corresponding to the lattice points S11-Snn of a key matrix 88 of the keyboard 10. Said lattice points S11-Snn of said key matrix 88 correspond to the input keys shown in FIG. 1, including not only the unlocking keys such as character keys 10a, control keys 10b and 10c, but also the locking slide keys 10e and 10f. Each of the latches L11-Lnn, corresponding to each key, has a structure of 2 bits constituting a memory for storing the key signal. All the latches L11-Lnn of the addressable latch group 60 are reset to "0" at the turning on of the power supply unit 13.
Each key switch 88a of the key matrix 88 is provided with a diode 88b in order to avoid stray signals in case plural keys are actuated simultaneously. In the following discussion, the key switches 88a will be designated as switches SW11-SWnn at corresponding lattice points.
There are shown also a decrementer 61; a logic circuit 59 composed of inverters 81, 82 and an AND gate 83 for zero detection of the signal read from the group of latches 60, providing a signal "1" from said AND gate 83 upon such zero detection; and AND gates 78, 79, 75, and 76 and OR gates 80 and 77 for resetting said group of latches 60.
An oscillator 66 generates synchronizing clock pulses for various units and basic signals for scanning the key matrix 88 and the LED matrix 89. The signals from said oscillator 66 are supplied through an AND gate 73 to a counter 65 so constructed as to repeat counting of the number of the lattice points S11-Snn of the matrix 88. The counter 65 counts the signals from said oscillator 66, and the output signals on said counter 65 are utilized as the addressing signals for the addressable group of latches 60 and also divided into the upper-digit signals and lower-digit signals which are respectively supplied to a decoder 52, which may be, for example, part number 74154 supplied by the Texas Instruments Corp., and to a multiplexer 63. The microprocessing unit 44 is capable of sensing the content of the counter 65 any time through a bus driver 86 and a data bus DB. Said decoder 62 scans the key matrix 88 in the lateral direction with the increment of the counter 65, while the multiplexer 63 vertically scans the matrix 88 during one step advancement of the decoder 62.
If a key switch 88a is found closed during the vertical scanning, switch SW34 for example, the multiplexer 63 provides an output signal "0", which is inverted by an inverter 74 into "1" and supplied to the AND gates 76, 79, and 84 in order to show the content of the counter 65 at this point. At this state the latch L34 corresponding to the closed key switch SW34 releases an output "0" whereby the gate 83 provides an output signal "1" to the AND gate 84. Thus said gate 84 provides an output signal "1" which is supplied as an interruption signal INT to the MPU 44. At the same time the reset output signal F="1" of a flip-flop 71 already reset and the output signal "1" of the AND gate 84 are supplied to a NAND gate 72 to provide an output signal "0", whereby an input AND gate 73 for the counter 65 is closed to terminate the counting function of the counter 65 at a count corresponding to the closed key switch SW34. Also the output signal "0" from the multiplexer 63 retains the AND gates 75 and 78 closed but opens the AND gates 76 and 79 thereby causing the OR gates 77 and 80 to provide output signals "1", which are used as the input signals for the latch address by the counter 65 corresponding to the closed key switch SW34. The group of latches 60 are so structured as to latch the input signal in synchronization with the output signal from the input AND gate 73 for the counter 65, so that the latch address is not changed but remains corresponding to the closed key switch SW34 while the function of the counter 65 is stopped. In response to the aforementioned interruption signal INT the MPU 44 reads the count of the counter 65 through the bus driver 86 to identify the closed key switch SW34, thus accepting the input information from key S34. Thereafter the MPU 44 releases an acknowledging signal "1" to the set input port of a flip-flop 71 through the address bus AB and a decoder 87 to release a set output signal F="0" from said flip-flop 71, whereby a NAND gate 72 provides an output signal "1" to open the gate 73, thus re-starting the counting action of the counter 65. Simultaneously the output signal from said gate 73 sets "11" in binary code, or "3" in decimal code, in the latch L34 corresponding to the closed key switch SW34. In response to the re-start of counting by the counter 65, the flip-flop 71 is reset for the next key detection.
In case said key switch SW34 is still closed after the scanning of all the lattice points S11-Snn of the key matrix 88 (this situation is normally encountered in the usually employed scanning speed), the multiplexer 63 again provides an output "0", but the corresponding latch L34 provides an output "3" to give output signals "0" from the gates 83 and 84, whereby the interruption signal INT is given to the MPU 44 and the AND gate 73 is closed. Consequently, the counter 65 continues the counting operation as if the key switch SW34 were not closed. However, since the AND gates 75 and 78 are closed by the output signal "0" from the multiplexer 63, a signal "3" is again set in the latch L34 corresponding to the closed key switch SW34 through the AND gates 76, 79 and OR gates 77, 80. In this manner the signal "3" is repeatedly set in said latch L34 while the corresponding key switch SW34 is closed. Then, when said key switch SW34 is opened, the multiplexer 63 provides an output signal "1" at each scanning to close the AND gates 76, 79 and to open the AND gates 75, 78 through the inverter 74, whereby a number step-decreased by the decrementer 61 is set in said latch L34 through the OR gates 77 and 80. In this manner the content of said latch L34 changes from "3" to "0" in succession. When said latch L34 finally releases an output signal "0", the AND gate 83 of the zero detection circuit 59 provides an output "1", which is converted to "0" by an inverter 85 and closes also the AND gates 75 and 78. Thus the OR gates 77, 80 release output signals "0" to set said latch L34 and all other latches L11-Lnn to "0" in response to the counting operation of the counter 65.
FIGS. 19A, 19B-1 and 19B-2 show the various signals when a key S34 is actuated in a 4×4 key matrix. FIG. 19B shows the manner in which FIGS. 19B-1 and 19B-2 should be arranged. In FIGS. 19B-1 and 19B-2, T represents the duration of the actuation of the key S34 as identified by the circuit.
As explained in the foregoing, the present key input device is so structured as to accept the key signal at the first scanning after the key switch is actuated and not to accept said key signal in the succeeding scannings by the output of the latch storing the key signal and is therefore capable of rapid signal reading, since even an unstable key signal is accepted at the first scanning and is not accepted thereafter.
Also the present key entry system, accepting the key signal only at the first scanning, allows to use the key matrix not only for momentary keys but also for locking slide keys such as the keys 10e, 10f shown in FIG. 1. For the same reason, the so-called N-key roll over method is easily applicable.
The key signals entered in this manner by the key actuations are processed by the MPU 44 and supplied to the printer control unit 16 for performing the determined printing operation.
As shown in FIG. 18-2 a circuit is provided for displaying the actuated input keys S11-Snn with light-emitting diodes D11-Dnn, wherein provided is a cathode driver 64 for dynamic driving of the light-emitting diodes D11-Dnn in an LED matrix 89 in response to the output from the decoder 62. A multiplexer 67 receives the upper digit signals which are the same as those supplied to the decoder 62 from the counter 65 and an address bus AB for supplying the display information from the MPU 44 to a display buffer 68. The lighting operation is achieved by reading the content of an address in the buffer 68 corresponding to the count of said counter 65, storing said content in a latch circuit 69 and driving an anode driver 70 accordingly. Also a change in the lighting state is achieved by designating the buffer 68 by the decoder 87, whereby the multiplexer 67 connects the address bus AB to the buffer 68, and by designating the changed address from the address bus AB to transfer the changed data from the data bus DB to said buffer 68.
It is to be noted that the present embodiment is capable of allowing various functions not achievable with the conventional typewriters. In the following are explained such functions of which usefulness will be made evident from the corresponding key manipulations. Even the ordinary keys found in usual typewriters can perform unique functions when used in combination with certain keys belonging to the present embodiment. In the following the functions and operating procedure of the keys are explained first, and the control process relating to particular keys for specific functions will then be explained. In this manner the electronic typewriter of the present embodiment will be further clarified.
FIG. 20 shows, in a front view, the control panel of the electronic typewriter of the present embodiment, wherein one of the mode keys 10d is labeled PITCH and designates the number of characters per inch as explained in the foregoing. Upon actuation of said PITCH key the display in a display unit L1, composed for example of light-emitting diodes La, Lb, Lc, Ld, is shifted cyclically in the order of "10", "12", "15", and PS", in which PS stands for proportional spacing with a variable number of characters per inch according to the characters printed. Another of the mode keys 10d is labeled LINE SPACE and selects the amount of the line space wherein 1/6 inch is taken as the unit amount. Similarly, the portions labeled "3/4", "1", "11/2", and "2" in the display unit L2 are cyclically lighted in turn upon actuation of said LINE SPACE key. Still another of the mode keys 10d is labeled KB SELECT and is utilized for selecting a character in a key 10a representing three characters, for example, a key KIII. In the present embodiment the lamp I in the display unit L3 indicates the characters "¶" and "¶" which are further selectable by the control key 10b labeled SHIFT, while the lamp II indicates the character "|". Either of said lamps I and II is lighted by actuating the KB SELECT key.
One of the mode keys 10g is labeled FM CONTROL and selects one of three function codes JUST, AUTO, and OFF as indicated by the lamps of the display unit L4. The lamp JUST indicates a function of "right justification"0 in which right-hand ends of the lines are aligned, while a lamp AUTO indicates a function of automatic line feeding. A lamp OFF indicates no particular function instructed. Another of the mode keys 10g is labeled OP CONTROL and is utilized for determining the output printing mode of the electronic typewriter, wherein the lamps C, W, L, and STORE are cyclically lighted in the aforementioned manner. C, W, and L respectively indicate the printing by a character, by a word, and by a line, and STORE means the storage in an internal memory 54, in which the line printing mode L is employed.
A locking slide key 10e is designated in this embodiment as key SSW1 and is related to the decimal tabulator function for figures. It selects printing of figures in 3-digit groups separated by a space when positioned at "SP", or printing of figures in 3-digit groups separated by a comma when positioned at ",", or printing of figures without such grouping when positioned at "XX". A locking slide key 10f is designated in this embodiment as key SSW2 and selects the kind of type or underlined printing. "X X" stands for boldfaced type with a continuous underline, "X X" for boldfaced type with an underline for each word, "XXX" for boldfaced type, "Y Y" for ordinary type with a continuous underline, "Y Y" for ordinary type with an underline for each word, and "YYY" for ordinary type. There are also provided control keys 10b including keys labeled DECTAB for instructing the decimal tabulator function; LAYOUT with a lamp for instructing the column layout function; INDENT with a lamp for instructing an automatic indent mode; FORMAT with a lamp for giving instructions on page formatting; MAR REL for releasing left and right margins; MEMORY for initiating storage in the memory 54; NONPRT for reviewing the sentence memory; and REPEAT for repeated printing or entry of a character. Further provided are keys 10b labeled SHIFT for entering upper case characters or for certain special functions in combination with other keys; LOCK for locking said SHIFT key; BACK TRACE for correction of printing involving preceding lines; and TAB for advancing the carriage 26 to the next tabulator stop position. Also provided are control keys 10c including keys labeled BACK SPACE for shifting the printing position toward the left; X for erasing a character; INDEX for line feed of the printing sheet; REV INDEX for reverse line feed of the printing sheet; CODE with a lamp for special instructions in combination with other keys; CENT with a lamp for centering of the printing; ⋆ for interrupting the printing; LM for setting the left margin position; RM for setting the right margin position; SET for setting the tabulator stop positions; CLR for clearing the tabulator stop positions; RELOC for displacing the carriage 26 to the last printed position; and ← and → for moving the cursor on the display unit 9; as well as a second SHIFT key.
Surrounded by the broken line are character keys 10a, including keys labeled SPACE for shifting the carriage 26 towards the right for making a space and RETURN for returning the carriage 26 to the left-end position and line feeding the printing sheet.
FIG. 21 shows the internal structure of the flag group 50 shown in FIG. 6-2, wherein provided are the following flags.
A flag KB2 is set when the KB SELECT key is set to mode II to enable the key KIII to print "|" and is reset when the KB SELECT key is set to mode I. An INDENT flag is set at the start of the automatic indent mode in which the carriage 26 is always returned to a temporary left-hand margin stop position and is reset when said automatic indent mode is cancelled. An STR flag is set when the OP CONTROL key selects the mode STORE and is reset at the selection of any other mode. A flag TR is set at the input of a title followed by the actuation of the RETURN key for the purpose of referring to a character row and is reset when said reference is cancelled. A flag NP is set when the NONPRT is actuated and is reset when the reference to the character row is cancelled. A flag SC indicating the entry of a character row for searching is set upon entry of the character row for reference and is reset when the reference to the character row is cancelled. A flag CMV is set when one of four centering modes is established and is reset when the centering mode is cancelled. A flag TCNT is set when a centering mode between tabulator stop positions is instructed, a flag MCNT is set when a centering mode between the margin stop positions is instructed, a flag PCNT is set when a centering mode between designated positions is instructed, and a flag WCNT is set when a centering mode between S words is instructed. Flags TCNT, MCNT, PCNT, and WCNT are reset when the corresponding centering mode is cancelled.
FIG. 22 shows the internal structure of the register group 51 shogun in FIG. 6-2. A register LEPT indicates the last position of the characters stored in the line buffer 52. A register PRTEPT indicates the print end point in the characters stored in the line buffer 52. A register CRGPT indicates the position of the carriage. 26 from the left margin stop position on the printing sheet, thus representing the displacing distance of the carriage 26 from said position. A register DCRGPT stores the amount of displacement to be performed by the carriage 26 in the word-unit (W-mode) or line-unit (L-mode) printing mode in which the carriage 26 is not displaced immediately after the entry of key signals. A register PITCH stores the printing pitch information selected by the PITCH key, so that the MPU 44 can read the printing pitch from said register PITCH. A register LNSP stores the amount of line feed or the selection state of the LINE SPACE key. Registers FMC and OPCONT respectively store the states of the FM CONTROL key and the OP CONTROL key. Registers LM and RM store the left and right margin stop positions in the same unit as in the register CRGPT. Registers SSW1 and SSW2 store the state of the keys SSW1 and SSW2 on the control panel. A register DLM is utilized for diverting the left margin stop position in case of the automatic indentation mode.
Also registers TAB1 to TABn respectively store the tabulator stop positions in the same unit as in the register LM. A register WORK is utilized for temporary storage or diversion of the information during other control processes. A register CPT is utilized in the correction process and indicates a point in the line buffer 52 corresponding to the carriage position. This register WORK stores the data of printed characters and associated printing pitch, etc. and supplies, when a correction is needed, said data to the MPU 44 from the older data to the newer data in the same manner as in a first-in-first-out stack to inversely reproduce the displacement of the carriage 26 and the advancement of the printing sheet, thus allowing the carriage 26 to reach the final character position of the previously printed line. Also a register LC stores the number of lines advanced on the printing sheet.
FIG. 23 shows the internal structure of the line buffer 52 shown in FIG. 6-2 having unit memories from 0 to n. In each unit memory, the addresses I, II, and III respectively store the kind of character, the printing pitch, and the kind of type which are utilized for the correction process and other purposes. The data stored in the address I are the character key information supplied from the keyboard control unit 24 31 shown in FIG. 6-1. The data stored in the address II represent the printing pitch corresponding to the state of the PITCH key or to the content of the PITCH register. The data stored in the address III represent the kind of type corresponding to the state of the slide switch SSW2 shown in FIG. 20 or the content of the register SSW2 in the register group 51. The capacity of the line buffer 52 is so selected that it can store a number of characters in excess of the maximum number of characters in a line, for example 300 characters over 2 lines. Thus by actuation of the BACK SPACE key the carriage 26 can be returned from the left-hand end position to the final print position of the preceding line. Stated differently, such final print position of the preceding line can be calculated from the carriage displacing instruction, distance of carriage displacement, and amount of line feed, all stored in said line buffer 52. Even when said preceding line is printed with a blank space at the left-hand end of the line, a memory area of the line buffer 52 preceding to the first character in said line stores a code corresponding to a space in the address I, a printing pitch in the address II, and a non-print code in the address III as the kind of type, so that the displacement of the carriage 26 to the final print position of the preceding line is made possible by decoding the thus stored data by the MPU 44 in an order opposite to that in the data entry. In the system as explained in the foregoing, the control sequence is initiated at the turning on of the power supply unit 13 to the electronic typewriter. Immediately after the start of power supply, the control units 24, 16, 48, 49, etc. shown in FIGS. 6-1 and 6-2 are initialized. Then the register group 51, lime buffer 52, and flag group 50 are cleared. Subsequently, in order to restore the state before interruption, the data of the entire register group 51 stored in a non-volatile memory 57 shown in FIGS. 6-1 and 6-2 are recalled to the register group 51 At the same time, according to the states of various registers, the lamps for the PITCH, LINE SPACE, FM CONTROL, and OP CONTROL keys are controlled and the carriage indicator lamp 12 is lighted. Similarly the lamp of the KB SELECT key is controlled by the state of the KB2 register stored in the secondary memory 57.
In this manner it is possible to restore the state immediately before the interruption even when the power supply unit 13 is turned off or interrupted by a line failure. Then in response to the actuation of a key, 10a-10g, there is initiated a key discriminating sequence for distinguishing character keys 10a from control keys 10b, 10c. Said discrimination is achieved by the value of the key signals. The character keys 10a are distributed continuously on the key matrix 88 shown in FIGS. 18-1 and 18-2, and the control keys 10b, 10c are similarly distributed continuously, so that there results a boundary value between the group of character keys 10a and the group of the control keys 10b 10c. Consequently, it is rendered possible to discriminate a key 10a-10g by comparing the corresponding key signal with said boundary value. In case a character key 10a is identified, there is executed a process on the line buffer 52. As shown in FIG. 20, the SPACE and RETURN keys are considered to belong to the character keys 10a. On the other hand, in case a control key 10b, 10c is found, said control key 10b, 10c is further identified and a corresponding control sequence is executed.
FIGS. 24 and 25 show the basic control sequences of the line buffer storage process LBFSTR. In the LBFSTR sequence shown in FIG. 24, in response to the entry of the kind of character, printing pitch, and kind of type from a character key 10a to the line buffer (LB) 52, the registers LEPT and DCRGPT are step increased. Then the LBFSTR sequence is branched according to the content of the register OPCONT shown in FIG. 22. In case the register OPCONT indicates C-mode or character-unit printing, there is immediately initiated a print sequence BFPNT with consecutive display on the display unit 9. In the case of W-mode (word-unit printing), the entered key is identified if it is the SPACE or RETURN key, and, if it is not, the consecutive display alone is given without printing. In the case of L-mode (line-unit printing), the entered key is identified if it is the RETURN key, and, if it is not, the consecutive display alone is given without printing. In the word-unit printing mode the printing is initiated upon actuation of the RETURN or SPACE key, while in the line-unit printing mode the printing is initiated upon actuation of the RETURN key. In this manner is achieved character-unit printing and display, word-unit printing and display, or line-unit printing and display.
In case a new character is entered after the line buffer (LB) 52 is filled with the kind of character, printing pitch, and kind of type over the entire memory areas 0-n, the stored data are shifted three steps to the left and the contents of registers LEPT and PRTEPT are step reduced. In this manner the three data stored in the 0th area at the left-hand end of the buffer memory 52 are removed and the nth right-hand end memory area is emptied to accept the kind of character, printing pitch, and kind of type for the (n+1)th character. Also in response to the actuation of the SPACE or RETURN key, the related data are successively stored in the line buffer 52 as shown in FIG. 23, so that the correction of characters is possible as long as they are stored in said line buffer 52. Since the data for the SPACE or RETURN key are in this manner stored as character information together with the associated printing pitch and non-print information, it is possible to make corrections by tracing the print backward in any mode of printing.
The buffer printing (BFPRT) process is conducted according to the print control sequence BFPRT shown in FIG. 25. In said BFPRT sequence the contents of the registers LEPT and PRTEPT are compared, and, if they are mutually different, a character is printed and the registers PRTEPT and CRGPT are both step increased. This sequence is repeated until the contents of the registers LEPT and PRTEPT become mutually equal. In this manner said sequence BFPRT performs the printing of unprinted characters stored in the buffer 52. Upon completion of said sequence BFPRT, the contents of the registers PRTEPT and LEPT are mutually the same, and the contents of the registers CRGPT and DCRGPT are also mutually the same.
The procedures of storage of a character row or a sentence and of display and printing from such stored sentence will now be explained.
The key operations for the write-in of a character row or a sentence into the sentence memory 54 are conducted as shown in FIG. 26.
At first the OP CONTROL key is actuated to light the STORE lamp. Then the MEMORY key is actuated to light the MEMORY key lamp, thus indicating a state for sentence storage. Then entered are the characters for the title name, which are displayed on the display unit 9, followed by the actuation of the RETURN key, whereby the printing of the thus entered title name, the return of the carriage 26, and the line feed of the printing sheet are executed. At this point an alarm is given from loudspeaker 42 if the entered title name already exists. Thereafter are entered the characters to be stored, and the RETURN key is actuated to print and store said characters. Upon actuation of the MEMORY key, the title name is recorded in association with the entered characters and the MEMORY key lamp is extinguished. The ⋆ key, if actuated during the entry of characters, will function as a temporary stop signal in the printing of the characters recalled from the memory 54.
In the following the process of character storage is explained.
In FIG. 27, the MPU 44 shown in FIG. 6-1 lights the MEMORY key lamp in response to the first actuation of the MEMORY key, and checks the register STR of the register group 50 to see if the storage (STR=1) or readout (STR=0) of characters is requested. Said flag STR is set by the actuation of the OP CONTROL key to the STORE mode. In case of the character readout the program proceeds to the memory readout control sequence MRD shown in FIGS. 29-1 and 29-2. In case of character storage, the program proceeds to the next KEY INT step for awaiting key actuation, and, since the MEMORY or RETURN key is not yet actuated in this state, the program further proceeds to the next character entry step. In response to the key entry of the title name, the aforementioned buffer process routine LBFSTR shown in FIG. 22 is executed to store the characters in succession into the line buffer 52, with simultaneous display on the display unit 9. Upon completion of the entry of the title name, the RETURN key is actuated as shown in FIG. 26, and the program in FIG. 27 proceeds to the branch from the step "RETURN?". Then checked is the state of the flag TR. Since said flag TR is reset in the initial state, the program proceeds to the buffer printing routine BFPRT for printing the title name. Then the flag TR is set, the title name in the line buffer (LB) 52 is diverted into the WORK register, and the title name thus diverted is compared in the MPU 44 with all the title names stored in the sentence memory 54.
If the same title name is already registered in the sentence memory 54, an acoustic alarm is generated from the loudspeaker 42, and the MEMORY key lamp is extinguished.
If the same title name does not exist, the program awaits the following key entry at the KEY INT step. The title name in the line buffer 52 is extinguished when it is diverted into the WORK register, but the display of the title name on the display unit 9 is continued since the title name in said WORK register is supplied to the display control unit 48.
Also in response to the actuation of the RETURN key, the printing sheet having the printed title name is advanced by a line, and the carriage 26 is returned to the left margin stop position.
At this point the carriage return command, distance of carriage displacement from the left-end position, and amount of line feed are stored in the line buffer 52 in the order of key actuations as shown in FIG. 23.
Also in the carriage advancement without printing by the actuation of the SPACE key, the data for space, printing pitch, and non-print information are stored as shown in FIG. 23. Such data relating to the printing are serially transferred, together with the data for title name and characters, to the WORK register and the sentence memory 54. Also in the readout frown the memory 54 for display or printing, said data are eliminated and the character information alone are displayed and/or printed.
Upon entry of characters for storage, the program proceeds to the sequence LBFSTR according to which the characters are sequentially stored in the line buffer 52 and displayed in succession on the display unit 9. Upon actuation of the RETURN key after the entry of a character row or a sentence, since the flag TR is set in this state, the characters in the line buffer 52 are stored in the sentence memory 54, and the program again enters the sequence LBFSTR and proceeds to the sequence BFPRT for printing the characters.
Succeeding storage of the sentence is achieved by the repetition of the above-mentioned procedure. During this operation, the content of the line buffer 52 is not cleared but is extinguished from the leading end only in case of overflows, and this process is effective for permitting use of the character correction process as explained in the foregoing.
In response to the actuation of the MEMORY key at the end of the entry of characters, the title name is registered in association with the thus entered characters. At the same time, the MEMORY lamp is extinguished and the flags STR and TR are reset.
FIG. 28 shows the manner in which FIGS. 28-1 and 28-2 should be arranged. Now reference is made to FIGS. 28-1 and 28-2 showing the key operations in the display and printing of the characters read from the memory 54.
At first the OP CONTROL key is actuated to turn off the STORE lamp. Then actuated is the MEMORY key, whereby the MEMORY key lamp is lighted to indicate the stand-by state for the display and printing of characters read from the memory 54. The display or printing is selected by the operator. In case of display the NONPRT key is actuated, whereby the corresponding NONPRT key lamp is lighted to indicate that the display mode for the characters read from the memory 54 is initiated.
In said mode, first entered is the title name, which should naturally be the same as the registered title name. Then, in case of display from a particular character row in the sentence, the operator performs the actuation of the ⋆ key, entry of said particular character row, and the actuation of the RETURN key. Also, in case of the display from the start of said sentence, the operator merely actuates the RETURN key following the entry of the title.
Upon actuation of the RETURN key there are displayed for example 20 characters from the beginning of the sentence. At this state the cursor position on the display unit 9 can be displaced by word units with the ← or →) key, and deletion, insertion, etc. is made possible by the BACK SPACE and X keys. The display is terminated by the actuation of the MEMORY key. Also the entire display of characters can be deleted by the actuation of the key CLR while said characters are displayed on the display unit 9. Upon actuation of the MEMORY or CLR key, the NONPRT and the MEMORY key lamp are extinguished.
The printing of stored characters can be achieved in at least in three forms, i.e., the printing of the entire sentence without title, the printing of the entire sentence with title, or the printing of the first two lines of said sentence with title. These printing forms are respectively achieved by the entry of the title name, followed by the entry of "/0", "/1", or "/2" further followed by the actuation of the RETURN key. Also the entry of "/0" may be omitted in the first form. The printing is initiated immediately after the RETURN key is pressed. Also as explained in the foregoing, the printing can be temporally interrupted at a position of the ⋆ key entered in the course of character entry. Also the printing can be interrupted at any point by the actuation of the ⋆ key during the course of printing. After the completion of printing of a sentence corresponding to a title name, said printing can be repeated by simply actuating the RETURN key. Also by actuating "/2" without title name in the third form, there are printed all the registered title names respectively accompanied by two lines of sentence. The present mode can be terminated by actuating the MEMORY key, whereupon the MEMORY key lamp is turned off to indicate the termination of said mode. In the following are explained the internal functions corresponding to the above-mentioned key operations.
As explained in the foregoing, the memory readout sequence MRD is initiated in case of the flag STR=0 in FIG. 27. The sequence MRD starts from a key actuation waiting step KEY INT, and the entered key signal is thereafter identified.
As shown in FIGS. 28-1 and 28-2 the operator determines whether the sentence readout is made on the display unit 9 or by the printing unit 43.
By actuating the NONPRT key followed by the entry of the title name, the sentence stored in the sentence memory 54 is displayed on the display unit 9.
Also the entry of the title name without actuating the NONPRT key provides the printing of said sentence on the printing sheet by the printing unit 43. In this manner the stored sentence can be reproduced for enabling the operator to identify if such stored sentence can be utilized for preparing a new sentence. Also correction can be easily made on the display unit 9.
The sentence readout by printing is useful in making corrections, etc. because in the readout by display it is sometimes difficult for the operator to understand the entire sentence because of the limitation in the capacity of the display unit 9.
FIG. 29 shows the manner in which FIGS. 29-1 and 29-2 should be arranged. FIGS. 29-1 and 29-2 show the key operations in the memory sequence MRD.
In case of the readout by the display unit 9, the NONPRT key is actuated to set the flag NP. Then the title name, for example "NO3" or "NEW YEAR'S CARD", of the sentence to be recalled is entered from the keyboard 10.
Upon the entry of said title name, the program proceeds to the aforementioned line buffer storage process routine LBFSTR to store the entered title name in the line buffer 52 and to display said title name on the display unit 9.
Then the operator confirms the title name displayed and actuates the RETURN key.
The program checks the state of the flag TR, which is reset in the initial state, and sets said flag TR.
Then the title name stored in, the line buffer 52 is diverted into the WORK register to continue the display, and said line buffer 52 is cleared. Since the flag NP is already set by the actuation of the RETURN key, the display unit 9 displays the sentence corresponding to said title name, by comparing the title name stored in the work memory 112 with the title names in the sentence memory 54 in the MPU 44. Such display on the display unit 9, having for example a capacity of 20 characters, allows the operator to approximately confirm if the stored sentence is usable for the purpose of the operator. Also the entire sentence corresponding to the title name displayed on the display unit 9 can be erased by actuating the CLR key. In this operation the program proceeds in a step CLR? to the branch YES, then in a step TR=1? to the branch YES since the flag TR is already set by the actuation of the RETURN key, and the title name and the corresponding sentence are all cleared from the sentence memory 54.
Also, during the display of the title name or the sentence on the display unit 9, it is possible to delete or correct the words displayed by means of the ← or → key.
Furthermore, after the entry and display of the title name, it is possible to cause the display of the sentence from the beginning thereof or from an interim position thereof. In this case the operator actuates the ⋆ key, and the program checks the state of the flag TR. As TR=0 in this state since the RETURN key has not been actuated, the program sets said flag TR, then also sets the flag SC, diverts the displayed title name to the WORK register, and clears the line buffer 52. However the display of the title name is continued by the signal from the WORK register. Then the characters for searching from an interim position of the sentence are entered and stored in the line buffer 52 according to the aforementioned sequence LBFSTR with the simultaneous display on the display unit 9. Upon actuation of the RETURN key, the program checks the state of the flag TR, which is already set by the ⋆ key, then proceeds in a step SC=1? to the YES branch as the flag SC is also set, and diverts the character for search in the WORK register to continue the display. As the flag NP is set by the NONPRT key, the program further proceeds to the YES branch to display the sentence from an interim position on the display unit 9.
More specifically, in case the characters "NEW" for search are stored in the WORK register, the MPU 44 searches the same characters from the beginning of the sentence stored in the sentence memory 54, and displays the sentence following said same characters. In this manner lit is rendered possible to rapidly locate the desired part of the sentence. In case another part of the sentence starting from the same characters "NEW" is desired, the ⋆ key is again actuated whereby the program goes through the steps TR=1? and SC=1?, then checks the state of the flag NP which is set in this state, and displays another part of the sentence also starting from the characters "NEW". The above-mentioned procedure is also achievable with the printing unit 43, in which case the title name is entered without actuating the NONPRT key, and the ⋆ key is actuated.
Thus, in the same manner as explained in the foregoing, the program sets the flags TR and SC and diverts the title name in the buffer 52 into the WORK register for maintaining the display of the title name on the display unit 9. Then, upon entry of the characters for search, the display of the title name is replaced by said characters, and, upon the actuation of the RETURN key, said characters for search are diverted into the WORK register and displayed because TR=1 and SC=1 in this state. Since the NONPRT key is not actuated in this state, the program proceeds in the step NP=1? to the NO branch to cause the printing unit 43 to print a part of the sentence starting from said characters for search. During said printing the characters for search are maintained on the display unit 9, so that the printing can be immediately interrupted by the ⋆ key in case an error is found in the characters. Also, in the case of merely recalling the stored sentence by the printing unit 43, the operator has the freedom of selecting one of three printing forms mentioned in the foregoing.
In the first printing form in which the entire sentence is printed without the title name, the keys "/", "0" and "RETURN" are actuated in succession after the entry of the title name. Thus the program proceeds in the step TR=1? to the NO branch, since the flag T2 is not set in the beginning, then sets the flag TR and diverts the title name in the WORK register. Then the program proceeds in the step NP=1? to the NO branch, as the flag NP is not set-in this case, and the MPU 44 identifies the data "/0" and executes the printing by supplying the entire sentence and the related print data from the sentence memory 54 to the line buffer 52. In this state the format at the sentence registration can be exactly reproduced, since all the data such as space, carriage return, printing pitch, sheet line feed, etc. are stored in the sentence memory 54 together with the character information.
In this manner, the registered sentence can be immediately utilized for the preparation of a new sentence.
Also the display of the title name is maintained on the display unit 9 during said printing without title name so that the printing can be interrupted by the ⋆ key in case an error in the title name or in the key entries is discovered, thus allowing the operator to avoid waste in time and in the printing sheet. Also, any number of copies can be-prepared by repeating the actuation of the RETURN key.
Also, in the second or third printing form, the MPU 44 identifies the data "/2" or "/3" entered after the title name entry and causes the printing of the entire sentence with title name or of two lines of sentence with title name. The display of the title name on display unit 9 is maintained also in these printing forms. Furthermore, in the first or second printing form, the printing is automatically interrupted at a point where the ⋆ key is actuated in the course of the registration of the sentence.
The above-mentioned mode is terminated by the actuation of the MEMORY key, whereby the MEMORY and NONPRT lamps are turned off. Also, if the title name entry is omitted in the third printing form, the MPU 44 identifies the absence of title name at the diversion of the title name into the WORK register by the actuation of the RETURN key, and causes the printing of all the title names stored in the sentence memory 54 and two lines of sentence respectively belonging to said title names, thus allowing rapid review of the registered information. The number of lines to be printed can be arbitrarily selected by a numeral key "2", "3", etc. actuated successive to the "/" key.
In the following the registration and readout of page formats are explained. In case the entry points EP1-EP11 on the printing sheet P are different from line to line as shown in FIG. 30, it is convenient if these entry points EP1-EP11 can all be registered and the carriage 26 can be brought automatically to these entry points EP1-EP11 at the printing and line feed. In order to meet such requirement the present embodiment is further provided with the functions of registration and readout of the page formats.
The registration of the page format is effected according the sequence shown in FIG. 31, in which the OP CONTROL key is at first actuated to light the STORE lamp. Then the FORMAT key is actuated to establish the page format registration mode, whereupon the FORMAT key lamp is turned on to indicate said mode. Then entered is the title name for the page format, which should start from a character in order to distinguish said title name from that for the registration of the tabulator stop positions to be explained later. The title name entry is terminated by the actuation of the RETURN key. Thereafter the title name is printed and the printing sheet P is advanced by a line to indicate that the entered title name has been accepted. However, if the entered title name already exists, there will be given an alarm in the same manner as explained in the foregoing, and the entered title name is not accepted. The operator displaces the carriage 26 to the entry point EP1 in the first line by means of the SPACE key, etc., and actuates the ⋆ key to designate the entry point EP1. Upon completion of the registration of the entry points (EP1 only in the example shown in FIG. 30) in the first line, the RETURN key is actuated to instruct the storage of all the entry points (EP1) in the first line, and this procedure is repeated for the 2nd through nth lines (n=6 in the example shown in FIG. 30). Upon completion of the storage of the page format, the FORMAT key is actuated to terminate the registration procedure, whereby the FORMAT key lamp is turned off to indicate that the entry reception is terminated. In the illustrated example there is a blank line between the entry points EP10 and LP11, and such blank line can be obtained by actuating the RETURN key without the ⋆ key after the RETURN key is actuated following the registration of EP10.
Now FIG. 32 shows the procedure of readout of the thus registered page format. In said procedure the OP CONTROL key is actuated at first to turn off the STORE lamp. Subsequently the FORMAT key is actuated, whereby the FORMAT key lamp is turned on in the same manner as in the registration of the page format. Then the title name is entered, and the entry is completed by the actuation of the RETURN key. At this point the registered page format is recalled so that the carriage 26 is shifted to the next entry point EP1, EP2, etc. upon each actuation of the ⋆ key. Thus a document of the form shown in FIG. 30 can be prepared by entering characters following the actuation of the ⋆ key. This mode is terminated by the actuation of the FORMAT key, whereby the FORMAT key lamp is turned off.
In the following are explained the registration and readout of the tabulator stop positions. The tabulator stop positions, for example set at EP6, EP9 and EP7, EP10 in the format shown in FIG. 30, are cancelled when the tabulator stop positions are set for another line. Thus in case it is desirable to retain the tabulator stop positions, a function of registering such stop positions and recalling them later is quite useful. FIG. 33 shows the procedure of registering the tabulator stop positions, in which the OP CONTROL key is actuated to light the STORE lamp, then the FORMAT key is actuated to light the FORMAT lamp, and a particular title name which should start with a numeral is entered. If the same title name already exists, an alarm is given in the same manner as explained in the foregoing and the entered title name is not accepted. Upon actuation of the RETURN key after the entry of the title name, the data for tabulator stop positions already stored in the registers TAB1-TABn by the SPACE or SET key are registered in the sentence memory 54. FIG. 34 shows the procedure of recalling such stop positions, in which executed in succession are the actuation of the OP CONTROL key to turn off the STORE lamp, actuation of the FORMAT key to turn on the FORMAT lamp, entry of the title name for the registered tabulator stop positions, actuation of the RETURN key and the ⋆ key, whereupon the carriage 26 is automatically shifted to the first of the registered tabulator stop positions.
The functions of the above key operations are explained in the following. FIG. 35 shows how FIGS. 35-1 and 35-2 should be arranged.
Upon detection of the actuation of the FORMAT key by the MPU 44, the program proceeds to the sequence FORMAT shown in FIGS. 35-1 and 35-2. The program first clears a line counter LC for counting the number of lines on the printing sheet P, then checks the flag STR, and, if said flag STR is set by the STORE mode of the OP CONTROL key, executes the registration of the page format or the tabulator stop positions. In case said flag STR is not set, there is conducted the readout of the page format or the tabulator stop positions according to the format readout sequence FMRD shown in FIG. 36. In the sequence FORMAT shown in FIGS. 35-1 and 35-2, if the flag STR is set, the program enters a key entry waiting step KEY INT.
In response to the entry of the title name, the line buffer storage routine LBFSTR is initiated to store the title name in the line buffer 52 and display the same on the display unit 9. Then actuated is the RETURN key in order to indicate the completion of the title name entry. Since the flag TR is not set in this state, the buffer printing sequence BFPRT is executed to print the title name, to return the carriage 26 to the left margin stop position, to advance the printing sheet P by a line, and to set the flag TR. Then the program checks the content of the first digit of the line buffer (LB) 52, and, if it is a numeral, proceeds to the YES branch to store the title name of the line buffer (LB) 52 starting with a numeral and the data of tabulator stop positions stored in the registers TAB1-TABn into the sentence memory 54.
In case said title name starts with a character indicating the registration of a page format, the title name in the line buffer (LB) 52 is diverted into the WORK register for continuing the display. Then the carriage 26 is displaced to an entry point EP1, EP2, etc. by means of the SPACE key, etc. and the ⋆ key is actuated to divert the content of the register CRGPT, indicating the carriage distance from the left-end reference point, into the WORK register. In case there are plural entry points EP1-EP11 as shown in FIG. 30, the content of the register CRGPT is stored in the WORK register in succession by repeating the actuations of the SPACE key and the ⋆ key. Upon completion of the registration of entry points EP1 etc. in a line, the RETURN key is actuated. Since the flag TR is set in this state, the program proceeds to the YES branch to set the line counter LC from 0 to 1, and stores the content thereof in the WORK register corresponding to the storage of the entry point EP1, etc.
The above-mentioned procedure is repeated for the number of lines in the page format, thereby storing the entry point data of every line in the WORK register. Upon actuation of the FORMAT key, the content of said WORK register, including the title name, line number, and entry points EP1, etc. in each line, is registered in the sentence memory 54, and the FORMAT lamp is turned off to complete the registration of the page format.
In the readout of the thus registered page format, the OP CONTROL key is set to a mode other than the STORE mode to reset the flag STR. Thus in response to the actuation of the FORMAT key, the program proceeds, in the step STR=1?, to the NO branch to execute the format readout sequence FMRD shown in FIG. 36. In response to the entry of the title name of the page format or tabulator stop positions the line buffer storage sequence LBFSTR is executed to display the title name, and in response to the actuation of the RETURN key the program proceeds, in the step TR=1?, to the NO branch in the aforementioned manner. Then the first digit of the line buffer (LB) 52 is checked, and, if it is a numeral indicating a title name for the tabulator stop position, the data of the tabulator stop positions in the sentence memory 54 corresponding to said title name are transferred to the registers TAB1-TABn for again setting the tabulator stop positions. The contents of said registers TAB1-TABn are sensed by the MPU 44 to restore the data of the previous tabulator stop positions, thus enabling automatic tabulator setting of the carriage 26.
Also in case of a title name starting with a character indicating a page format, the page format corresponding to said title name in the sentence memory 54 is transferred to the WORK register and the flag TR is set. Thereafter in response to the actuation of the ⋆ key, the data for the entry points EP1-EP11 in the WORK register are supplied to the MPU 44 to automatically displace the carriage 26 to the entry point EP1 for example. Thus, in the example shown in FIG. 30, automatic carriage displacement and sheet feeding for the entry points EP1-EP11 is effected by actuating the ⋆ key eleven times without touching the RETURN key. This is due to the fact that the sentence memory 54 remembers the carriage return commands and the amount of sheet feeding instructed by the RETURN key at the registration of the page format.
Also at the readout from the sentence memory 54, the data stored therein override the state of the PITCH, LINE SPACE, and OP CONTROL keys selected at the keyboard 10. For example, when the page format is recalled and the carriage 26 is displaced to an entry point EP1 for example by the ⋆ key, the actuation of a character key 10a provides the character-unit printing mode (C-mode) even if the OP CONTROL key is set at the W-mode for the word-unit printing, since the sequence BFPRT in LBFSTR in FIG. 36 is mot executed as shown in FIG. 24 but is executed the next time because of the state TR=1.
In this manner the printing from the entry point EP1 for example can be conveniently conducted in response to each entry of the character. Also during the readout function of the page format the title name of said page format is continuously displayed by the sequence LBFSTR so that it is possible to locate a mistake in the selection of the registered page format.
Now reference is made to FIGS. 37 to 39-2 showing an embodiment allowing easy correction or insertion of printed characters.
In the print unit equipped in the conventional office computer or calculator or in the key-controlled printer such as an electronic typewriter, the correction or insertion of printed characters can only be made by the displacement of the carriage or printing sheet through visual observation or by manual operation with special correcting utensils on the printing sheet removed from the printer and has therefore been an extremely cumbersome operation even for an experienced operator.
The present embodiment explained in the following is capable of avoiding such difficulties.
FIG. 37 shows an example of printing on a printing sheet P, in which the characters, A, B, a, b, etc. are printed at arbitrary positions under the key instructions, by means of the displacement from left to right of a carriage 26 supporting for example a daisy typefont wheel 30.
For the lower case characters a, b, etc. the line spacing can be reduced for example to 3/4.
FIG. 38 shows an embodiment of the printer in a block diagram, wherein letters are used to designate block representations of units which were designated by numerals in the more detailed Figures. The block diagram shows a keyboard KBD comprising alphabet keys KAa-KZz, numeral keys KN0-KN9 shown in FIG. 44, and control keys K1-K6 for giving various commands to the carriage CA; a central processing unit CPU; a paper feed control PF which controls a roller RO for the feeding of the printing sheet P; a drive control unit HD for a typefont wheel WH; a carriage CA supporting said typefont wheel WH and performing displacement in the lateral direction; and a drive control unit CD for the carriage CA. A carriage position counter CC for detecting the carriage position stores the displacing distance of the carriage CA by counting the drive pulses for a stepping motor CM for said carriage CA. Also provided is a memory or line buffer LB for the correction or insertion of the printed characters and provided with a capacity for 300 characters over 2 lines. Inside said memory LB each memory area for a character is divided into three addresses I, II, and III, wherein the address I stores the kind of character such as A, B, a, b, =, $, etc. in coded form, the address II stores the printing pitch or the amount of carriage displacement corresponding to the size of each printed character, even when said printing pitch is the same as that for the neighboring characters, and the address III stores the kind of type such as printing with an underline.
It is now assumed that the printing pitch is equal to a constant unit pitch 1PT regardless of the size of the printed character, that the kind of type does not include special printing type such as underlined printing but is limited to an ordinary printing of characters NMP, and that the feed pitch of the printing sheet P is limited to an ordinary unit pitch 1PF. By the actuation of a carriage return (CR) key K1 the carriage CA is displaced to the left-hand end of the sheet P, which is simultaneously advanced by a line. Now, upon entry of a character A from the keyboard KBD, an address circuit AD instructs the storage of a code representing the character A in the address I of the first memory area 1 in the line buffer LB, a code 1PT representing said constant printing pitch in the address II, and a code NMP representing a simple printing in the address III.
When the type A is brought to the printing position by the rotation of the typefont wheel WH, the CPU reads the content of the address I of the first memory area 1 of said line buffer LB to print the character A in the 1st line and in the 1st column as shown in FIG. 37, and the carriage CA is displaced to the right by one digit amount under the control of the carriage drive control unit CD. Then, upon entry of the next character B from the keyboard KBD the address circuit AD is step advanced to store a code for the character B in the address I of the second memory area 2 in the line buffer LB and to store the data 1PT and NMP in the addresses II and III in the same manner as for the preceding character A.
The CPU receives the data from the address I of the second memory area 2 indicated by the address circuit AD, and prints the character B in the 1st line and 2nd column as shown in FIG. 37 through a known coincidence procedure.
In this state the content of the carriage position counter CC is step advanced to "2" indicating the distance of the carriage CA from the left-end position.
Similarly in response to the entries of characters C and D from the keyboard KBD the address circuit AD stores the codes for C and D in the addresses I of the 3rd and 4th memory areas 3, 4 and the codes 1PT and NMP in the addresses II and III. The CPU prints said characters C and D in the 3rd and 4th columns of the 1st line as shown in FIG. 37, and the carriage position counter CC stores "4" indicating the distance of the carriage CA from the left-end position. Then in response to the actuation of the carriage return (CR) key K1 in the keyboard KBD, the address circuit AD Stores a code RET representing the returning or reverse displacement of the carriage CA in the address I of the 5th memory area 5 in the line buffer LB. It also stores, in the address II, a code 4ST representing the carriage displacement "4" from the left-end position obtained from the carriage position counter CC, and, in the address III, a code 1PF respresenting the ordinary sheet feeding pitch.
FIG. 39 shows how FIGS. 39-1 and 39-2 should be arranged. FIGS. 39-1 and 39-2 show the state of data storage in the line buffer LB. At this point the carriage CA is returned to the left-end position, and the printing sheet P is advanced upwards in the known manner by the rotation of a rubber roller RO by an ordinary line pitch 1PF. Also the carriage position counter CC in the carriage drive control unit CD is reset. Then a space (SP) key K3 in the keyboard KBD is actuated to displace the carriage CA to the right by one character in order to, form a space in the 2nd line as shown in FIG. 37. Simultaneously the address circuit AD stores a code SPA representing a blank space in the address I of the 6th memory area 6 in the line buffer LB, a code 1PT indicating the printing pitch in the address II, and a code NOP indicating absence of printing in the address III. Also the carriage position counter CC has a count "2" in the same manner as explained in the foregoing. Then in response to the entries of the characters E and F, the corresponding character codes, printing pitches, and kinds of type are stored in the addresses I, II, and III in the 7th and 8th memory areas 7, 8 of the line buffer LB. The characters E and F are printed as shown in FIG. 37, and the carriage position counter CC stores "3". Let us assume that it is found at this point that the character C in the 3rd column of the 1st line needs to be corrected for example to a character Y. Upon actuation of a back trace (BT) key K2 provided exclusively for correction or insertion, the CPU reads, by stepwise reversing the address circuit AD, the content of the 7th memory area 7 of the line buffer LB to obtain-the codes NMP and 1PT as shown in FIGS. 39-1 and 39-2, whereby the CPU shifts the carriage CA to the left by one character pitch 1PT. Upon another actuation of the back trace (BT) key K2, the address circuit AD is changed from "7" to "6" to indicate the sixth memory area 6 in the line buffer LB, in response to which CPU shifts the carriage CA by one pitch 1PT toward the left-end position. Upon one more actuation of the back trace (BT) key K2, the CPU decodes the 5th memory area 5 to find the data for line feed for one pitch 1PF, carriage displacement for 4 steps, and carriage return command, whereby the carriage CA is displaced 4 steps, to the right and is stopped automatically at the character D in the 4th column of the 1st line shown in FIG. 37. At the same time the printing sheet P is inversely fed downwards by the inverse rotation of the rubber roller RO.
In this manner the carriage CA can be automatically brought to the position of the last character in the preceding line. Thus, upon a further actuation of the back trace (BT) key K2, the carriage CA is displaced leftwards by one pitch 1PT to the position of the character C at the 3rd column in the 1st line, whereupon it is rendered possible to erase the character C with the correcting ribbon 33 by actuating the correction (CO) key K6 and to print the character Y anew by entering said character, and the data in the line buffer LB is changed from C to Y by the function of the address circuit AD. After the correction is completed by repetitive actuations of the back trace (BT) key K2 and the correction (CO) key K6, a relocate (RL) key K5 is actuated whereby the CPU reads tthe address "8" immediately before the actuation of the back trace (BT) key K2, calculates the distance in the lateral direction and that in the sheet feed direction from the present address to the original address "8", and returns the carriage CA to a position immediately before the actuation of the key K2. Thereafter the characters G, H, and I are similarly entered and stored in succession in the line buffer LB through the address circuit AD, and the carriage position counter CC is advanced to "6". Upon completion of the printing of characters G, H, and I, the carriage return (CR) key K1 is actuated to return the carriage CA to the left-end position and to advance the printing sheet P by one line 1PF. In case the lower-case characters are to be printed in the 3rd line, the line spacing for sheet advancement by the key K1 is changed from 1 line for example to 3/4 line by giving a corresponding instruction from the keyboard KBD prior to the actuation of the key K1. Thereafter the lower-case characters a, b, c, . . . are printed in the similar manner, and the lower-case characters h, i, . . . are printed in the 4th line after the sheet advancement of 3/4 line to obtain the print as shown in FIG. 37. As explained in the foregoing, the line buffer LB in succession stores the character information, carriage return command, carriage displacing distance, and sheet feed amount as shown in FIGS. 39-1 and 39-2. Also the backward displacement of the carriage CA in the correcting operation can be achieved by actuating the back trace (BT) key K1 once and steadily pressing the repeat (RP) key K4, whereby the address circuit AD repeats the subtraction to supply the contents of the line buffer LB in succession to the CPU and to repeat the reversing motion of the carriage CA. In this manner it is possible to reach the position of correction at a high speed. Furthermore it is possible to return the carriage CA to the previously printed lines by instructing the number of lines of reversing motion with numeral keys KN in the keyboard KBD and by using the back trace (BT) key K2 and the repeat (RP) key K4.
More specifically it is possible, regardless of the number of lines, to return the carriage CA within a range of 300 characters.
As an example, when the carriage CA is at the 5th line in FIG. 37, it is possible to return the carriage CA to the position of the character A at time 1st column in the 1st line, by pressing the numeral key KN4 and by actuating the keys K2 and K4. For this purpose there can be provided a register CS for storing said number "4", and the carriage CA is not stopped at each carriage return command but only at such carriage return command when the number of said commands coincides with the number stored in said register CS.
The control method with a line buffer LB as employed in the present embodiment is practically useful, since the case of printing a maximum of 150 characters on a sheet is rather seldom.
Furthermore it is in fact not necessary to store every carriage return command, displacing distance, and amount of sheet feeding as shown in the 34th and 35th memory areas in FIGS. 39-1 and 39-2, since the sheet feeding may be conducted manually and the carriage return command itself can be included in the data of distance of carriage displacement.
Also the line buffer LB is preferably backed up with a battery BAT as shown in FIG. 38, in order to retain the content even when the power supply is interrupted for some reason and thus to facilitate the correction, after the re-start of the function, on the work done before the interruption of the power supply.
Now reference is made to FIGS. 40, 41, and 42 showing a printer capable of printing form lines by the key operations. FIG. 40 shows an embodiment WH of part of a typefont wheel 30. FIGS. 41 and 42 show samples of printing on a printing sheet P.
Conventionally patterns other than characters and numerals, such as form lines, must be inscribed with a scale and a ball-point pen, etc. and therefore cannot be made neatly.
In consideration of the foregoing difficulty, the present embodiment enables the printing of form lines with neatly formed coroners by selective use of vertical-line and horizontal-line types with key operations.
FIG. 40 shows a part of an example of a daisy typefont wheel WH adapted for use in the present embodiment. Said typefont wheel WH is provided, in addition to the ordinary types CT, with a vertical-line type CV and horizontal-line types CH1, CH2 for forming the vertical and horizontal form lines as show in FIGS. 41 and 42. The type CH1 is provided approximately in the center of a type area and is utilized for printing a minus symbol "-" as shown in the 2nd column in the 1st line in FIG. 41, whereas the type CH2 is provided at the lower part of a type area and is utilized for printing an underline as shown in the 2nd, 3rd, 4th, and 5th columns in the 3rd line in FIG. 41. Also the type CV is utilized for printing various vertical lines as shown at the 1st column in the 1st to 3rd lines and 6th to 11th lines in FIG. 41, and at the 1st column in the 7th to 11th lines, at the 7th and 9th columns in the 8th to 10th lines, and at the 3rd and 6th columns in the 12th line in FIG. 42. As shown in FIGS. 41 and 42, the printer of the present embodiment is capable of forming vertical and horizontal lines with types controlled by key operations and without particular scale or other writing utensils.
However, in the form line printing shown in FIG. 41, the obtained form is not aesthetic in that the horizontal line at the 1st column in the 3rd line is broken by a half pitch, that the horizontal line at the 1st column in the 5th line is excessively long, and that the horizontal line constituting the underline for the characters E, F, G, and H in the 3rd line is too close to said characters.
These drawbacks can also be prevented by the present embodiment shogun in FIG. 43 in a block diagram, wherein letters are used to designate block representations of units which were designated by numerals in the more detailed Figures. In said block diagram, a keyboard KBD is provided with a vertical-line print key KV, a horizontal-line print key KH, a repeat print key KR, a line spacing key KP for changing time type spacing or line feeding to a half, a backspace key KA, a shift key KS for using said keys KP, KH, etc. for two purposes, in addition to other known character keys, numeral keys, control keys, etc. (not shown).
Also there are provided a central processing unit CPU, a control circuit CD for a carriage drive motor CM, a control circuit PD for a sheet feed motor PM, a carriage CA supporting the typefont wheel WH shown in FIG. 40, and a printing sheet P. In case of printing the vertical line as shown in FIGS. 41 and 42, the known control keys are actuated for displacing the carriage CA to the right or to the left. In response the CPU activates the drive circuit CD and releases a right-shift (forward) signal 1FC or a left-shift (backward) signal 1BC through a signal line l1 or l2 respectively to rotate the carriage drive motor CM in the forward or backward direction respectively through an OR gate OR1 thereby stepwise displacing the carriage CA to a desired position for example in the 1st column. Then in response to the actuation of the key KV, a flip-flop FV in the CPU is set and a vertical line "|" is printed for example at the 1st column in the 7th line on the printing sheet P.
Then in response to the actuation of the repeat key KR, the CPU releases a forward sheet feed signal 1FP through a line l5 of the control circuit PD to drive the sheet feeding motor PM through an OR gate OR2, thereby advancing the printing sheet P by one line through the rotation of the roller RO.
Then upon actuation of the repeat key KR the vertical line "|" is printed in the same column of the next line since the flip-flop FV is maintained in the set state. In this manner said vertical line is printed at the same column position in response to each actuation of the key KR. Also an excessive printing eventually made can be erased in the known manner with the correcting ribbon 33 through corresponding key operation.
In case of printing the horizontal line "-", in response to the actuations of the shift key KS and the key KH in this order, the CPU resets the flip-flop FV. However, the printing of a horizontal line with the carriage CA positioned at the 1st column as shown before will result in a form line as shown in the 1st column, 5th line in FIG. 41. In order to avoid such defective line printing, the key KP is actuated after the shift key KS is actuated. In response the CPU releases a half-space right-shift (forward) signal 1/2 FC to the line l3 of the control circuit CD to displace the carriage CA to the right by 1/2 space. In this manner the carriage CA becomes positioned between the 1st and 2nd column, so that the horizontal line "-" obtained by the actuation of the key KH is positioned between the 1st and 2nd columns as shown in the 5th and 11th lines in FIG. 42. Also in case the carriage CA is originally positioned in another place, it can be brought to a position between the 1st and 2nd columns by actuating the known back space key KA for a desired number of times followed by the actuation of the key KP, whereby the left-shift (backward) signal 1BC and the half-space left-shift (backward) signal 1/2 BC are supplied to the lines l2 and l4 respectively of the control circuit CD. Also as shown in the 7th and 9th columns in the 8th to 10th lines in FIG. 42, the vertical line "|" can be suitably shifted by a half space to the left or to the right by the keys KV, KP, and eventually KA to provide vertical lines for a matrix well balanced with the positions of the printing d1-d3, c1-c3, etc. The above-mentioned half-space process can further be applied to the sheet advancement to provide an easily legible printed form. For this purpose the control circuit PD for the sheet advancement is provided with signal lines l5 to l8 for selectively providing the one-line forward or backward advance signals 1FP and 1BP respectively and half-line forward or backward advance signals 1/2FP and 1/2BP respectively.
For example in response to the actuation of the key KP, the CPU provides the signal 1/2FP through the output line l7 of the control circuit PD to advance the printing sheet P by a half line. Also in response to the actuations of the shift key KS and key KP, the carriage CA is moved to the right by a half space through the output line 13 of the control circuit CD. By actuating character keys E, F, G, and H, these characters are printed in the middle positions of the columns and lines as shown in FIG. 42, maintaining suitable spaces from the form lines above and at left. Also by said half-line sheet feeding the horizontal line at the 9th column in the 9th line becomes suitably positioned with respect to the characters "D" and "1" in spite of the fact that the type for said horizontal line is positioned at the lower end of the type area as shown in FIG. 42.
Also the vertical line "|" can additionally be used for various purposes such as in indicating the date as shown at the 3rd and 6th columns in the 12th line in FIG. 42.
As explained in the foregoing, the present embodiment allows obtaining easily legible print formats by the use of vertical-line and horizontal-line type in combination with a half-space displacement of the carriage CA and a half-line displacement of the printing sheet P under suitable key control, and such print formats are more legible than those obtained by dot matrix printing.
FIGS. 44, 45, 46A, and 46B show an embodiment of the electronic device capable of increasing the print processing speed and providing more legible print forms.
For example in the conventional desk-top electronic calculator with a printer, an entered number is printed only when an operand key, such as "+", is actuated following the entry of numerals, and for this reason the printing of the entire number requires a certain time.
This drawback is prevented by the present embodiment in which the printing of the integer part of a number is initiated at the entry of the decimal point, with appropriate punctuation in said integer part. In this manner it is rendered possible to shorten the processing time as the integer part can be printed while the decimal fraction part of the number is entered by the numeral keys KN, to reduce errors in key entry as the numerals are printed with appropriate punctuation, and to avoid useless entries of the decimal fraction part in case an error is found in the entry of the integer part.
FIG. 44 shows the present embodiment in a block diagram, in which letters are used to designate block representations of units which were designated by numerals in the more detailed Figures. The block diagram shows a keyboard KBD which is provided with numeral keys KN0-KN9, a decimal point key KP', a slide switch SS for selecting punctuation by blank or by a particular symbol (,), a control key KD for numeral printing with a fixed decimal point position, and control keys KC (K+, K-, KX, K , K%, K=). Also there are shown a register KR for storing the key signals from the keyboard KBD, a number display unit DSP, a central processing unit CPU, and a printer PRT having a serial printing head H for printing from left to right on a printing sheet P. FIG. 45 shows an example of the printing, and FIGS. 46A and 46B illustrate the order of the display and printing.
By first manipulating for example a numeral key KN8 followed by the control key KD, the datum "8" is stored in a latch L in the CPU to fix the position of the decimal point at the 8th column from the left-hand end of the printing sheet P.
Now, upon actuation of the numeral key KN1, the numeral "1" is stored in the register KR and displayed on the display unit DSP, and then upon actuation of the numeral key KN2, the numeral "2" is also stored in the register KR and a number "12" is displayed on the display unit DSP as shown in FIG. 46A, part I. No printing is made at this stage.
Also a counter C in the CPU stores a number "2" indicating the number of numeral key actuations. Then, in response to the actuation of the decimal point key KP', the CPU subtracts "2" stored in the counter C from "8" stored in the latch L to obtain the difference "6", and displaces the printing head H to the 6th column from the left-hand end of the printing sheet P to print a numeral "1" at this position, then to print a numeral "2" to the right, and then to print the decimal point "." further to the right as shown in FIG. 46B, part I. During said printing the fraction part "34" can be entered by the numeral keys KN and is displayed on the display unit DSP as shown in FIG. 46A, part II. Upon subsequent actuation of a control key KC the printing head H is displaced in succession to the right to print the numerals "3" and "4" as shown in FIGS. 45 and 46B, part II. During said printing it is possible to enter the numerals for the printing in the next line. At this point the counter C is cleared but the content "8" of the latch L is retained. Upon completion of the printing "34" the printing sheet P is advanced by a line, and the printing head H is in a stand-by state for the printing of the next line. Then the numerals in "123456" are entered by the numeral keys KN1-KN6 and are displayed on the display unit DSP (FIG. 46A, part III) through the register KR as explained in the foregoing, and the counter C stores a number "6". Upon actuation of the decimal point key KP', the CPU senses the possibility of punctuation from the number "6" in the counter C, adds "1" to the counter C to obtain "7" and subtracts said number "7" from "8" stored in the latch L to obtain "1" in the foregoing manner, whereby the printing head H initiates the printing from the left-hand end of the printing sheet P. At the same time the CPU senses the state of the slide switch SS, which is set at the blank punctuation state in FIG. 44, to execute the printing with blank punctuations (FIG. 46B, part III). The entry and printing of the fraction part and the line feed operation are conducted as explained in the foregoing.
In case the slide switch SS is set at ",", the print is punctuated with the symbol "," as exemplified by "7,654.321" in FIGS. 45 and 46B, part VI.
As explained in the foregoing the present embodiment is advantageous in reducing the errors in operation as the integer part is immediately printed with appropriate punctuation in response to the actuation of the decimal point key KP', thus providing an easily legible print with a fixed decimal point position and increasing the processing speed. Thus the present embodiment has a wide range of applications, particularly including electronic typewriters.
FIG. 47 shows the manner in which FIGS. 47-1 and 47-2 should be arranged. FIGS. 47-1 and 47-2 show an embodiment of the electronic typewriter, particularly the electronic typewriter provided with a display unit 9 for displaying the characters to be printed and a character generator 100 for generating character information for display.
The use of character generators in the electronic typewriter is already known, but for displaying the characters used in various countries there have been required a character generator and a control circuit of a very large capacity. For this reason it has been a common practice to mount a character generator suitable for the country of destination, although this complicates the specifications of the typewriter and necessitates the operation of replacement work.
Thus, the present embodiment provides an electronic typewriter capable of displaying the characters of various countries without increasing the capacity of the memory.
Now reference is made to FIGS. 47-1 and 47-2 showing the basic structure of such an electronic typewriter, in which a keyboard 10 is provided with character keys 10a common to various countries and with character keys 10h exclusive to the country of destination. The entered key signals for printing are first displayed on a display unit 9.
There are provided an oscillator 90 for generating a basic frequency for dynamic drive of the display unit 9; a counter 91 of a capacity of the number of digits of the display unit 9; a decoder 92 for generating a digit signal corresponding to the count of said counter 91; a digit driver 93; and a multiplexer 102 for supplying the count of the counter 91 or a signal supplied from the MPU 44 through an address bus AB to a display buffer 101 as an address signal thereto. Said display buffer 101 is capable of storing the character signals entered from the keyboard 10 at least for the capacity of the display unit 9, for example 20 characters. By designating the display buffer 101 from the address decoder 105, the multiplexer 102 provides the signal of the address bus AB to the display buffer 101 as the address signal therefor, and the character signal in the display buffer 101 is made changeable by the signal from the data bus DB. A main character generator (CG) 100 for common characters converts the character signals from the display buffer 101 into character font represented in dot matrix form. A secondary character generator 106 stores the typefonts for particular countries and has a capacity corresponding to the countries of destination. A multiplexer 97 provides the character font from the main character generator 100 or from the data bus DB to the latch 96. A driver 95 drives the display unit 9 in response to the signal from said latch 96. A manual switch 98 composed for example of selectable diodes in a matrix array is utilized for selecting a country in the secondary character generator 106. A bus driver 99 transmits the information of the switch 98 to the MPU 44. In case of displaying the common characters 10a, the digit signal indicated by the count of the counter 91 is supplied to the display unit 9 through the decoder 92 and the digit driver 93, and the corresponding character signal is read from the display buffer 101 addressed by the count of said counter 91 through the multiplexer 102. Said character signal is converted into a character pattern by the main character generator (CG) 100, then latched in the latch 96 through the multiplexer 97 and supplied to the display unit 9 through the driver 95 for display in cooperation with the digit signal corresponding to the content of the counter 91. A dynamic display is achieved by repeating the above-mentioned procedure with the frequency of the oscillator 90. There are also provided a memory 103 for storing the reference character signal and a comparator 104.
Since certain vowels, currency marks, etc. are different from country to country, the character generator 100 needs to have an enormous capacity if all these characters are to be incorporated therein, and the character generator 100 itself needs to be remade if a country of destination is added. However, in the present embodiment the character generator 100 only contains the characters, numerals, and symbols common to all the countries, and the memory 103 and comparator 104 inspect for characters not contained in the character generator 100, and, upon detection of such a character, set a flip-flop 107 to supply an interruption signal INT to the MPU 44. The MPU 44, already identifying the country of designation by the state of the switch 98 through the bus driver 99, discriminates the character signal for which the interruption signal INT is given. Based on said character signal the MPU 44 generates the address signal for the secondary character generator 106 and supplies the character signal therefrom through the data bus DB and multiplexer 97 to the latch 96. In this manner the adjustment for the change of country of destination can be simply accomplished by appropriately positioning the switch 98 in the secondary character generator 106.
Let us assume now that the main character generator 100 stores a common character font composed of A, B, C, D, E, and F each composed of 5×12 dots, and that the following codes are allotted for the characters in the display buffer 101:
A: 000
B: 001
C: 010
D: 011
E: 100
F: 101
Also it is assumed that the following codes are allotted for the currency marks of specified countries:
¥: 110
$: 111
In this case a reference signal "101" is stored in the memory 103, and the comparator 104 is so structured as to set the flip-flop 107 for initiating the interruption procedure upon receipt of a signal larger than said signal "101".
The secondary character generator 106 stores the character font corresponding to the currency marks ¥ and $.
The keyboard 10 shown in FIG. 47-2 is designed for Japan and is provided with common keys 10a and exclusive key 10h, a Yen currency key "¥", and the switch 98 is set for Japan.
In response to the actuation of the "¥" key 10h, the MPU 44, being already aware that the switch 98 is set for Japan, stores a code "110" in the display buffer 101, and the comparator 104 compares said code with the reference signal "101" stored in the memory 103 and, the latter being smaller, sets the flip-flop 107 thereby sending an interruption signal INT to the MPU 44 indicating a character other than those stored in the main character generator 100. Simultaneously receiving the code ¥=110 through the data bus DB, the MPU 44 generates an address signal for calling the character ¥ in the secondary character generator 106 through the address bus AB and supplies said character ¥ into the multiplexer 97 through the bus driver 99 to display the character ¥ on the display unit 9.
On the other hand the switch 98 is set to the United States when the keyboard 10 for the United States shown in FIG. 48 is mounted. In this manner the MPU 44 knows that the apparatus is adjusted for the United States and, in response to the actuation of the exclusive "$" key 10h, generates a code "111" for storage in the display buffer 101. The comparator 104, similarly identifying that the reference code "111" is smaller, releases the interruption signal INT in the same manner as explained in the foregoing. In this case the MPU 44 receives the code "111" through the data bus DB and thus addresses the character $ in the secondary character generator 106.
As explained in the foregoing the present embodiment employs a main character generator storing common characters and symbols and a secondary character generator storing characters and symbols changing from country to country, and performs the display usually with the main character generator but with the secondary character generator only when the desired character is not present in the main character generator. Consequently the adjustment for each country can simply be achieved by appropriate positioning of the switch.
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A printing apparatus system includes a plurality of type units each having a plurality of type elements and each being different from the others. Each type unit may be mounted in the apparatus. A detector detects which of the type units is so mounted and produces a detection signal representative thereof. The printing pressure with which each type element is imprinted on a print medium is determined in accordance with the particular type wheel mounted in the apparatus as indicated by the detection signal. Additionally, the amount of advance of an ink ribbon for imprinting a type element on a type unit is determined in accordance with the particular type unit mounted in the apparatus, again as indicated by the detection signal.
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BACKGROUND OF THE INVENTION
[0001] The invention relates to the field of spraying apparatus, in particular to a washing device and a method for operating a washing device according to the preamble of the respective independent patent claims.
DESCRIPTION OF RELATED ART
[0002] Such a washing device is known, for example, from WO 2004/101163 A1. A shower head is described therein, in which water nozzles are arranged in pairs, so that the jets from two nozzles of a pair impact one another and create droplets by way of this. The purpose of the device is to provide a pleasant shower experience at different operating pressures between 0.2 bar and 10 bar, and also to reduce the water consumption compared to conventional shower heads. Thereby, apart from the water droplets, one should, however, prevent a mist of very fine droplets from occurring. For this, the jets impacting one another are preferably arranged such that they do not fully intersect one another.
[0003] Furthermore, it is known, for example, from WO 98/07522, to install a heater in a shower sprinkler, in order to heat water directly before dispensing through the shower sprinkler. Thereby however, a large amount of heating power is required in accordance with the quantity of water flowing through.
[0004] An electrical shower is described in the product handbook “The Heatstore Aqua-Flow. Pumped Electric Shower Handbook” of the company Heatstore Limited, Island Park, Bristow Broadways, Bristol BS11 9FB, downloaded from www.heatstore.co.uk on Jul. 11, 2006. The shower is provided in order to be fed from a cistern, and thus, comprises a pump for delivering the water. A two-stage electrical heater is provided for heating the water, whose heating power is 8.5 kW/7.8 kW or 9.5 kW/8.7 kW, depending on the model. The temperature of the dispensed water is set by way of varying the water throughput quantity. A hand-operated control valve is arranged downstream of the pump for this. The entry pressure in front of the apparatus may not be too high, probably for the protection of the pump, which is why the apparatus may not be connected to water supply mains, and may not be arranged more than 10 m below the cistern. The heating power as well as the throughput quantity, is thus relatively high.
[0005] DE 100 04 534 A1 describes a hydro-massage nozzle for producing a pulsating waterjet. For this, the massage nozzle is suitably activated by pumps or valves. The massage nozzle is provided for operation in a pool such as a shower bath, jacuzzi, swimming pool or exercise pool, thus for operation below water, so that no atomisation takes place.
[0006] BE 514 104 shows a spray head with atomisation by way of jets impacting one another. A spray core comprises four or more oblique bores with a diameter of 1 mm to 12 mm, which are directed onto a common focal point. A sieve acts as a dirt filter. A pressure increase by a pump for example, is not, however, mentioned.
BRIEF SUMMARY OF THE INVENTION
[0007] It is therefore the object of the invention to provide a washing device and a method for the operation of a washing device, or for the preparation of water for washing, of the initially mentioned type, which permits a reduction of the consumption of energy and/or water compared to the state of the art.
[0008] A further object of the invention is to provide a washing device which may be installed with little effort and in particular may also be installed into buildings or installations with existing water mains and electrical mains, without significant modification of the mains.
[0009] A further object is to provide a washing device and a method for the operation of a washing device, which is not susceptible with regard to the spreading of infectious diseases.
[0010] These objects are achieved by a washing device and a method for operating a washing device with the features of the respective independent patent claims.
[0011] The washing device for dispensing water or a mixture based on water, in particular in the sanitary field, for example in a shower or a sink, includes at least one outlet for spraying fluids with a low flow rate and under a high pressure, as well as at least one delivery device for increasing the fluid pressure to an operating pressure of the outlet, before spraying.
[0012] If the washing device is connected to a water main, then the operating pressure of the outlet lies above the nominal pressure of the water mains. This nominal pressure is typically about 2.5 bar, and the pressure in the house installations (depending on the regulations of the local water main company) is typically limited to 5 bar or 6 bar for the protection of the conduits.
[0013] The spraying of the fluid is effected naturally in a gaseous medium, and with a washing device, typically in the atmosphere or the surrounding air, in which the washing device is operated.
[0014] The sprayed fluid as a rule is water or a water-based mixture. An addition such as soap or another cleaning agent or disinfectant may be admixed to the water. The mixture may come from all nozzles. It is also possible to supply the different nozzles with different fluids or fluid mixtures, for example one nozzle with water and another with fluid soap, or one with water and another with disinfectant. In further embodiments of the invention, gaseous fluids may be fed through individual nozzles. A gas jet under high pressure may also be used for atomising a fluid jet. The gas jet may, in particular, be a steam jet.
[0015] The washing device, apart from the sanitary field, may also be applied in the therapeutic, field, the cosmetic field as well as the pharmacy field. The admixed fluids thereby may also contain cosmetic or medical active ingredients.
[0016] With the application in other fields, additives such as nutrients, fertilisers, pesticides etc. may also be admixed, wherein a good atomisation and, thus, an increase in the total surface of the fluid to be atomised takes place. Basically, fluids other than those based on water maybe sprayed with similar types of means, for example fuels in drives or heaters, or chemicals in processing chemistry. Industrial applications of the atomisation methods and atomisation devices for coating and impregnating are likewise possible.
[0017] By way of the pressure increase, it is possible, despite a small throughput rate, to spray the fluid such that a pleasant washing experience or shower experience arises. In particular, in trials, it has been found that the skin is completely moistened, even with unexpectedly low throughput rates, and there is no sensation that too little water is dispensed. This perception is due to the fact that the particle size of the water droplets is significantly reduced compared to conventional showers, on account of the spraying or atomisation with an increased pressure and accordingly by way of narrow nozzles. By way of this, the whole surface of the fluid droplet is significantly larger than with the same fluid quantity with larger drops, and the effect on wetting the body is accordingly also increased. For example, given the same volume, drops of 50 micrometers radius have a 20 times greater contact surfaces than a drop of 1 mm radius.
[0018] This delivery device or pump, as a part of the washing device, is thus arranged in a preferably local manner, in the vicinity of the outlet or a shower head, thus in a bathroom or as an installation element of a mobile or stationary shower cubicle. Basically, a central pressure increase, for example in a building for several installations, is also conceivable. Such a central pressure increase may be provided for whole buildings, or several units may be applied for the central pressure increase, for example, in each case one unit for one storey, or in each case one unit for a vertical supply line through several storeys. Thus, the pump noises may be kept away from the users in an improved manner. However, existing conduits in buildings as a rule are overburdened with the preferably applied operating pressures of the outlet of 10 to 40 or 50 bar, in particular 15 to 25 bar, and new pressure conduits for water would have to be applied for this. The pump for example is electrically operated.
[0019] Vice versa, with the application of de-centralised pumps, one may also apply several pumps per washing device, in particular if different fluids are mixed in the washing device. Thus one may provide an individual pump for each of the fluids, and the quantity of this fluid may be controlled by way of activation of the respective pump. Thereby, the mixture of the fluids is either effected before the spraying or during the spraying itself. In order for a clean spraying to take place in the second case, the pumps may, for example, be activated in a coordinated manner, or at least one pair of nozzles directed counter to one another and which are fed by the same pump may be present for each of the fluids. Thus, a clean atomisation takes place for each of the fluids, independently of the exact delivery quantity and jet speed of the other fluid. The impact points of the several nozzle pairs (corresponding to the several fluids) may coincide, or may for example be distanced to one another in the main spraying direction.
[0020] A control of the throughput quantity may be effected by way of control of the pump(s) or by way of mechanical control means at the outlet or in the feed conduit. Such a mechanical control means is e.g. a manually adjustable reduction valve.
[0021] The washing device is particularly suitable for the installation in transport means such as trains, aircraft, campers or other mobile set-ups, such as travelling washing installations, etc. on account of the low water consumption. Other applications are, for example, in showers or washing installations, in public swimming baths, in dish washers or for the irrigation of plants.
[0022] In a further embodiment of the invention, the pump or a means for pressure production is operated in a manual manner. Thus firstly, pressure may be produced in a pressure storage means without external energy supply, and a washing device may be used subsequently or over a longer period of time. This embodiment of the invention is particularly advantageous when it is combined with the solar production of warm water. With this, one obtains a completely autonomous washing unit with low water consumption. Preferably thereby, the pressure storage means is identical with a water storage means, and furthermore comprises a surface which may be exposed to radiation, for heating the water storage means. The pressure, thereby, may be stored by way of expansion of a flexible vessel and/or by way of compression of an air volume in the pressure storage means.
[0023] In one preferred embodiment of the invention, the washing device includes a heating device for heating the water or the fluid. This heater may be designed in a comparatively small manner thanks to the low throughput rate. In particular, it may be designed as a tankless water heater, thus without any storage means in which the water is heated, as is the case with boiler heating or thermal storage heating. The heater may be operated electrically, with a fluid fuel such as gas or oil, or also in a different manner.
[0024] In another embodiment of the invention, the supply with warm water is effected from a boiler, thus from a storage heating installation or generally with stored warm water.
[0025] An electrical heater may be operated with existing electrical house installations on account of the low required heating power. The heating may be arranged in a decentralised manner by way of this, i.e. each shower or washing device has its own heater, and no central warm water provision is required. Various advantages result from this, in particular for installations in hotels:
[0026] One requires only a single cold water supply for the washing device, and one may make do without a warm water supply.
[0027] The storage losses and the conduit losses of a conventional central warm water provision are eliminated, on account of the de-centralised heating which is only effected on demand.
[0028] No cultures of infectious diseases such as legionnaire's disease may arise since the system only contains cold water until shortly before use.
[0029] The heating device is preferably set up for heating the water with closed-loop control shortly before dispensing at a predefined dispensing temperature. With this, one may set a temperature by way of a manually adjustable setting device, e.g. by way of a dial. The water temperature is measured and is automatically controlled with a closed loop by way of adapting the heating power. This is significantly more accurate, quicker and more comfortable than the conventional closed-loop control of the temperature by way of setting a mixing ratio at a mixing tap. Preferably thereby, the manually adjustable rated temperature of the closed-loop temperature control is limited to a predefined value and/or the dispensing temperature is limited to a predefined value. Such a value for washing devices for persons is for example 45° C. or 50° C. or 55° C. With this, on the one hand one prevents scalding, and on the other hand the heating power may be kept low or limited in accordance with the maximal throughput quantity.
[0030] In another preferred embodiment of the invention, unheated water is admixed to the heated water after the heating, in order to reduce the water temperature. With this, the heating may be operated at a different (more efficient) operating point, than if the heating were to reach the lowered temperature without admixture. For example, the heater may heat the water to about 90° C., whereupon (for sanitary applications) it may be brought to a lower dispensing temperature by way of admixing cold water. One may also use a higher dispensing temperature for other applications.
[0031] Amongst other things, tankless water heaters, as are disclosed in EP 0 832 400 B1, or in EP 0 869 731 B1 are suitable for the heating. These documents are adopted into the application by way of reference. Accordingly, a heated tube is suspended such that it is movable or deformable on operation. The cause for the movement or deformation may be temperature changes, pressure changes and/or vibrations of a pump. Furring in the tube may be detached by way of this. These tankless water heaters were originally conceived for coffee machines and thus—compared to conventional washing devices and shower devices—for relatively low throughput quantities. They may be combined with spraying devices with a low throughput according to the present invention, possibly whilst adapting the heating power. These tankless water heaters are, in particular, suitable for high operating pressures, in particular up to 10 bar or more. The closed loop control of the temperature may also be effected by way of a closed-loop control of the electrical heating power or by way of admixing cold water.
[0032] The washing device, thus, preferably comprises a supply with cold water and a supply with energy for the heating, but no supply with warm water. The energy supply may be an electrical one or a supply with a combustible gas. Another supply, however, may not be ruled out.
[0033] The washing installation may thus be designed as a compact construction unit with only one cold water connection and one electrical supply connection. Such a construction unit, in a housing contains the pressure pump and the heater as well as preferably a pre-treatment unit for the fed water, or fluid. The pre-treatment unit preferably comprises one or a combination of the following functions: coarse filter, micro-filter, disinfection, antibacterial treatment, deliming. Operating elements for the control of the temperature and/or pressure may be present as control inputs. These may be attached to the construction unit itself or on a relocated operating unit.
[0034] In a preferred embodiment of the invention, the maximal throughput quantity of the outlet is 5 l/min or 3 l/min, and preferably 1.0 to 1.5 to 2 l/min, which corresponds to a heating device with a maximal heating power of about 3 kW.
[0035] In a preferred embodiment of the invention, the maximal throughput quantity of the outlet is 1 l/min and preferably 0.5 l/min, which corresponds to a heating device with a maximal heating power of about 1 kW. These conditions are suitable, for example, for an outlet in a water tap for a wash basin (or rinse basin or sink).
[0036] The throughput quantities mentioned above, in each case relate to one nozzle set. The throughput is accordingly increased when applying several nozzle sets. The heating power for an electrical heater is typically limited to 2, 4 or 6 kW depending on the fuse protection and the number of applied phases. The maximal throughput quantity with a de-centralised heating is limited by way of this, which represents an important incentive to reduce the throughput quantity whilst simultaneously maintaining the washing quality.
[0037] In a further preferred embodiment of the invention, the washing device comprises a mixing device for mixing the water with soap before dispensing. This mixing device may be switched on and off, so that the washing installation may be operated in a first operating mode and second operating mode, wherein soap is admixed to the water and the water throughput for example is less than 3 l/min or less than 1 l/min and is preferably 0.5 l/min, in the first operating mode (“lathering”), and no soap is admixed to the water and the water throughput is up to 1 l/min or (with a shower) up to 3 l/min or up to 5 l/min in the second operating mode (“rinsing”).
[0038] In a preferred embodiment of the invention, the outlet comprises a nozzle body, said nozzle body comprising two nozzle disks, wherein the nozzle disks are arranged, rotatable to one another in different positions. Thereby, one set of nozzles of the first nozzle disk is connected to different sets of nozzles of the second nozzle disk, depending on the angle of rotation. If the first nozzle disk is an upper nozzle disk, i.e. the nozzle disk which is impinged by pressurised water, and the second nozzle disk is a lower one which faces the consumer or the spray direction, then one nozzle set with selectable characteristics may be coupled to the feeding nozzle set of the upper nozzle disk by way of rotating the second nozzle disk.
[0039] In the case that the first nozzle disk is a lower nozzle disk, then one of different feeding nozzle sets of the second upper nozzle disk may be selected by way of rotating the first nozzle disk. Different feeding nozzle sets may for example be fed with different fluids or fluid combinations, so that a selection of the mixture of the sprayed fluid is possible by way of rotating the first nozzle disk.
[0040] In a preferred embodiment of the invention, the atomisation is accomplished by way of a fluid jet impinging an obstacle with a high relative speed. Thereby, the obstacle may be a moved or stationary solid body or at least one further jet of a fluid, thus a liquid jet or a gas jet. The relative speed arises on account of the speed of the fluid jet and/or a movement of the solid body. Means for achieving a high relative speed are therefore nozzles for producing a fluid jet, under certain circumstances, in combination with a pump for pressure increase, and/or moved solid bodies, onto which one or more fluid jets impinge. In particular, such a solid body, hereinafter also called atomisation body, may rotate with a high speed of revolution. The revolution speed is directed to the desired relative speed and the radius of an impact point of a fluid jet, with respect to the rotation axis.
[0041] The relative speed between the particles in the fluid jet and the atomisation body is above 20, 30 or 40 m/s and preferably at least approximately 50 m/s. A suitable size and speed of the atomised jet is achieved with this.
[0042] In a preferred embodiment of the invention, the atomisation is accomplished by way of the outlet comprising at least one nozzle set with at least two nozzles for producing fluid jets impacting one another and for atomising the fluid. The nozzle set, for example, comprises two, three, four or more nozzles, whose jets at least approximately hit one another in one point. In a further variant, the jets may be deliberately displaced slightly, so that they do not impact in a point, in order for example to effect a massage sensation.
[0043] If the fluid, apart from water, comprises a further medium such as soap, then this further medium may be admixed to the supply of all nozzles or however only individual nozzles. For this, the washing device comprises a mixing device for admixing soap into the fluid supply of at least one of the nozzles.
[0044] With an adequately low viscosity, the further medium may alternatively be fed as a liquid to at least one nozzle in an unmixed manner. In both cases, the liquids are additionally mixed and distributed on colliding. Basically, it is also possible when supplying the nozzles with different fluids, to thereby vary the supply pressure, the type of the several applied pumps and the nozzle diameter of the nozzles amongst one another, according to the respective liquids. An optimal, balanced atomisation may be achieved with this. For example, soap may be led from above to the impact point of the colliding jets and thus be admixed.
[0045] In a preferred embodiment of the invention, the washing device comprises protective bodies which are arranged in the direction of the nozzles, so that a liquid jet which is not hit by other fluid jets impinges a protective body. With this, given a blockage of a nozzle, one prevents the jet from another nozzle of the nozzle set from directly hitting the skin or eyes.
[0046] However, it has been found that should there be no perfect alignment of the jets of a nozzle set, these partly atomise and the remaining part causes a “prickling” effect on the skin, which, depending on the intensity and personal preference, may be perceived as being pleasant or as massaging. For this reason, in a preferred embodiment of the invention, the nozzles are not aligned to one another in an exact manner, but for example, one with an intersection (overlapping) of the jet surfaces of 60% or 80%. One may, however, also switch over between operating modes with a different intersection and, thus, a different shower sensation. This may be effected by way of switching over between several nozzle sets, or by way of mechanical variation of the alignment of at least one nozzle of a nozzle set.
[0047] An asymmetry of the atomised water jet arises by way of the only partial intersection of the jet surfaces. Other possibilities for producing an asymmetry are, for example, the application of different nozzle diameters with at least two nozzles of a nozzle set. However, two nozzles of a nozzle set may also be operated with different fluid pressures. This may be achieved by way of using separate pumps per nozzle or by way of using different pressure reduction means (throttles) per nozzle. Basically, it is also possible to vary and control different pressures per nozzle also over time. The shape and thus also a movement of the atomised jet may be dynamically varied with this.
[0048] In a preferred embodiment of the invention, the outlet comprises exactly one nozzle set. The outlet may be manufactured in a very compact and simple manner by way of this.
[0049] Preferably, a diameter of the nozzles 3 is between 0.1 or 0.2 or 0.3 mm and 1.3 mm to 2 mm, in particular between 0.4 mm and 0.7 mm. The length of the nozzles for achieving a laminar flow in the jet, is at least double the diameter. Preferably thereby, a pressure of 10 bar to 50 bar, in particular of 15 bar to 25 bar is used as the operating pressure of the outlet, wherein the pressure is preferably essentially constant, thus is not pulsating. Half the impact angle, relative to the vertical, preferably lies between 35 and 55 degrees, in particular at 45 degrees. It may, however, basically be between zero and almost 90 degrees.
[0050] In a preferred embodiment of the invention, the pressure may be set by a user. Thereby, either the pressure is set in a controlled manner according to the sensation of the user, or a nominal value is set by the user, to which one controls with a closed loop by way of pressure measurement and by way of a pressure regulation.
[0051] In further preferred embodiments of the invention, the outlet has at least one nozzle for producing a water jet or fluid jet, as well as a movable or fixedly arranged atomisation body for atomising this jet. The jet is, thus, directed onto the atomisation body. A fixedly arranged atomisation body is attached on the outlet in a fixed manner and is not movable with respect to the jet or the jets.
[0052] In a preferred embodiment of the invention, the atomisation body may be moved along a line with respect to the at least one nozzle. A change of the atomisation characteristics or of the geometry of the droplet cloud produced on atomising is achieved by way of this.
[0053] Preferably, the nozzle is directed along the mentioned line in each case onto a different region of the atomisation body, in accordance with the position of the atomisation body. Thereby, the regions have different characteristics, in particular a different orientation with respect to the jet and/or a different surface structure.
[0054] In a further preferred embodiment of the invention, the atomisation body may be rotated about a rotation axis with respect to the at least one nozzle. Different functions may be achieved by way of this. On the one hand, a differently fashioned region of the atomisation body may be rotated into the jet or the jets by way of a temporary rotation about the rotation axis, similarly as with the linear displacement, so that the atomisation characteristics are changed. On the other hand, one may achieve an atomisation without the fluid jet from the at least one nozzle having a particularly high pressure or a high energy, by way of a permanent rotation with a high rotation speed. This embodiment may, also, therefore be realised without a pressure increase or pump.
[0055] Preferably, the atomisation body is at least approximately an ellipsoid of revolution, in particular a sphere, or at least approximately a disk, wherein the at least one nozzle is directed onto a disk surface or onto a disk edge. The atomisation body may also have a prismatic shape with an arbitrary cross section.
[0056] The method for operation of a washing installation for dispensing water or a water-based mixture, and optionally a further liquid, preferably in the sanitary field, in particular in a shower or a sink, comprises the following steps:
[0057] increasing the water pressure or the fluid pressure to an operating pressure of an outlet; and
[0058] spraying the water or the fluid at a high pressure and low throughput rate through the outlet.
[0059] Further preferred embodiments are to be deduced from the dependent patent claims. Thereby, the features of the method claims may be combined, analogously, with the device claims and vice versa.
BRIEF DESCRIPTION OF THE DRAWINGS
[0060] The subject matter of the invention is hereinafter explained in more detail by way of the preferred drawings. In each case there are shown schematically in:
[0061] FIG. 1 a first embodiment of a washing device;
[0062] FIG. 2 a further embodiment;
[0063] FIG. 3 one design of a protective body;
[0064] FIG. 4 a construction unit of a washing device;
[0065] FIG. 5 an installation with several washing devices;
[0066] FIG. 6 a washing installation or shower cubicle;
[0067] FIG. 7 an arrangement of two nozzles in a plan view a) and in a lateral view b);
[0068] FIG. 8 a structure of a water disk, as arises with impacting water jets;
[0069] FIG. 9 a perspective view of a nozzle set with three nozzles;
[0070] FIG. 10 an arrangement of two nozzle pairs in a plan view a) and in a lateral view b);
[0071] FIG. 11 an outlet with a soap feed;
[0072] FIG. 12 a nozzle body with two nozzle disks which may be rotated to one another;
[0073] FIG. 13 a single-piece nozzle body;
[0074] FIGS. 14 and 15 detailed view of nozzle openings;
[0075] FIG. 16 a two-part nozzle body;
[0076] FIG. 17 an outlet with an atomisation body;
[0077] FIGS. 18 to 20 further atomisation bodies;
[0078] FIGS. 21 and 22 a disk as an atomisation body;
[0079] FIG. 23 an arcuate disk as an atomisation body;
[0080] FIG. 24 pressure relations and throughput relations with various nozzle types;
[0081] FIG. 25 heat power requirement with different water throughputs; and
[0082] FIG. 26 heat power requirement in relation to the heating power.
[0083] The reference numerals used in the drawings and their significance are listed in a conclusive manner in the list of reference numerals. Basically, the same parts are provided with the same reference numerals in the figures.
DETAILED DESCRIPTION OF THE INVENTION
[0084] FIG. 1 shows a first embodiment of a washing device 10 . This comprises an outlet 1 with at least one nozzle set 2 . The nozzle set 2 , in turn, comprises two or more nozzles 3 . Fluid at a high pressure and thus a high speed or energy is dispensed in a directed manner with the nozzles 3 on operation. The nozzles 3 of a nozzle set 2 are directed such that the dispensed fluid jets intersect one another and preferably meet at one point. The fluid is atomised by way of this, and thus creates a high moistening/wetting effect. The fluid as a rule is water, wherein however another fluid or a mixture of water with a further substance such as soap, disinfectant etc. may be dispensed at one, several, or all nozzles.
[0085] The fluid is led to the outlet 1 preferably via a hose 19 or generally via an outlet conduit which is designed with regard to the operating pressure of the outlet, thus may withstand this operating pressure. The outlet conduit may be assembled in a fixed manner. The outlet may be a shower sprinkler assembled in a fixed manner or a shower sprinkler which is movable and is held by hand, or a shower head. The liquid is heated by the heater 5 having an energy supply 13 , and is delivered by a pump 6 and brought to an increased operating pressure. In another embodiment of the invention, the heater 5 is arranged in front of the pump 6 in the flow direction, so that therefore the pump 6 is designed for delivering the already heated water. Preferably a micro-filter 7 is arranged at the feed of the fluid 11 or is arranged at another location of the fluid path, in order to prevent the nozzles 3 from becoming blocked. In the shown embodiment of the invention, the supply of the fluid is a cold water supply 11 .
[0086] The filter 7 is preferably provided for filtering particles with a size of more than 100, in particular over 50 micrometers, from the water or the liquid.
[0087] FIG. 2 shows a further embodiment which has no heating 5 but instead of this is supplied via a mixing tap 8 , with which water from a cold water supply 11 and a warm water supply 12 are mixed to the desired temperature.
[0088] A soap feed 15 is drawn in as a further embodiment of the invention, via which soap may be admixed to the water by way of a mixing device 14 . Instead of soap, also other fluid or powder-like additives may be admixed in this manner. The mixing device 14 may usefully be switched on and off, so that one may switch between one operating mode “lathering” with soap, and an operating mode “rinsing” without soap. In this case, the mixing device 14 must be arranged extremely close to the shower head, so that only water leaves to shower head as soon as possible after switching of the mixing device 14 . Preferably, the delivered water quantity per unit of time, thus the throughput is increased with the operating mode “rinsing” compared to the operating mode “lathering”, for example by way of switching over between different nozzle sets 2 , or by way of raising the water pressure by the pump 6 , or by way of variation of the nozzle diameter.
[0089] FIG. 3 shows one design of a protective body 4 . A fluid jet which does not hit another fluid jet, or does this only in an inadequate manner, may be captured by the protective body 4 . This may particularly be the case if a nozzle is blocked or damaged. One prevents the jet from directly impacting the skin or the eyes by way of the protective body 4 . The protective bodies or suitable formations of the outlet 1 are also arranged in a manner such that they in each case lie in the jet direction of the individual nozzles 3 , but with a functionally correct operation of the outlet 1 are not essentially hit by the atomised fluid, thus are essentially of no hindrance to the sprayed fluid.
[0090] FIG. 4 shows a construction unit 16 of a washing device. Depending on the embodiment, the previously presented elements, such as in particular the heater 5 , the pump 6 , the micro-filter 7 , and, as the case may be, also the mixing device 14 and the soap feed 15 etc., are grouped together in a compact unit in a housing, in the construction unit 16 . The housing comprises an energy supply 13 and a cold water supply 11 , and feeds the outlet 1 via the hose 19 . Optionally, operating elements 18 for the control or regulation (closed loop control) of the temperature or pressure may be arranged on a recessed operating unit 17 . In another variant (drawn in a dashed manner), the operating elements 18 are arranged on the construction unit 16 itself.
[0091] In another preferred embodiment of the invention, the construction unit 16 has the same elements with the exception of the pump 6 , and is connected to an external pump for increasing the pressure. The external pump may supply several such construction units 16 . A washing device system according to this embodiment, thus, comprises at least one construction unit 16 and an external pump and a pressurised water conduit for feeding the at least one construction unit 16 by the pump 6 .
[0092] Preferably, the pump 6 and the heater 5 , activated by the operating unit, are switched on for operating the washing device for dispensing heated water. Warm water may be taken in a quasi direct manner, thus without any significant heating-up time, since the heater 5 preferably has no storage means. As the case may be, for this, the pump may be switched on with a small delay of a few seconds, i.e. less than 2 or 5 or 10 seconds. Alternatively, the pump 6 in this time may be controlled from standstill, and be gradually run up to the normal delivery power, so that the dispensing temperature may be increased already from the beginning.
[0093] In another preferred embodiment of the invention, the switching-on and switching-off of the washing device is controlled by an electrical switch or sensor at the outlet 1 . Alternatively, a mechanical valve is arranged on the outlet 1 or in the feed conduit 19 . When the user opens the valve, a pressure change in the feed conduit 19 takes place, which is detected by a sensor in the construction unit 16 , whereupon the washing device, with pump and, as the case may be, also the heater 5 , is switched on by way of the control of the construction unit 16 .
[0094] FIG. 5 shows an installation with several washing devices 10 . Only one cold water supply 11 and the energy supply 13 is present at each of the washing devices 10 . The washing devices 10 are for example arranged at several locations of a building or a mobile washing installation.
[0095] FIG. 6 shows a washing installation or shower cubicle. Several outlets 1 which are preferably supplied with heated pressurised water via a common supply unit 16 , are arranged in this above and laterally of the washing space. It has been found that a very good homogenous heat distribution and a pleasant shower sensation arise by way of this. The same effect arises also with only one nozzle head when the shower cubicle remains closed. The thermal transmission to body is very good despite the small quantity of water which is used. The small drops very quickly heat the room air, which provides a homogeneous sensation of warmth. The homogeneous heat distribution is due to the fact that the air is very quickly warmed by way of the large surface area of the droplets. The droplets cool immediately on account of their low mass. A temperature equilibrium occurs very quickly.
[0096] FIG. 7 schematically shows an arrangement of two nozzles 3 in a plan view a), seen in the direction of a main spray direction of the device, and in a lateral view b). The jets 21 of the liquid which are aligned onto one another meet in a impact point or collision point 20 . The two jets 21 define a first plane. The water droplets which are sprayed by the impact form a spray body which is symmetrical to a further plane, wherein the second plane is essentially perpendicular to the first plane. An angle θ between the jets 21 and a bisecting line of an angle are drawn in the lateral view.
[0097] FIG. 8 shows the structure of a water disk, as arises with impacting water jets. As in FIG. 7 , the main spray direction also runs downwards in FIG. 8 . The shown parameters: v o ; jet speed; r: distance of the impact point to the disk edge; 2θ: impact angle; h: thickness of the disk; 2 R; jet diameter; φ: angular position.
[0098] If two equally strong water jets are directed against one another, then a thin water disk is formed between them. The disk disintegrates at a certain distance from the point of impact of the two jets, and produces fine drops by way of this.
[0099] If the two water jets are equally strong, then the vertical components of their impulses neutralise on impact, and a thin water layer propagates horizontally by way of the pressure which has arisen at the moment of impact. The disk is destroyed as soon as holes arise, which increase further in size on account of the surface tension of the water.
[0100] The nozzles and, thus, the produced fluid jets as a rule are round, but may also have a rectangular cross section or generally have a prismatic shape.
[0101] Calcifications in the nozzles are not formed at all or are then eroded again by way of (for the sanitary field) high operating pressures and the low water temperatures.
[0102] FIG. 9 schematically shows a perspective view of a nozzle set 2 with three nozzles 3 . Water disks, whose planes, seen from above and with equally strong jets, lie in the angle bisecting line between the jets, arise at the impact point. In an analogous manner, more than 3 nozzles 3 may also be arranged essentially on a circle and be directed onto the point of impact. Half the impact angle φ lies in each case between the jets and the perpendicular axis of symmetry of the nozzle set 2 . Each of the nozzles 3 is supplied with fluid via a nozzle supply conduit 22 by way of the common pump 6 . The nozzle supply conduits 22 are only drawn in schematically in the figure, but in reality they are formed e.g. by way of cavities between the individual parts of the outlet 1 . In another preferred embodiment of the invention, different nozzles 2 are supplied with different liquids, thus given three nozzles with two or three different liquids. Such different fluids may for example be soaps, soap solutions, disinfectants, etc.
[0103] In another preferred embodiment of the invention, the outlet 1 comprises several nozzle sets which are arranged next to one another in a row or are arranged on a circular arc or circle.
[0104] In a further embodiment of the invention, the outlet 1 comprises at least two nozzle sets, wherein the nozzles 3 are arranged at least approximately in a plane, and the impact points of the two nozzle sets 2 are distanced to one another in a direction which runs at least approximately perpendicular to this plane. FIG. 10 schematically shows such an arrangement in a plan view a) and a lateral view b): Two nozzle sets 2 , 2 ′ are arranged transversely to one another: The jets 21 of each nozzle set 2 , 2 ′ define a plane of the nozzle set 2 , 2 ″. The planes of the two nozzle sets 2 , 2 ′ are at an angle to one another, and in the shown example are at least approximately at right angles. The impact points of the two nozzle sets 2 , 2 ′ are preferably distanced to one another, but both lie on the intersection line of the two planes.
[0105] FIG. 11 shows an outlet 1 with a soap feed 23 . The soap feed 23 is arranged in the outlet 1 above the impact point 20 , so that the fed soap drops or runs into the region of the impact point 20 . The soap is entrained and mixed by way of the water jets which impact one another. The soap feed 23 is preferably controllable or may be switched on and off. For this, it comprises, for example, a control means, for example a closure or a valve or a pump which is controllable, which means may be switched on and off via control lead or by hand. In a preferred embodiment of the invention, the soap feed, as a metering means, comprises an intermediate storage means. The intermediate storage means is filled with a certain quantity of soap on actuation of the control means, and subsequently dispenses this again successively to the fed water, as in FIG. 11 , to the impact point 20 , until it is empty.
[0106] The soap may be fluid or powder-like, and may be led with the soap feed 23 closer to the impact point 23 than is indicated in the figure. In this manner, other fluids or powder-like additives may also be admixed instead of soap. Also gaseous additives may be supplied or blown with its own nozzle as a gas jet onto the impact point 23 in a directed manner.
[0107] FIG. 12 shows a nozzle body 40 as part of an outlet 1 . The nozzles are formed by bores in a nozzle body. Three nozzles are shown by way of example, but combinations of two, four or more nozzles may be realised in the same manner. In the simplest case, the nozzle body 40 is of one piece. In the embodiment of FIG. 12 , the nozzle body comprises an upper nozzle disk 41 and a lower nozzle disk 42 which are arranged rotatable to one another. The two nozzle disks 41 , 42 are pressed against one another, for example, by way of a central screw 45 and/or by way of a flange ring 46 . The fastening on the outlet 1 may likewise be effected with a central screw 45 and/or the flange ring 46 . FIG. 12 shows the nozzle body 40 in cross section and the two nozzle disks 41 , 42 separately, in each case in a plan view.
[0108] The nozzle body 40 is arranged in the outlet 1 , such that the upper nozzle disk 41 is impinged with the fluid under pressure, and the lower nozzle disk 42 faces the spray direction. The upper nozzle disk 41 comprises a set of upper bores 43 , and the lower nozzle disk 42 at least two sets of lower bores 44 . The position of the upper bores 43 may be selectively brought to correspond with the position of one of the sets of the lower bores 44 by way of rotating the nozzle disks to one another. Thus different sets of lower bores 44 are in operation in a selective manner. These are preferably designed in a different manner, so that different spray characteristics result, depending on the selection of the lower set of bores. This different design may, for example, relate to the diameter of the nozzles or their mutual alignment.
[0109] In another preferred embodiment of the invention, the upper nozzle disk 41 comprises several sets of upper bores 43 , which in each case are fed with different fluids or fluid combinations. The lower nozzle disk 42 in this embodiment only comprises one set of lower bores 44 , and may be connected in each case to one of the sets of the upper bores 43 by way of rotation, so that a different composition of the sprayed fluid results, depending on the selection of the upper set of bores.
[0110] FIG. 13 shows a single-piece nozzle body 40 or a lower nozzle disk 42 , in cross section, as well as details of the nozzle openings. The nozzle body 40 or the nozzle disk 42 is preferably manufactured of metal or a technical plastic, for example by way of injection molding, wherein the nozzle channels 48 are preferably formed by way of moving slides. The plastic, for example, is polyoxymethylene (POM) or polyamide (PA) or polyphenylene sulphide (PPS) and may be provided with inclusions of other materials.
[0111] FIG. 14 shows a detailed view of a cross section through a first embodiment for the design of the nozzle openings, preferably whilst using a two-component injection molding method. One nozzle opening at the outer end of a nozzle channel 48 is formed by a projecting tube piece 46 of a softer plastic, which is peripherally injected by the harder technical plastic of the nozzle body 40 or of the nozzle disk 42 . The softer plastic may be deformed by, so that furring breaks away.
[0112] FIG. 15 shows a detailed view of a cross section through a second embodiment for the design of the nozzle openings. A nozzle opening at the outer end of a nozzle channel 48 is formed by a pipe piece 47 of metal, for example chrome steel, which is peripherally injected by the technical plastic of the nozzle body 40 or the nozzle disk 42 . With this, the exit openings of the nozzles may be formed with greater precision than would be possible with the manufacture solely of plastic.
[0113] One the one hand the nozzles are adequately long and comprise a smooth inner surface, by which means a laminar flow is achieved, for achieving a precise jet. Preferably, the nozzles are at least double the length of their diameter. On the other hand, the reflection edges at the end of the nozzle inner side are shaped in a suitable manner, preferably by way of them forming a right angle. This is preferably the case for all embodiments of the invention.
[0114] The tube pieces may be formed on a single piece of metal and be peripherally injected together, as is shown in FIG. 16 , for achieving a high precision. In particular, the nozzle channels 48 may be formed in a disk-like insert or differently shaped insert 49 . The insert 49 is peripherally injected with the plastic, for forming the nozzle body 40 or the nozzle disk 42 , wherein the plastic has a continuation of the nozzle channels 48 .
[0115] FIG. 17 shows an outlet 1 with an atomisation body 34 . The atomisation body 34 is linearly displaceable in the direction of an axis 33 and/or arranged in a rotatable manner about this axis 33 . A drive unit 32 effects this movement or movements, and for this comprises one or two individual drives or motors. At least one nozzle 3 is directed onto the atomisation body 34 , so that the fluid jet of this nozzle 3 impinges the atomisation body 34 on operation of the washing device 10 . With a linearly displaceable atomisation body 34 , the jet hits a differently oriented surface and/or a differently structured surface, according to the position of the atomisation body 34 . For example, with the atomisation body 34 of FIG. 18 , which for example is an ellipsoid of revolution, a jet hits a sector of the surface at a height angle α with respect to the equator of the ellipsoid. Thus, the impact angle of the jet onto the atomisation body 34 and the average direction of the atomised jet vary in dependence on the height angle α.
[0116] In a preferred embodiment of the invention, the atomisation body 34 has different surface structures along the displacement axis, so that different atomisation characteristics may be achieved by way of displacing the atomisation body 34 . For example, with the atomisation body 34 of FIG. 17 , the surface for different regions of height angles α may in each case have different roughnesses. FIG. 18 shows an atomisation body 34 with this characteristic, but without it having an ellipsoid as a basic shape. The atomisation body 34 is essentially rotationally symmetrical and/or prismatic with respect to the axis or rotation axis 33 . For example, along the rotation axis 33 , it comprises a first sector 341 with a toothed surface, a second sector 342 with a smooth surface and a third sector 343 with a roughened surface, similar to sandpaper. By way of displacing the atomisation body 34 , the jet is atomised on the one or other sector 341 , 342 , 343 with completely different characteristics. In the shown embodiment, therefore each of the sectors has a different surface structure and one or more different orientations of the surface with respect to a jet.
[0117] In another embodiment according to FIG. 19 , the atomisation body 34 is a rotation cylinder, thus has different surface structures with a constant impact angle and reflection angle with a displacement along the axis 33 . Such an embodiment may be applied in a rotating or non-rotating manner, wherein in both cases the different surfaces of the sectors 341 , 342 , 343 may be applied by way of displacement along the axis 33 .
[0118] Such an atomisation body 34 may be applied with different operating modes, wherein certain embodiments for the invention may also be directed only to individual ones of these operating modes. In a first operating mode, the water jets or fluid jets 21 in the nozzles 3 are produced with a high pressure, and the linear displacement ability of the atomisation body 34 is used in order to obtain different or dynamically variable atomisation bodies. For this, it is not absolutely necessary for the atomisation body 34 to also be rotatable or to be rotated. The energy for atomisation originates from the high speed of the jets. By way of moving the atomisation body 34 , be it by way of rotation and/or displacement, differently structured surface regions may be brought into the region of the jet 21 .
[0119] In a second operating mode, the atomisation body 34 is rotatable with a high speed about the rotation axis 33 . The energy for atomisation originates from the rotation of the atomisation body 34 , so that the nozzles may be operated at high pressure but also at low pressure, which means that they may be operated without a pump 6 . Thereby, the atomisation body 34 may also be displaceable as in the first operating mode, but it may also be non-displaceable.
[0120] FIG. 20 shows an atomisation body 34 in the form of an ellipsoid of revolution, with further sectors 344 , 345 , 346 with different surface structures. On rotating the atomisation body 34 about the rotation axis 33 , different sectors 344 , 345 , 346 are hit by the jet 21 . The impact angle and the reflection angle are changed by way of displacement along the rotation axis 33 . This displacement body 34 is thus not envisaged for a rapid rotation for atomisation. The further sectors 344 , 345 , 346 correspond to different “degrees of longitude” whilst the sectors 341 , 342 , 342 of FIGS. 18 and 19 correspond to different “degrees of latitude” or height angles α.
[0121] FIGS. 21 and 22 show a disk as an atomisation body. Here at least one nozzle 3 is directed onto a disk surface 36 or onto the disk edge 37 . The disk surface 36 may have different surface structures depending on the radius, which is indicated in FIG. 21 by a shaded region. The disk surface 36 may also be profiled, which means that the disk surface 36 is not plane, but has a rotationally symmetrical profile as a function of the radius. With this, different impact angles and reflection characteristics may be achieved by way of displacing the nozzle 3 along the radius.
[0122] The disk surface 36 , in a different embodiment of the invention, is curved according to FIG. 23 , for example in the form of a spherical surface, so that the reflection angle is also dependent on the radius of the impact point.
[0123] Suitable rotational speeds for rotating atomisation bodies 34 range from 5,000 to 200,000 rpm. The average droplet size in the atomised jet is varied by way of varying the rotational speed, wherein the droplet size is dependent on the relative speed between the jet and the atomisation body 34 . It has been shown that a droplet size of about 20 to 80 micrometers requires a relative speed of about 50 m/s This for example means that for this, with a stationary atomisation body 34 , the jet must have a speed of about 50 m/s. Vice versa, if the jet has a speed of only a few m/s, then the atomisation body 34 must move at this speed at the impact point. This for example means that a surface point of a disk or a cylinder with a diameter of 30 mm must rotate at approx. 30,000 rpm.
[0124] FIG. 24 shows pressures and throughput rates F for various nozzle diameters and nozzle numbers. With each curve, the respective value X/Y represents a nozzle number X and a nozzle diameter Y in millimetres, thus for example 2/0.7 represents an arrangement with 2 nozzles of 0.7 mm diameter.
[0125] In a preferred embodiment of the invention, the maximal throughput quantity of the outlet is 3 l/min and preferably 1.5 to 2 l/min, which corresponds to a heating device with a heating power of about 3 kW. Preferably, 3 nozzles with a diameter of 0.4 mm are operated at a pressure of 20 bar. Half the impact angle φ is preferably 45°. Most, thus about 80% or more of the produced droplets thereby preferably have a diameter of below 100 micrometers.
[0126] FIG. 25 shows a heating power requirement P in kW for different water throughput quantities in litres per minute in dependency on the produced temperature difference ΔT. A throughput quantity of 14 l/min corresponds to a normal shower, 12 l/min corresponds to an adjustable shower, 9 l/min to an economy shower and 1.5 l/min corresponds to one embodiment of the invention. A continuous power of 25 kW is required in order for example to heat the continuously running water to a temperature difference of 30° at 12 litres/minute. Thereby, an optimal efficiency of the heating is assumed. With a throughput quantity of 1.5 l/min only about 2 kW is required.
[0127] This lies within the framework of a heater 5 which may be supplied by a common house installation with 230V alternating current or 400V three-phase current. FIG. 26 shows a heating element for low throughput quantities of 1.2 and 3 l/min, as may be realised according to the invention. For this, maximal realisable values for heating powers are drawn in: a lower horizontal line at a first heating power of approx. 3.6 kW and a higher upper horizontal line at a second heating power of appear. 6 kW. This corresponds to a supply at 230 or 400 Volts at 16 Amps.
[0128] The shower water must be heated to about 20 to 35 degrees depending on the season and the desired water temperature. This corresponds to the shaded region in the representation. In this region, thus an electrical instantaneous (tankless) heating may be used for throughput quantities between 1 and 2 litres. A storage heater or boiler or a more powerful heater is required for greater throughput quantities.
LIST OF REFERENCE NUMERALS
[0000]
1 outlet
2 , 2 ′ nozzle set
3 nozzle
4 protective body
5 heater
6 pump
7 micro filter
8 mixing tap
10 washing device
11 cold water supply
12 warm water supply
13 energy supply
14 mixing device
15 soap feed
16 construction unit
17 operating unit
18 operating elements
19 hose, feed conduit
20 impact point and water disk
22 fluid jet
22 nozzle supply conduit
23 soap feed
32 drive
33 rotation axis
34 atomisation body
341 - 346 sectors of the atomisation body
35 atomisation disk
36 disk surface
37 disk edge
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A washing device ( 10 ) for dispensing water in the sanitary field, in particular in a shower or a sink, including an outlet ( 1 ) for spraying fluids with a lower throughput rate, as well as a delivery device ( 6 ) for increasing the fluid pressure before the spraying. In a preferred embodiment of the invention, the washing device ( 10 ) includes a heating device ( 5 ) for heating the water. In a preferred embodiment of the invention, the atomisation is accomplished by way of a fluid jet ( 21 ) hitting an obstacle ( 21; 34 ) with a high relative speed. Thereby, the obstacle may be a moved or stationary solid body ( 34 ) or at least one further fluid jet ( 21 ). Preferably, the spraying is accomplished by way of the outlet ( 1 ) including at least one nozzle set ( 2 ) with at least two nozzles ( 3 ), for producing impacting fluid jets ( 21 ) and for atomising the fluid.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to animal medical collars and to dog medical collars in particular.
[0002] It is often necessary or desired to fit a restrictive medical collar to an animal to restrict the animal from chewing or licking wounds, stitches, casts or braces, and the like. These medical collars are generally frusto conical in shape and fit around the animal neck and open forwardly around the animals head. U.S. Pat. No. 5,797,354 for “Collar for Mounting Around the Neck of an Animal,” discloses such a medical collar made from a flat arced shaped piece of material which may be folded into the frusto conical shape around an animal's neck and head to prevent the animal from chewing or licking an injury. The '354 patent is herein incorporated by reference in it's entirety.
[0003] U.S. Pat. No. 6,382,140 for “Apparatus and Method for Encapsulating an Animal's Head,” discloses a clear spherical medical collar however, such clear colors affect the animals vision and smell, and do not provide a natural experience to the animal.
[0004] Unfortunately, these known designs for Cone Collars only permit the animal to see straight ahead (tunnel vision effect). While such collars are successful in preventing the undesirable behavior, they also often cause the animal wearing the medical collar to be nervous and may result in accidents and possibly further injury. Without peripheral vision the animal is in effect wearing blinders and will unwittingly catch, bump, or rub the collar on furniture, walls, doors and other objects creating an unsafe environment for both the animal and it's surrounding. The animal will naturally do this as a means of navigating its way, similar to a blind person adjusting their attitude with a cane or hands and arms outstretched. Many animals become so disoriented wearing a cone collar with their peripheral vision blinded, they enter into a state of depression and/or paranoia. Some animals refuse to eat. Others will not move about and most just stumble over things not visible from their perspective.
BRIEF SUMMARY OF THE INVENTION
[0005] The present invention addresses the above and other needs by providing an improved animal medical collar which includes openings allowing pets, domestic, and captive wild animals wearing the medical collar to freely see and smell their surroundings while preventing access to a wound or surgical area. The openings are sized and spaced to allow the animal to view and smell it's surroundings and provides increased air circulation around the animal's head. Providing such viewing and perception of odors and scents relieves the stress and anxiety the animal would otherwise experience.
[0006] The improved medical collar of the present invention is created from a pliable, clear or semi-opaque, sheet plastic material, die cut to a semi-circle shape with a smaller inner semi-circle inset boundary incorporating collar and assembly attachment arrows. The die cut shape also contains multiple perforations of different size and shape windows throughout the body of the cone that may easily be removed. The veterinarian or animal husband simply positions the improved medical collar checking size, location of the eyes and ears of the animal in relation to the position of the windows. Selection and removal of windows that enhance peripheral vision, hearing, and ventilation outside the reach of the protected area will create a custom application. Thus providing the beneficial qualities of the design to be achieved without compromising the protective elements. The semi-circle plastic shape is then rolled about a central axis to form a truncated cone and assembly is completed with the fitting of the attachment arrows into designated slots accommodating animal's size to achieve a snug fit. The improved medical collar design also allows for this customization of the collar to be concurrent with the healing progression of the animals affected area(s) and a safer environment for the animal while the collar is in place.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0007] The above and other aspects, features and advantages of the present invention will be more apparent from the following more particular description thereof, presented in conjunction with the following drawings wherein:
[0008] FIG. 1A is a side view of a prior art medical collar worn by a dog.
[0009] FIG. 1B is a front view of the prior art medical collar worn by the dog.
[0010] FIG. 2A is a side view of an improved medical collar according to the present invention worn by the dog.
[0011] FIG. 2B is a front view of the improved medical collar according to the present invention worn by the dog.
[0012] FIG. 3 shows the improved medical collar lying flat.
[0013] FIG. 4 shows the improved medical collar rolled into a cone.
[0014] FIG. 5 is a slot cut-out of the improved medical collar according to the present invention.
[0015] FIG. 6 is a round cut-out of the improved medical collar according to the present invention.
[0016] FIG. 7 shows a side view of the dog wearing the prior art medical collar and the resulting loss of vision.
[0017] FIG. 8 shows a side view of the dog wearing the improved medical collar according to the present invention with openings providing vision and smell.
[0018] FIG. 9 shows a side view of the dog wearing a second embodiment of an improved medical collar according to the present invention with fixed openings providing vision and smell
[0019] Corresponding reference characters indicate corresponding components throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0020] The following description is of the best mode presently contemplated for carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of describing one or more preferred embodiments of the invention. The scope of the invention should be determined with reference to the claims.
[0021] A side view of a prior art medical collar 12 worn by a dog 10 is shown in FIG. 1A , and a front view of the prior art medical collar 12 worn by the dog 10 is shown in FIG. 1B . The prior art medical collar 12 prevents or restrict the dog 10 from chewing or licking wounds, stitches, casts or braces, and the like. Unfortunately, the prior art collar 12 prevents the dog 10 from seeing and smelling it's surroundings often causing the dog 10 to be nervous and may result in accidents and possibly further injury.
[0022] A side view of an improved medical collar 14 according to the present invention worn by the dog 10 is shown in FIG. 2A and a front view of the improved medical collar 14 worn by the dog 10 is shown in FIG. 2B . The improved medical collar 14 includes a multiplicity of round and slotted openings 16 and 18 allowing the dog 10 to see and smell it's surroundings. The openings 16 and 18 may be of varying size and shape, and provide sufficient vision and smell to the dog 10 to allow the dog 10 to have normal perception of it's surroundings. Preferably, the openings 16 and 18 are in the top half 54 of the medical collar 14 (see FIG. 9 ) and have an area of between approximately 25 percent and approximately 50 percent of the top half 54 , and more preferably the openings 16 and 18 have an area of approximately 50 percent of the top half 54 .
[0023] The improved medical collar 14 is formed from a flat sheet having an inside arc 14 a , an outside arc 14 b , a first end 14 c connecting the inside arc 14 a to the outside arc 14 b , and a second end 14 d connecting opposite ends of the inside arc 14 a to the outside arc 14 b . The second end 14 d attachable to the first end 14 c to form the flat sheet into a truncated cone.
[0024] The improved medical collar 14 is shown lying flat forming a semi-circle in FIG. 3 and rolled into a cone in FIG. 4 . The openings 16 and 18 are provided as cut-outs 16 a and 18 a which may be punched out to create the number of openings desires. The improved medical collar 14 further includes slots 22 and arrows 24 which are engaged to form the collar 14 into a cone around a dog's, or other animal's, neck. The improved medical collar 14 also includes straps 26 and slots 28 to form loops 29 for attaching the medical collar 14 to a typical dog collar such as a leash is attached to.
[0025] The slot cut-out 18 a of the improved medical collar 14 is shown in detail in FIG. 5 and the round cut-out 16 a is shown in detail in FIG. 6 . The slot cut-outs include four cuts or slices 30 forming the shape of the slot and four tabs 32 which may be cut, torn, or broken to open the slot 18 a . The round cut-outs 16 a include two semicircular cuts or slices 34 forming the shape of the round cut-out 16 a and two tabs 32 which may be cut, torn, or broken to open the round cut-out 16 a.
[0026] A side view of the dog 10 wearing the prior art medical collar 12 with the resulting loss of vision is shown in FIG. 7 and a side view of the dog 10 wearing the improved medical collar 14 according to the present invention with openings 16 and 18 providing vision and smell is shown in FIG. 8 . An eye 40 of the dog 10 is visible though the opening 40 thereby providing vision to the dog. In many instances, the entire nose 42 of the dog 10 is recessed inside the prior art medical collar 12 thereby limiting the dog's ability to smell objects in it's surroundings.
[0027] A side view of the dog 10 wearing a second embodiment of an improved medical collar 48 according to the present invention with fixed openings 56 and 58 providing vision and smell, and directional hearing respectively to the dog 10 . The medical collar 48 has a forward half 52 and an upper half 54 . The fixed openings 56 and 58 are positioned proximal to the eyes 10 a and ears 10 b (see FIG. 1A ) of the dog 10 , and are preferably positioned in the intersection of the forward half 52 and the upper half 54 of the medical collar 48 on opposite sides of the medical collar 48 . The openings 56 and 58 are preferably pairs of openings on opposite sides of the medical collar 48 . The bottom half of the medical collar 14 and 48 is preferably solid or substantially solid to prevent licking. While some holes may be present in the bottom half, for example for attaching ends 14 a and 14 d (see FIG. 3 ) the substantially solid medical collar does not have openings large enough for the dog to lick through.
[0028] The orientation of the medical collar 14 or 48 is preferably maintained by a weighted bottom. For example, the overlapped portion 15 provides weight to tend to provide a rotational orientation, and when a leash type dog collar is attached to the medical collar using the loop 29 (see FIG. 4 ), the leash collar may be positioned with a heavy buckle aligned with the overlapped portion 15 to help maintain the medical collar orientation. Additionally, a weight 50 may be attached to the bottom of the medical collar 48 to maintain the rotational position of the medical collar 48 on the dog 10 (see FIG. 4 ).
[0029] In instances where the weight of the collar is not sufficient to maintain the orientation of the collar, and clip to grasp some of the dog's hair, or a harness may be used to maintain the position of the medical collar 14 or 48 on the dog.
[0030] While the invention herein disclosed has been described by means of specific embodiments and applications thereof, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope of the invention set forth in the claims.
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An improved animal medical collar includes openings allowing pets, domestic, and captive wild animals wearing the medical collar to freely see and smell their surroundings while preventing access to a wound or surgical area. The openings are sized and spaced to allow the animal to view and smell it's surroundings and provides increased air circulation around the animal's head. Providing such viewing and perception of odors and scents relieves the stress and anxiety the animal would otherwise experience.
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This application is a continuation of application Ser. No. 09/210,269, filed Dec. 11, 1998, which now U.S. Pat. No. 6,298,315 application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates in general to measurement apparatus; more particularly, to a system and method for analyzing components of a distribution; and more particularly still, to a system and method for analyzing deterministic and random components of signals.
2. Description of Related Art
A commonly encountered problem in processing measurements is to accurately determine the physical processes and key parameters associated with the distribution. In many cases, a distribution may have both deterministic and random components associated with it. It is essential to extract important information on what kind of physical processes are involved in the distribution and how much each process contributes to the measured distribution.
The present available statistical tools do not allow separation of deterministic and random components. Instead such tools determine a mean and sigmna for the entire distribution. The present invention provides a solution to this and other problems, and offers other advantages.
SUMMARY OF THE INVENTION
The present invention discloses a method, apparatus, and article of manufacture for analyzing measurements. The invention provides a method for separating and analyzing the components of a distribution, such as deterministic and random components. The method performs the steps of collecting data from a measurement apparatus, constructing a histogram based on the data such that the histogram defines a distribution, fitting tail regions of the distribution, and calculating the deterministic and random components of the distribution. The tail regions are defined by calculating the first and second order derivative of the histogram. The tail regions are fitted to predefined models and the fitted parameters are determined. The statistical confidence of the fitted parameters is estimated. Although this method may be applied to any distribution, it works particularly well to analyze signal distributions such as jitter signal distributions. The deterministic and random components of jitter can have many uses, including: 1) determining the operation margin for a digital system; 2) calculating and predicting the error probability for a digital system; 3) providing diagnostics for digital system characterization and debug; and 4) providing pass/fail values to production tests.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring now to the drawings in which like reference numbers represent corresponding parts throughout:
FIG. 1 is an exemplary illustration of a representative hardware environment for a signal analyzing system according to an embodiment of the present invention;
FIG. 2 is a flow diagram illustrating the steps performed by the analysis program according to an embodiment of the present invention; and
FIG. 3 is a chart illustrating a typical display screen according to an embodiment of the present invention.
DETAILED DESCRIPTION
In the following description of the preferred embodiment, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration a specific embodiment in which the invention may be practiced. It is to be understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present invention.
FIG. 1 is an exemplary illustration of a representative hardware environment for a signal analyzing system 100 according an embodiment of the present invention. A typical configuration may include a measurement apparatus 102 that measures the time interval between two events (start and stop) through counters. A measurement apparatus is disclosed in U.S. Pat. No. 4,908,784, which is hereby incorporated by reference. A typical measurement apparatus is the Wavecrest DTS-2075, available from Wavecrest Corporation, Edina, Minn.
Those skilled in the art will recognize that other systems that enable signal/distribution analysis that are based on real world measurement (i.e., measurements that are non-ideal or subject to uncertainty) would be applicable. Generally, this would include any product that can act as a distribution source. These devices include an oscilloscope, Automated Test Equipment (ATE), spectrum analyzer, network analyzer, TIA (time interval analyzer), universal time frequency counter, and modulation domain analyzer. Other devices may include a CCD, an x-ray camera, a MRI, and an ultrasound.
The measurement apparatus 102 interfaces to a workstation 104 and operates under the control of an analysis program 106 resident on the workstation 104 . The analysis program 106 is typically implemented through data analysis software. One commercially available analysis software is the Wavecrest Virtual Instrument (VI) software, available from Wavecrest Corporation, Edina, Minn. Other analysis software includes LABVIEW, MathCad, MATLAB, Mathematica, among others. The workstation 104 comprises a processor 108 and a memory including random access memory (RAM), read only memory (ROM), and/or other components. The workstation 104 operates under control of an operating system, such as the UNIX® or the Microsoft® Windows NT operating system, stored in the memory to present data to the user on the output device 110 and to accept and process commands from the user via input device 112 , such as a keyboard or mouse.
The analysis program 106 of the present invention is preferably implemented using one or more computer programs or applications executed by the workstation 104 . Those skilled in the art will recognize that the functionality of the workstation 104 may be implemented in alternate hardware arrangements, including a configuration where the measurement apparatus 102 includes CPU 118 , memory 140 , and I/O 138 capable of implementing some or all of the steps performed by the analysis program 106 . Generally, the operating system and the computer programs implementing the present invention are tangibly embodied in a computer-readable medium, e.g. one or more data storage devices 114 , such as a zip drive, floppy disc drive, hard drive, CD-ROM drive, firmware, or tape drive. However, such programs may also reside on a remote server, personal computer, or other computer device.
The analysis program 106 provides for different measurement/analysis options and measurement sequences. The analysis program 106 interacts with the measurement apparatus 102 through the on-board CPU 118 . In one embodiment, the measurement apparatus 102 provides arming/enabling functionality such that the apparatus 102 can measure a signal either synchronously or asynchronously. The signal is fed to the channel input arming/enabling controls 120 , 122 , 124 , and 126 to which event that a measurement is made. Counter/interpolators 128 , 130 , and 132 measure the time elapse between the start and stop events. Interpolators provide fine time resolution down to 0.8 ps. In response to input controls 120 , 122 , 124 , and 126 , multiplexer 134 controls the counter/interpolators 128 , 130 , and 132 based on a clock 136 signal. Clock 136 is typically a precise crystal oscillator.
Those skilled in the art will recognize that the exemplary environment illustrated in FIG. 1 is not intended to limit the present invention. Indeed, those skilled in the art will recognize that other alternative hardware environments may be used without departing from the scope of the present invention.
FIG. 2 is a flow diagram illustrating the steps performed by the analysis program 106 according to one embodiment of the present invention. The present invention is directed towards analyzing the deterministic and random components of a distribution. In one embodiment of the present invention, the analysis program 106 analyzes the jitter of a signal. Jitter in serial data communication is a difference of data transition times relative to ideal bit clock active transition times. Jitter in digital systems is the difference between an ideal clock period and an actual clock period. As in all signals, jitter has deterministic and random components. Deterministic jitter is bounded in its amplitude and can be measured peak to peak. Random jitter is unbounded in its amplitude and Gaussian in nature. Since random jitter is probabalistic, it must be quantified by one sigma of standard deviation estimate. Random jitter is modeled by a Gaussian distribution. The distribution may be the superposition of multiple Gaussian functions. The analysis program separates the deterministic and random components of the jitter.
Block 200 represents the analysis program 106 collecting data from the measurement apparatus 102 . The data may be physically based or model based.
Block 202 represents the analysis program 106 generating a jitter histogram by calculating the local statistics in each time bin. A histogram is a statistical representation of the distribution of measured physical parameters. The bin size may be fixed or variable for a given distribution. Mathematically, a histogram indicates how the number of measurements change over the measured parameters. The general procedure for generating a histogram is: 1) measurement apparatus 102 measures a signal parameter (for example, period, frequency, duty cycle, etc.) repeatedly to obtain a statistical sample; 2) analysis program 106 sorts the data in a descending (ascending) order; 3) analysis program 106 automatically defines bin sizes, and the total number of measurements that fall into bin ranges is then accumulated; 4) A data set of the number of measurements versus the various measured parameters, namely histogram, is then composed and plotted graphically. Although the present embodiment describes a histogram, the present invention may apply to any kind of distribution. For example, amplitude versus time (waveform), amplitude versus frequency (spectrum), time versus time (jitter time function), time versus frequency (jitter spectrum).
Block 204 represents the analysis program 106 searching and determining the is tail parts of the histogram by the first and second order derivative method. The tailparts may be found in any isolated area of the distribution. In the exemplary embodiment, the tailpart distributions start from the edge of the far left (or right) of the histogram to the first maximum, as is shown in FIG. 3 .
Block 206 represents the analysis program 106 starting the χ 2 (chi-squared) method for fitting the tails of the histogram distributions χ 2 is defined as: χ 2 = ∑ i = 1 n ( y mod - y i Δ y i ) 2 ( 1 )
where ymod is the model expected value as defined as: y mod = y max - ( x - μ 2 σ ) 2 ( 2 )
Where y max is the maximum value, μ is the mean, and σ is the standard deviation, for a Gaussian distribution model. They are the fitting parameters. xi and yi are pairs of data which composite a distribution. (In the case of the histogram, xi is the measured parameter, yi is the accumulated events corresponding to xi). Δyi is the error of yi data. The best fitting parameters will be obtained by minimizing the χ 2 . ymod can be any arbitrary function. χ 2 is provides accurate model parameter deduction using measurements which are subject to errors and statistical fluctuation.
Block 208 represents the analysis program 106 obtaining the Gaussian distribution parameters. The parameters μ and σ are obtained for the first (left) and second (right) tails of the distribution.
Block 210 represents the analysis program 106 doing a statistical check of the Gaussian fitting to determine the applicability of the model or the adequacy of the measurements.
Block 212 represents the analysis program 106 calculating the deterministic jitter (DJ) and random jitter (RJ) based on the following formulas: DJ=μ 2 −μl and RJ=(σ 1 +σ 2 )/ 2 .
Block 214 represents the analysis program 106 calculating the statistical confidence of the DJ and RJ estimates. Methods to calculate a normalized chi squared error are well known in the art.
In the jitter example, the distribution may be multiple Gaussian. In that case, the method may be revised to account for superposition of multiple distributions.
Block 216 represents the analysis program 106 displaying a plot of the RJ and DJ on output 110 . When the DJ and RJ are obtained, the total jitter (TJ=DJ+RJ) is ready to calculate.
Another example of the method and apparatus according to this invention is spectral analysis. The analysis program 106 may determine noise processes using spectral distribution data. Important parameters, such as power index and exponential growth rate can be deduced. The Gaussian model applied to the jitter analysis is replaced by power-law and exponentials which are more appropriate for noise processes.
Generally, the distribution fitting analysis performed by the analysis program 106 may be applied to any model. The jitter embodiment described above applies tail fitting to a Gaussian distribution which is appropriate for determining the deterministic and random components of jitter.
It will be appreciated that FIG. 2 represents a methodology, routine, and/or logical flow of program steps which may be implemented to perform the method of the present invention. Other programming steps may be included and such specific logical flow is intended by way of illustration of a preferred routine.
FIG. 3 is a chart illustrating a typical display screen according to an embodiment of the present invention. After analyzing a signal received from the measurement apparatus 102 , the analysis program 106 may provide a chart showing the first (left) tail 300 and second (right) tail ( 302 ) of a fitted Gaussian distribution.
The foregoing description of the preferred embodiment of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. It is intended that the scope of the invention be limited not by this detailed description, but rather by the claims appended hereto.
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A method, apparatus, and article of manufacture for analyzing measurements. The invention provides a method for separating and analyzing the components of a distribution, such as deterministic and random components. The method performs the steps of collecting data from a measurement apparatus, constructing a histogram based on the data such that the histogram defines a distribution, fitting tails regions wherein deterministic and random components and associated statistical confidence levels are estimated.
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BACKGROUND
[0001] A broad-band wireless access (BWA) network may support data, voice, and video multicasting and broadcasting services (MBS) as BWA networks comprise high bandwidth. A large number of mobile subscriber stations (MSS) may be present in the BWA network and the MSS may move from one wireless cell to other. While delivering MBS, the MSSs in the multicast group may provide feedback, which may be treated as noise on the feedback channel. The feedback from the MSSs of the multicast group may result in collision of ACK/NACKs, which may increase retransmissions and delay in error recovery. The retransmissions may consume bandwidth.
BRIEF DESCRIPTION OF THE DRAWINGS
[0002] The invention described herein is illustrated by way of example and not by way of limitation in the accompanying figures. For simplicity and clarity of illustration, elements illustrated in the figures are not necessarily drawn to scale. For example, the dimensions of some elements may be exaggerated relative to other elements for clarity. Further, where considered appropriate, reference labels have been repeated among the figures to indicate corresponding or analogous elements.
[0003] FIG. 1 is a wireless environment, which includes one or more mobile stations and base stations that enhance reliability of MBS over WBA network according to one embodiment.
[0004] FIG. 2 is a flow-diagram, which illustrates an operation of feedback leaders and the base station to enhance reliability of MBS over WBA network according to one embodiment.
[0005] FIG. 3 is a sequence diagram, which illustrates signals exchanged between a feedback leader and the base station to enhance reliability of MBS over WBA network according to one embodiment.
[0006] FIG. 4 is a flow-diagram, which illustrates an operation of the feedback leaders and the base station to enhance reliability of MBS over WBA network according to other embodiment.
[0007] FIG. 5 is a sequence diagram, which illustrates signals exchanged between a feedback leader and the base station to enhance reliability of MBS over WBA network according to other embodiment.
DETAILED DESCRIPTION
[0008] The following description describes embodiments of enhancing reliability of multicast and broadcast video streaming over BWA networks. In the following description, numerous specific details such as logic implementations, resource partitioning, or sharing, or duplication implementations, types and interrelationships of system components, and logic partitioning or integration choices are set forth in order to provide a more thorough understanding of the present invention. It will be appreciated, however, by one skilled in the art that the invention may be practiced without such specific details. In other instances, control structures, gate level circuits, and full software instruction sequences have not been shown in detail in order not to obscure the invention. Those of ordinary skill in the art, with the included descriptions, will be able to implement appropriate functionality without undue experimentation.
[0009] References in the specification to “one embodiment”, “an embodiment”, “an example embodiment”, indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.
[0010] Embodiments of the invention may be implemented in hardware, firmware, software, or any combination thereof. Embodiments of the invention may also be implemented as instructions stored on a machine-readable medium, which may be read and executed by one or more processors. A machine-readable medium may include any mechanism for storing or transmitting information in a form readable by a machine (e.g., a computing device).
[0011] For example, a machine-readable medium may include read only memory (ROM); random access memory (RAM); magnetic disk storage media; optical storage media; flash memory devices; electrical, optical, acoustical or other forms of propagated signals (e.g., carrier waves, infrared signals, and digital signals). Further, firmware, software, routines, and instructions may be described herein as performing certain actions. However, it should be appreciated that such descriptions are merely for convenience and that such actions in fact result from computing devices, processors, controllers, and other devices executing the firmware, software, routines, and instructions.
[0012] A wireless cell 100 including one or more mobile stations and base stations, which may enhance reliability of MBS in a BWA network in accordance with one embodiment is illustrated in FIG. 1 . In one embodiment, the wireless cell 100 may comprise one or more mobile subscriber stations MSS 110 - 1 to MSS 110 -N and a base station (BS) 150 .
[0013] In one embodiment, the base station 150 may support video MBS as the base station 150 may support high bandwidth. In one embodiment, a video packet, which is multicast or broadcast may comprise I-frames, B-frames, and P-frames. In one embodiment, the I-frames may be associated with higher priority as compared to B-frames and P-frames. In one embodiment, the base station 150 may support features, which may enhance reliability of MBS over BWA networks.
[0014] In one embodiment, the base station 150 may select a set of feedback leaders from which a feedback may be received. In one embodiment, the number of feedback leaders selected may determine based on the frames that the video packet comprise. In one embodiment, the number of feedback leaders selected may be high while transmitting I-frames as compared to B-frames and P-frames. In one embodiment, the number of feedback leaders (M) may be lesser than the total number of MSSs (N). In one embodiment, the base station 150 may select MSS 101 - 1 , 101 - 3 , and 101 -K as feedback leaders.
[0015] In one embodiment, the base station 150 may support wireless channels (e.g., channel-A, channel-B, channel-C, and channel-D) and the base station 150 may request MSS 101 - 1 , 101 - 3 , and 101 -K to provide feedback on channel-A, for example. In one embodiment, the base station 150 may not check the channel which the feedback leaders MSS 101 - 1 , 101 - 2 , and 101 -K may be tuned into before sending the request. In one embodiment, the request may comprise control information such as the channel identifier (channel_id), group of pictures (GOP), and the type fields. In one embodiment, the channel for which the feedback is requested may be determined based on the contents of channel_id field. In one embodiment, the base station 150 receive feedback (ACK or NACK) for channel-A from the feedback leaders MSS 101 - 1 , 101 - 3 , and 101 -K. If the feedback received is NACK, the base station 150 may probabilistically retransmit the video packets.
[0016] As the number of feedback leaders (M) is less than the total number of MSSs (N) provisioned in the wireless cell 100 , the feedback signals may also be less compared to all the MSSs providing the feedback. As a result, the amount of ACK/NACK and the amount of retransmissions may decrease. In one embodiment, the feedback from the selected feedback leaders may enhance reliability and conserve bandwidth by decreasing the noise on the feedback channel.
[0017] In other embodiment, the base station 150 may check the channel that the feedback leaders MSS 101 - 1 , 101 - 3 , and 101 -K are tuned into and may send a request for getting a feedback on the same channel that the feedback leaders MSS 101 - 1 , 101 - 3 , and 101 -K are tuned into. In one embodiment, the base station 150 may vary the number of feedback leaders and may select different feedback leaders at different intervals of time in a round-robin fashion. In one embodiment, the number of feedback leaders may depend on the type of frames transmitted in video packets.
[0018] In other embodiment, the base station 150 may change the modulation and coding (MCS) schemes for the packet transmissions to further enhance the reliability of MBS over the BWA networks. In one embodiment, the base station 150 may determine the modulation and coding scheme to be used based on the feedback received from the feedback leaders over a time window.
[0019] In one embodiment, the base station 150 may support standards based broad-band wireless access technologies such as wireless microwave access for interoperability (Wi-MAX). In one embodiment, the base station 150 may support standards such as IEEE 802.16.
[0020] In one embodiment, the feedback leaders may receive the request from the base station 150 and generate a feedback comprising ACK or a NACK. In one embodiment, the feedback leaders MSS 101 - 1 and 101 -N may receive a request and identify the channel based on the contents of the channel id information. In one embodiment, the channel_id information may identify the channel-A, while the MSS 101 - 1 , 101 - 3 , and 101 -K may be tuned to channel-C. However, the MSS 101 - 1 , 101 - 3 , and 101 -K may provide feedback on the channel-A. In one embodiment, the feedback may comprise ACK (acknowledgement) if the MSS 101 - 1 , 101 - 3 , and 101 -K successfully decodes the video packet and NACK (non-acknowledge) otherwise.
[0021] In other embodiment, the MSS 101 - 1 , 101 - 3 , and 101 -K may receive a request to provide feedback on the channel that the MSS 101 - 1 , 101 - 3 , and 101 -K may be tuned into. If the request for feedback is for a channel which the MSS 101 - 1 , 101 - 3 , and 101 -K are tuned into, the MSS 101 - 1 , 101 - 3 , and 101 -K may not retrieve the channel_id to identify the channel. In one embodiment, the channel_id field may be set to a default value to indicate that the feedback is requested for the channel which the feedback leaders MSS 101 - 1 , 101 - 3 , and 101 -K are tuned into.
[0022] A flow-diagram illustrating an operation of feedback leaders and base station, which may enhance reliability of video MBS over WBA network according to one embodiment, is depicted in FIG. 2 .
[0023] In block 210 , the base station 150 may define a set of feedback leaders such as MSS 101 - 1 , 101 - 3 , and 101 -K. In one embodiment, the base station 150 may select M feedback leaders from a total of N (N>M) mobile subscriber stations 101 - 1 to 101 -N. In one embodiment, the value of M may change based on the type of frames that a video packet may carry. In one embodiment, the base station 150 may select the feedback leaders based on a round-robin fashion.
[0024] In block 230 , the base station 150 may poll the feedback leaders MSS 101 - 1 , 101 - 3 , and 101 -K to receive a feedback on a channel identified by the base station 150 . In one embodiment, the base station 150 may identify channel-A and poll the feedback leaders MSS 101 - 1 , 101 - 1 , and 101 -K to receive the feedback on the channel-A. In one embodiment, the base station 150 may send a request to the feedback leaders 101 - 1 , 101 - 3 , and 101 -K and the request may comprise control information such as a channel_id, which may equal the identifier of the channel-A.
[0025] In block 250 , the feedback leaders 101 - 1 , 101 - 3 , and 101 -N may send a feedback for the channel-A. In one embodiment, the feedback leaders may use the channel_id of the request to identify the channel for which a feedback is to be sent. In one embodiment, the feedback leaders may be watching a different channel-B, or C, or D and irrespective of the channel the feedback leaders are watching, a feedback on the channel-A is sent to the base station 150 . In one embodiment, the feedback leaders 101 - 1 , 101 - 3 , and 101 -K may send ACK after decoding the video packet and may send NACK otherwise.
[0026] In block 270 , the base station 150 may check whether the feedback equals NACK and control passes to block 290 if the feedback is NACK and the process ends otherwise. In block 290 , the base station 150 may retransmit the video packet.
[0027] A sequence diagram, which illustrates the signals exchanged between a feedback leader and the base station to enhance reliability of MBS over WBA network according to one embodiment, is depicted in FIG. 3 .
[0028] In one embodiment, the base station 150 may send a request REQ_ACK 310 to the feedback leaders MSS 101 - 1 , 101 - 3 , and 101 -K. In one embodiment, the request may comprise control info such as channel_id; GOP; and type fields. In one embodiment, the feedback leaders may respond to the request REQ_ACK 310 by sending a ACK/NACK 340 . In one embodiment, the feedback leaders MSS 101 - 1 , 101 - 3 , and 101 -K may use the channel_id to identify the channel for which a feedback is to be sent. In one embodiment, the feedback leaders may send either ACK or NACK based on whether the feedback leader decoded the video packet.
[0029] A flow-diagram, which illustrates an operation of the feedback leaders and the base station to enhance reliability of MBS over WBA network according to other embodiment, is depicted in FIG. 4 .
[0030] In block 410 , the base station 150 may define a set of feedback leaders such as MSS 101 - 1 , 101 - 3 , and 101 -K. In one embodiment, the base station 150 may select M feedback leaders from a total of N (N>M) mobile subscriber stations 101 - 1 to 101 -N. In one embodiment, the value of M may change based on the type of frames that a video packet may carry. In one embodiment, the base station 150 may select the feedback leaders based on a round-robin fashion.
[0031] In block 430 , the base station 150 may poll the feedback leaders MSS 101 - 1 , 101 - 3 , and 101 -K to receive a feedback on a MBS channel, which is watched by the feedback leaders MSS 101 - 1 , 101 - 3 , and 101 -K.
[0032] In block 450 , the feedback leaders 101 - 1 , 101 - 3 , and 101 -N may send a feedback for the channel-A, which is watched by the feedback leaders. In one embodiment, the feedback leaders 101 - 1 , 101 - 3 , and 101 -K may send ACK after decoding the video packet and may send NACK otherwise.
[0033] In block 470 , the base station 150 may check whether the feedback equals NACK and control passes to block 490 if the feedback is NACK and the process ends otherwise. In block 490 , the base station 150 may retransmit the video packet.
[0034] A sequence diagram, which illustrates the signals exchanged between a feedback leader and the base station to enhance reliability of MBS over WBA network according to one embodiment, is depicted in FIG. 5 .
[0035] In one embodiment, the base station 150 may send a request REQ_ACK 510 to the feedback leader MSS 101 - 3 . In one embodiment, the feedback leader MSS 101 - 3 may respond to the request REQ_ACK 510 by sending ACK/NACK 540 . In one embodiment, the ACK/NACK 540 may comprise a channel_id for the base station 150 to identify the channel for which a feedback is sent. In one embodiment, the feedback leaders may send either ACK or NACK based on whether the feedback leader decoded the video packet.
[0036] Certain features of the invention have been described with reference to example embodiments. However, the description is not intended to be construed in a limiting sense. Various modifications of the example embodiments, as well as other embodiments of the invention, which are apparent to persons skilled in the art to which the invention pertains are deemed to lie within the spirit and scope of the invention.
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A broad-band wireless access (BWA) network may support high bandwidth, which may allow video multicast and broadcast services (MBS) over the BWA networks. The BWA network may comprise a base station and mobile subscriber stations provisioned in each wireless cell. The base station may select feedback leaders, which includes a sub-set of the mobile subscriber stations. The base station may send a first request to the feedback leaders and receive a response to the first request that is to indicate whether a packet transmitted prior to sending the first request is to be retransmitted. The feedback leaders may provide a feedback on the first channel, while watching a second channel. Also, the feedback leaders may provide feedback on the first channel while watching the first channel itself. Such an approach may enhance the reliability of the MBS over BWA networks.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation of application Ser. No. 12/746,050 filed Jun. 3, 2010, which is a national stage of PCT/US2009/067720 filed Dec. 11, 2009, which claims priority from U.S. Provisional Application 61/121,733, filed on Dec. 11, 2008, the disclosure of which is incorporated herein by reference in its entirety.
BACKGROUND
1. Field
Apparatuses and methods consistent with the exemplary embodiments relate to a security connecting system, and more particularly, to a security connecting system for providing interconnection between a single pair or multiple pairs of mating optical fibers.
2. Description of the Related Art
Optical fibers find extensive use for transmission of light for digital communications by modulating light signals to convey data or information. The fibers are fragile and have extremely small diameters. Typically, the optical fibers are coupled to a light transmitting device at one end, and light receiving device at the other end. The ends of the fibers may also be coupled in an end-to-end relationship with other mating fibers, and at times multiple optical fibers must be simultaneously coupled. In order to provide reliable coupling and ensure high efficiency in the transfer of light or light signals, it is critical that the ends of the optical fibers be precisely aligned with the ends of other fibers or devices to which they are coupled.
Ferrules are used to provide a mechanically robust mount within a connector for holding optical fibers in a desired position. The ferrule is usually a rigid tube or housing that aligns and protects the stripped end of a fiber. The ferrule may have a one or multiple fiber holes which extend in a through the longitudinal axis of the ferrule and a single fiber is passed through each fiber hole. Such ferrules may be made of metal, plastic glass or ceramic.
There is an increasing need for physical security and identification in a network. One method in the related art is to create physical “keying” features on a connector housing to prevent connection into an adapter unless the adapter too has the complementary “keying” feature. For example, a secured connecting system of the related art may use physical barriers to prevent unauthorized insertion of a connector plug into a connector receptacle in an adapter.
Another secured connecting system of the related art may use physical barriers to prevent unauthorized removal of a connector plug that is already connected to the adapter.
In both cases, the secured connecting systems of the related art require different connector housings with different physical barriers to prevent either unauthorized insertion of a connector plug into the receptacle of an adapter or unauthorized removal of a connector plug from the adapter.
Thus, a security connecting system which eliminates the need to create multiple types of connector housings and adapters to establish physical security in connecting system of a network is needed.
SUMMARY
According to an aspect of an exemplary embodiment, there is provided a multi-fiber connector including a housing; a multi-position ferrule disposed within the housing, the multi-position ferrule including a plurality of fiber holes arranged in a predetermined pattern; and at least one optical fiber. Each of the plurality of fiber holes is configured to receive one of the at least one optical fiber and each optical fiber is selectively inserted within one of the plurality of fiber holes at a selected position among the plurality of fiber holes. To create security in an inter-connection between multi-fiber connectors, only a portion of the plurality of fiber holes are populated with the at least one optical fiber and a remaining portion of the plurality of fiber holes are not populated with fibers.
The multi-fiber connector may include only one optical fiber. Alternatively, the multi-fiber connector may include at least two optical fibers. However, at least one of the plurality of fiber holes is not populated with the at least one optical fiber.
According to an aspect of another exemplary embodiment, there is provided a multi-fiber connector system including a first multi-fiber connector and a second multi-fiber connector.
The first multi-fiber connector includes a housing; a multi-position ferrule disposed within the housing, the multi-position ferrule including a plurality of fiber holes arranged in a predetermined pattern; and at least one optical fiber. Each of the plurality of fiber holes is configured to receive one of the at least one optical fiber and each optical fiber is selectively inserted within one of the plurality of fiber holes at a selected position among the plurality of fiber holes. In addition, only a portion of the plurality of fiber holes are populated with the at least one optical fiber and a remaining portion of the plurality of fiber holes are not populated with fibers.
The second multi-fiber connector includes a housing; a multi-position ferrule disposed within the housing, the multi-position ferrule including a plurality of fiber holes arranged in a predetermined pattern having matching positions corresponding to the predetermined pattern of the first multi-fiber connector; and at least one optical fiber. Each of the plurality of fiber holes is configured to receive one of the at least one optical fiber and each optical fiber is selectively inserted within one of the plurality of fiber holes at a selected position among the plurality of fiber holes. The plurality of fiber holes of the second multi-fiber connector are populated with the at least one optical fiber such that the first multi-fiber connector and the second multi-fiber connector have a matching configuration of populated fiber holes and unpopulated fiber holes.
The multi-fiber connector system may also include an adapter which includes a first receptacle configured to receive the first multi-fiber connector and a second receptacle configured to receive the second multi-fiber connector, such that the at least one optical fiber of the first multi-fiber connector and the at least one optical fiber of the second multi-fiber connector mate in coaxial alignment to effect an interconnection.
According to an aspect of another exemplary embodiment, there is provided a method of connecting multi-fiber connectors in a secure fiber optic network, the method includes selecting at least one fiber hole of a plurality of fiber holes of a first multi-fiber connector to populate with an optical fiber; selecting not to populate at least one fiber hole of the plurality of fiber holes of the first multi-fiber connector with another optical fiber such that only a portion of the plurality of fiber holes of the first multi-fiber connector are populated with at least one optical fiber and a remaining portion of the plurality of fiber holes of the first multi-fiber connector are not populated; inserting the at least one optical fiber in only the selected at least one fiber hole of the first multi-fiber connector; selecting at least one fiber hole of a plurality of fiber holes of a second multi-fiber connector to populate with another optical fiber; selecting not to populate at least one fiber hole of the plurality of fiber holes of the second multi-fiber connector with another optical fiber such that only a portion of the plurality of fiber holes of the second multi-fiber connector are populated with another at least one optical fiber and a remaining portion of the plurality of fiber holes of the second multi-fiber connector are not populated, inserting the another at least one optical fiber in only the selected at least one fiber hole of the second multi-fiber connector; inserting the first multi-fiber connector into a first receptacle of an adapter; and inserting the second multi-fiber connector into a second receptacle of the adapter such that the at least one optical fiber of the first multi-fiber connector and the another at least one optical fiber of the second multi-fiber connector mate in coaxial alignment to effect an interconnection. When a proper connection is formed, the first multi-fiber connector and the second multi-fiber connector have a matching configuration of populated fiber holes and unpopulated fiber holes.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and/or other aspects will become apparent and more readily appreciated from the following description of the exemplary embodiments, taken in conjunction with the accompanying drawings, in which:
FIG. 1A illustrates a multi-position ferrule of a multi-fiber connector according to an exemplary embodiment of the present invention.
FIG. 1B illustrates a multi-position ferrule of a multi-fiber connector according to another exemplary embodiment of the present invention.
FIG. 2 illustrates a connecting system according to an exemplary embodiment of the present invention.
FIG. 3 shows matching fiber positions in a pair of connector plugs, mating in a key-up-to-key-up configuration according to another exemplary embodiment.
FIG. 4 shows two pairs of matching fiber positions in a pair of connector plugs, mating in a key-up-to-key-down configuration according to another exemplary embodiment.
FIG. 5 shows two pairs of matching fiber positions in a pair of connector plugs, mating in a key-up-to-key-up configuration according to another exemplary embodiment.
FIG. 6 shows matching fiber positions in a pair of connector plugs with two rows of possible fiber positions, mating in a key-up-to-key-down configuration according to another exemplary embodiment.
FIG. 7 shows matching fiber positions in a pair of connector plugs with two rows of possible fiber positions, mating in a key-up-to-key-up configuration according to another exemplary embodiment.
FIG. 8 shows two pairs of matching fiber positions in a pair of connector plugs, mating in a key-up-to-key-down configuration according to another exemplary embodiment.
FIG. 9 shows two pairs of matching fiber positions in a pair of connector plugs, mating in a key-up-to-key-up configuration according to another exemplary embodiment.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
Exemplary embodiments will be described in detail with reference to accompanying drawings so as to be easily realized by a person having ordinary knowledge in the art. The inventive concept may be embodied in various forms without being limited to the exemplary embodiments set forth herein. Descriptions of well-known parts may be omitted for clarity, and like reference numerals refer to like elements throughout.
Fiber optic connectors typically interconnect a pair of optical fibers aligned in an end-to-end disposition to provide optical transmission therebetween. In a multi-fiber connector, two or more optical fibers may be contained within a single jacket. To interconnect such a multi-fiber optical cable, each fiber within the multi-fiber optical cable is secured to a respective connector. When multiple pairs of fiber optic connectors are to be connected, the fiber optic connectors require mutual alignment of respective fiber cores in a repeatable, separable interconnect.
According to an exemplary embodiment of the present invention, a ferrule is used together with the connector that connects the fiber cable either to another cable, to a transmitter or to a receiver. The ferrule keeps the optical fibers in a fixed position and accurately aligned within the connector. For example, an optical fiber may be inserted into a fiber hole of the ferrule, and fixed thereto by an adhesive. Additional optical fibers may be inserted into one of the remaining available fiber holes.
An end face of the optical fibers may be finished to be flush with or slightly protruding from an end face of the ferrule. The optical fibers held by the ferrule, particularly the fiber end faces, may be polished with a minor finish. When complimentary ferrules are adjoined, typically in an abutting relationship, two optical fibers mate in coaxial alignment to effect an interconnection. Accordingly, optically encoded information carried in the core of the optical fibers can be transmitted therebetween.
A Mechanical Transfer (MT) ferrule is one type of multi-fiber ferrule, and may be used to simultaneously connect multiple optical fibers using multiple fiber holes. Each fiber hole receives one optical fiber and fiber alignment is dependent on the arrangement of the fiber holes. The arrangement of the fiber holes can made in various patterns which may include two or more fiber holes. The arrangement of the fiber holes may also vary according to a pitch between holes and a hole diameter, however, the exemplary embodiments are not limited to any particular arrangement so long as two mating ferrules have a matching arrangement.
FIG. 1A illustrates a 12-hole MT ferrule 1 a as an example of part of a multi-fiber connector according to an exemplary embodiment of the present invention. Ferrule 1 a includes a body 2 in which a plurality of fiber holes 3 are formed therethrough and extend in a longitudinal direction. Each of the fiber holes 3 is capable of being populated with an optical fiber 5 of a multi-fiber optical cable. In addition, the ferrule 1 a includes guide-pin holes 7 formed in the body 2 and which are aligned with and receive guide-pins of another ferrule, a light emitting or receiving device.
According to the ferrule 1 a shown in FIG. 1A , only a portion of the fiber holes 3 available are selected to be populated with an optical fiber 5 . In particular, hole # 4 and hole # 6 from the left are populated with optical fibers of the multi-optical cable. The remaining fiber holes are left empty. Accordingly, only another ferrule having a matching configuration of populated fiber holes 3 will be able to form a proper connection with ferrule 1 a of FIG. 1A . In this example, another ferrule having holes # 4 and 6 populated with optical fibers will be able to form a proper connection with ferrule 1 a . On the other hand, a ferrule populated with fibers in holes # 1 and 2 will not be able to form a proper connection with ferrule 1 a.
FIG. 1B illustrates a 72-hole MT ferrule 1 b as another example of part of a multi-fiber connector according to an exemplary embodiment of the present invention. Ferrule 1 b includes 72 fiber holes 3 arranged in 6 rows of 12. Hole # 2 from the left in the third row is populated with an optical fiber of a multi-fiber optical cable. The other 71 holes are left empty. Thus, only another ferrule that has a fiber populated in the same manner can form a proper connection with ferrule 1 b.
Accordingly, through predetermined positioning of optical fibers in a multi-position ferrule within a connector, a secured network connection can be formed between two mating connectors. This is because two mating connectors, held together on separate sides of an adapter, will only have physically connecting optical fibers if the fibers on both connectors have matching positions. Thus, the information transfer through the mating pair(s) of optical fibers is secured since an incoming connector to an adapter, that already has a connectors on its other end, is prevented from making a physical connection between a pair or pairs of optical fibers, unless the positioning of the optical fibers within the connectors are matched.
FIG. 2 illustrates a connecting system according to an exemplary embodiment of the present invention. In particular, FIG. 2 shows matching fiber positions in a pair of connector plugs, which mate in a key-up-to-key-down configuration. The connecting system includes two cable assemblies 10 terminated with a connector plug 12 on each end section of an optical cable 14 . Each connector plug 12 includes a housing 16 and a multi-fiber ferrule 1 disposed within the housing 16 . The connecting system also includes an adapter 20 which has two receptacles 22 on either side, each receptacle 22 receiving one of the connector plugs 12 . Accordingly, a pair of connector plugs 12 are held together by the adapter 20 .
As shown in FIG. 2 , the positioning of the optical fibers 5 among the plurality of fiber holes 3 in the two connector plugs 12 mirror each other such that the optical fibers 5 in the two mating connector plugs 12 have a corresponding matching position that compliments each other. Because the connector plugs 12 shown in FIG. 2 have a matching positioning of optical fibers disposed within ferrules 1 , a proper connection between the connector plugs can be achieved when the two connector plugs 12 are connected by the adapter 20 . Thus, by using a predetermined and distinctive selection of positions among a plurality of possible fiber hole positions, security in the connecting system can be ensured.
The number of combinations and permutations achievable by the connection system is dependent on the number of available fiber positions on the multi-fiber ferrule 1 and the number of optical fibers needed for the specific connecting system.
Accordingly, the need to have different connector housings with different physical barriers to prevent either unauthorized insertion of a connector plug into the receptacle of an adapter or unauthorized removal of a connector plug from an adapter can be eliminated. That is, a common connector housing can be used for all connector plugs. In addition, one common adapter may be used to connect the connector plugs.
Identification of connector plugs with specific fiber positioning can be carried out through color-coding the components of the connector plugs, such as plug housings or connector plug boots. Identification of connector plugs with specific fiber positioning can also be carried out through number coding of the cable assemblies, or other types of marking.
FIG. 3 shows matching fiber positions in a pair of connector plugs 12 , mating in a key-up-to-key-up configuration according to another exemplary embodiment.
FIG. 4 shows two pairs of matching fiber positions in a pair of connector plugs 12 , mating in a key-up-to-key-down configuration according to another exemplary embodiment.
FIG. 5 shows two pairs of matching fiber positions in a pair of connector plugs 12 , mating in a key-up-to-key-up configuration according to another exemplary embodiment.
FIG. 6 shows matching fiber positions in a pair of connector plugs 12 with two rows of possible fiber positions, mating in a key-up-to-key-down configuration according to another exemplary embodiment.
FIG. 7 shows matching fiber positions in a pair of connector plugs 12 with two rows of possible fiber positions, mating in a key-up-to-key-up configuration according to another exemplary embodiment.
FIG. 8 shows two pairs of matching fiber positions in a pair of connector plugs 12 , mating in a key-up-to-key-down configuration according to another exemplary embodiment.
FIG. 9 shows two pairs of matching fiber positions in a pair of connector plugs 12 , mating in a key-up-to-key-up configuration according to another exemplary embodiment.
Accordingly, the exemplary embodiments uses the plurality of fiber holes feature of a multi-fiber ferrule to achieve physical security in the connecting system of a network. By choosing different discrete positions of a multi-fiber ferrule, proper connection can only be made if the mating pair of connectors both have fibers in the position(s) that complement each other.
Although a few exemplary embodiments have been shown and described, it will be appreciated by those skilled in the art that changes may be made in these exemplary embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents. For example, although the above exemplary embodiments utilize optical fibers, non-optical fibers could also be used without departing from the principles and spirit of the invention.
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Provided is a multi-fiber connector and a method of providing a secure fiber network, where the multi-fiber connector includes a housing; a multi-position ferrule disposed within the housing, the multi-position ferrule including a plurality of fiber holes arranged in a predetermined pattern; and at least one fiber. Each of the plurality of fiber holes is configured to receive one of the at least one fiber and each fiber is selectively inserted within one of the plurality of fiber holes at a selected position among the plurality of fiber holes. Additionally, only a portion of the plurality of fiber holes are populated with the at least one fiber and a remaining portion of the plurality of fiber holes are not populated with fibers.
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BACKGROUND OF THE INVENTION
The present invention pertains to an improved device for use on sewing machines to cut a chain of stitches and hold it in a specific location that facilitates its incorporation into the seam to be formed in the next workpiece.
As is well known, sewing machines that form seams utilizing stitches of the 400, 500, 600, etc. class, according to Federal Standard Catalog (U.S.A.) classifications on a succession of pieces of material, the seam is continued into the area intermediate the pieces of material. With seams of this type means are provided for detaching the pieces of material one from the other by appropriate automatic chain-cutting devices after the sewn pieces have been caused to travel beyond the needle and the presser foot of the machine.
By cutting the chain of stitches with such devices, one portion of minimal length remains attached to the stitched piece of material and the other being connected to the needle plate is manipulated to a position forwardly of the needle so that it can be incorporated into the initial portion of the seam that will be formed on the next piece of material or workpiece. This procedure prevents a slackening of the seam's initial stitches which would give the leading edge of the workpiece an undesireable appearance.
The known devices for performing this function include a chain-cutting device disposed adjacent the tongue of the needle plate which cooperates with a chain-orienting device and gripper apparatus located forwardly of the needle and usually adjacent the forward portion of the needle plate. These devices have not performed their intended function with complete satisfaction for that portion of the chain to be incorporated being located on the upper planar surface of the needle plate intermediate the needle hole, and gripping apparatus is very frequently and inadvertently displaced while positioning the next workpiece in the sewing area.
This inferference of the material to be sewn with the chain prevents the proper insertion of the latter into the new seam being sewn due to the pressure and friction of the piece of material on the chain which tend to dislodge it from the gripping apparatus and move it toward the trimmer knife of the machine that is adjacently disposed, thereby hindering subsequent handling of the chain.
Additionally, the known devices do not provide means for completely dislodging the chain of stitches from the needle plate tongue which is required if one wishes to prevent stitches from being formed before the material engages the needle.
Also, with the known devices the thread extending from the lower looper of the sewing mechanism is linked with the chain and is located on the needle plate in such close proximity to the trimmer knife during the time the chain is being held that it can be easily cut.
An object of the present invention is to improve the known devices so that the chain may be located in a predetermined position in which it will not be affected by the material to be sewn nor damaged by the machine's trimmer knife.
SUMMARY OF THE INVENTION
Regarding devices for cutting, holding and positioning a chain of stitches forwardly of the needle in a sewing machine which includes a chain-cutting device with orienting and gripping devices located in front of the needle, the object of the invention is achieved by an improvement that is characterized by the fact that the needle plate is provided with an integrally formed channel which extends parallel to the sewing axis and also traverses the distance from a point adjacent the needle hole to a position of contiguous relation with the gripping apparatus. This channel is adapted to position the chain that is being held by the gripper apparatus and serves to prevent any contact thereof with the workpiece which could possibly displace said chain.
When a new seam is started the chain is slowly withdrawn from the gripping apparatus and by means of the channel is guided to the stitching instrumentalities and incorporated into said seam.
Another feature of the invention is a shedding means that is integrally formed on the inner side of the tongue intermediate the needle hole and the free end of the tongue. This shedding means is oriented towards the chain-cutting devices and at an angle oblique to the direction of sewing. The shedding means is adapted to cooperate with the suction element of the chain cutting device to assist in withdrawing the chain of stitches from the tongue so that the chain will be drawn to a position spaced from said tongue and in general alignment with the channel in the needle plate.
The shedding device provides a means for effecting positive removal of all of the stitches from the tongue that were formed thereon immediately after completion of the sewing function on the workpiece.
Another feature of the invention is the provision of an arcuated guide slot formed in the base of the tongue and on that side of the latter opposite the needle hole. This arcuated guide slot is adapted to receive and position the threads of the chain of stitches when the latter is ejected from the chain cutting device. Additionally, the guide slot is disposed in close proximity with and is oriented in the direction of the channel in the needle plate and serves to maintain a separation between the threads therein, (especially the thread from the lower looper) and the machine's trimmer knife.
Other features and advantages of the invention will become more fully apparent by reference to the appended claims and as the following detailed description proceeds in reference to the figures of drawings wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a portion of a sewing machine showing the device according to the invention applied thereto;
FIG. 1a is a top view of an enlarged scale of the device shown in FIG. 1; and
FIGS. 2, 3 and 4 are views similar to FIG. 1 but showing different phases of operation of the device according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, the device for cutting and holding a chain of stitches in a selected position at the beginning of a seam according to the invention, is adapted to be used on a sewing machine of the type that forms an overcast stitch of the 500 class (U.S. Federal Standard Catalog).
As the general construction and operation of a sewing machine to which the present invention is applicable is well known and familiar to those conversant in the art, and as the invention is entirely concerned with a device for positioning a chain of stitches for incorporation into the initial stitches of a new seam, it is only considered necessary here to illustrate and describe those parts which are directly concerned with a preferred form of the invention.
The sewing machine includes among its various parts a needle 10 that is located above a needle plate 11 and an upper looper 12 which is disposed adjacent to a tongue 13 formed on the needle plate and around which the threads are joined to form the stitches for a seam. A lower looper 14 is located beneath the needle plate 11 in a conventionl manner with only a portion thereof being visible in the various figures of drawing.
The needle plate 11 is attached to a work surface 15 of the sewing machine and includes a slot or needle hole 16 into and from which the needle 10 is caused to travel to cooperate in a known manner with the lower looper 14.
One side of the needle hole 16 on the needle plate forms one side of a tongue 13 that extends in the same direction as the direction of feed, i.e., the direction in which the workpieces are caused to advance during the sewing operation by means of a conventional form of feed dog 17.
A well-known trimmer knife 18 and cooperating counterblade 19 are disposed in general alignment with one side of the tongue 13 and serve to trim the edge of the workpiece around which the stitches are to be sewn.
Adjacent the free end of the tongue 13 the machine supports a chain cutting device generally indicated by numeral 20 which includes a suction tube 21 having an opening 22 within which a conventional chain cutting knife 23 is mounted.
An orienting device is disposed within the opening 22 and serves to eject the chain of stitches drawn into the suction tube 21 after being severed from a sewn workpiece. When the chain is ejected it is caused to be extended forwardly of the needle 10 where it is in position to be acted on by a gripping apparatus generally indicated by numeral 25. This gripping apparatus 25 includes a gripper blade 26 and a suction-positioning tube 27.
In particular, the orienting device defines an elongated nozzle 24 that is adapted to direct a jet of air onto the chain so as to eject it from the tube 21 and cause it to extend to a position forwardly of the needle 10 where the end thereof is drawn into the suction-positioning tube 27.
While the end of the chain is being drawn into the suction positioning tube 27, that portion adjacent said end is caused to assume a position beneath the gripper blade 26.
A pneumatic member 28 provides a means for raising and lowering the gripper blade 26 for receiving and gripping the chain in timed sequence with the activation of the suction positioning tube 27.
The improved device according to the invention provides a means for positive positioning of the chain while being acted upon by the gripping apparatus 25 and defines an open channel 29 formed in and communicating with the upper surface of the needle plate 11.
This channel 29 forms an extension of the tongue 13 and extends parallel to the sewing axis from a position adjacent the needle hole 16 to the gripping apparatus 25. The channel 29 communicates with a recess 30 within which the gripper blade 26 is raised and lowered during the performance of its intended function.
The device according to the invention also includes a shedding means which forms an integral part of the tongue 13. This shedding device defines a surface 31 that is disposed at an angle oblique to the sewing axis which extends from the needle hole 16 to the terminus portion of the tongue that is depicted by numeral 32 and which is located adjacent to the opening 22 of the chain cutting device 20.
With the surface 31 of the shedding device being directed at an angle to the sewing axis and toward the chain cutting device 20, it serves to assist the latter in the removal of the stitches from the tongue 13.
An arcuated guide slot 33 is formed on that portion of the base of the tongue 13 opposite the needle hole 16 and extends in the direction which places it in a position of close proximity with the channel 29 (FIG. 1a). This guide slot serves to position and align the threads of the chain extending from the stitching instrumentalities after the chain has been released from the tongue 13 so as to align them with the channel 29 while maintaining them at a safe distance from the trimmer knife 18. This feature is of particular importance relative to the thread from the lower looper 14 which is the outermost thread and the one which would otherwise be the one most likely to be damaged by the counter blade 19.
To summarize the operation a seam 35 is shown in FIG. 2 which is formed on the edge of the workpiece 34 as the latter is caused to advance in a known manner during operation of the sewing machine.
Upon completion of the seam, the workpiece continues to advance so as to permit the chain cutting device 20 to draw in the chain of stitches 36 that project from the trailing end of the workpiece and which were formed on the tongue 13.
The drawing-in force of the chain-cutting device is sufficient to cause the above-mentioned chain to be cut off in close proximity with the trailing end of the workpiece
This force of drawing in the chain of stitches for cutting is of sufficient strength so as to effect a shedding of the stitches from the tongue 13.
The removal of the chain from the tongue is also facilitated by the shedding device 31, which extends toward the opening 22 so as to taper the body of said tongue in the direction of its end 32.
As shown in FIG. 3 movement of the chain in this manner locates it within the cutting device 20 which is spaced from the needle plate 11 and needle hole 16.
During this function the gripper device 25 is activated so as to be in readiness to receive the chain that has been shed from the tongue 13. The movable gripper blade 26 is moved vertically out of the recess 30 by the pneumatic device 28, and at the same time the suction-positioning tube 27 is activated.
Finally, with regard to FIG. 4, the orienting device 24 emits a jet of air from the nozzle which ejects the chain from the chain-cutting device and orients it in the area forwardly of the needle so that the suction in the tube 27 will draw the chain to a position beneath the blade 26. The blade is then lowered into gripping contact with the chain and in readiness for the next seam to be sewn.
During this function the chain is stretched forwardly so as to enter the recess 33 located at the base of the tongue 13 and enters into the channel 29 thus placing said chain in alignment with the sewing axis and below the upper planar surface of the needle plate 11.
The chain is caused to move in front of the needle and the loopers 12 and 14 to effect its entry into the recess 33 which locates said chain at a sufficient distance from the trimmer knife so as not to come into contact with it accidentally.
Under these ideal conditions, the seam may be picked up only if a new piece of material is moved into contact with the needle 10. The needle on its initial piercing of the material, draws from its source of thread and restores the positions relative to the other stitching instrumentalities that are necessary for the required formation of the stitches. Because stitches at this point can only be formed when a piece of material is present, there is no length of free stitches on the leading edge of the material to affect adversely the appearance of the finished seam.
In addition, the pressure exerted by the workpiece on the work surface 15 and the needle plate 11 cannot displace the chain 36 that is contained within the channel 29. The chain is caused to be pulled from the channel during the formation of a seam in the next workpiece and is sewn or locked into the initial stitches of said seam.
Although the present invention has been described in connection with a preferred embodiment, it is to be understood that modifications and variations may be resorted to without departing from the spirit and scope of the invention as those skilled in the art will readily understand. Such modifications and variations are considered to be within the purview and scope of the invention and the appended claims.
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A device for orienting a chain of stitches severed from a completed workpiece to a position where the end is taken by a gripping apparatus and the intermediate portion placed in a predetermined location where it cannot be displaced by the next workpiece while incorporating the chain into the initial stitches of the seam being formed thereon.
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BACKGROUND OF THE INVENTION
The invention relates to a vibratory device for compacting a substrate. Such a vibrarory device is usually used with a compacting plate which is installed on the substrate to be compacted. Such a vibrarory device includes balancing weights which rotate about an axis.
Such vibrarory devices are known as stampers, compacting plates, vibratory rollers, etc. and they are used to compact soil, concrete, tar, sand, etc.
The balancing weights when in rotation produce vibrations acting in all directions. The vibrations, especially those which are directed away from the ground to be compacted, negatively affect the working conditions of an operator of such a device. Besides, the uncontrolled vibrations negatively influence the driving mechanisms and other sensitive parts of the vibratory compactor.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a vibratory compactor of a simple construction which, when in operation, does not negatively affect the operator and only slightly affects the driving mechanisms and other sensitive parts of the vibratory compactor.
In pursuance of these objects and others which will become apparent hereafter, one feature of the present invention resides in providing a plate adapted to contact a substrate to be compacted; vibratory means mounted atop said plate for vibrating the same. The vibratory means include imbalance means mounted for rotation along a predetermined trajectory about an axis substantially parallel to the general plane of said plate. At least a portion of said trajectory has varying cross-section so that during at least a portion of each revolution the center of gravity of said imbalance means progressively moves between a first position in which it coincides with said axis and a second position in which there is a maximum distance between said center of gravity and said axis, and thereafter from said second position back to said first position. There are also provided drive means for driving said imbalance means in rotation.
In a preferred embodiment of the invention the imbalance means include at least a pair of bodies which are offset relative to ach other by an angle of 180° in the direction of rotation. The bodies are so selected with respect to their masses and spacings from the rotation axis that product of the mass of one body and the spacing of this body from the axis is at least during approximately half a revolution of the imbalance means is greater, and at no time period of the revolution smaller than the corresponding product of the other body. During this approximately half revolution the first body is situated on the side remote from the substrate side of the plane which passes through the rotation axis. The plane is either parallel to or inclined at an acute angle relative to the substrate.
During rotation of the imbalance means a force is generated which is primarily directed towards the substrate. This force may be used for compacting the substrate. At the start and the end of each revolution there are generated small forces which are directed upwardly. These forces, however, are compensated for substantially by the weight of the vibratory compactor. Therefore these small forces may be disregarded. The value of the compacting force depends on the trajactory of rotation of the imbalance means, on the distance between the center of gravity of the bodies and the axis of rotation and on the rotation speed.
In another embodiment of the invention one body is unchangeably spaced from the rotation axis, while the other body is spaced from the rotation axis by a varying distance. The distance between the center of gravity of the imbalance means changes during each revolution and is located in the plane which is parallel to the substrate. This distance changes during the first half phase of each revolution from zero to a maximum. During the second half phase of each revolution this distance is constantly on the zero value. Thus, during the second half phase of each revolution the center of gravity is located on the rotation axis. Such a feature is advantageous with respect to the vibratory compactor which has to have low vibrating frequency.
Still another embodiment of the present invention teaches bodies which have equal masses and are guided so that the distance between the center of gravity and the rotation axis during the period of each revolution when the bodies run along a first portion of the circular path located above the above-mentioned plane, that is on the side remote from the substrate is at least equal to that measured when the bodies run along a second portion of the circular path, which second portion is located between the plane and the substrate. At least during a section of said first portion this distance is larger than that measured during the second portion of the circular path.
Thus, the distance of the center of gravity from the above-mentioned plane which passes through the rotation axis and is substantially parallel to the substrate changes during each revolution progressively from zero to a maximum and thereafter from the maximum to zero. Such an arrangement renders it possible to obtain high vibrating frequencies.
At least one of the bodies runs along a guided trajectory around the rotation axis. The distance of this guided trajectory from the rotation axis is constant in the region between the substrate and the above-mentioned plane. This distance increases above this plane in direction of rotation, that is the distance is increased to a certain maximum and then decreases to the constant value. The plane may be arranged at an acute angle to the substrate, that is relative to its zero position namely parallel to the substrate. The plane may be rotated either in or opposite relative to the direction of rotation. Changes of the position of the plane relative to the substrate results in changes in direction of the vibration forces and therefore in changes of the components of those forces. The force components which do not affect the compacting work are used for moving the vibratory compactor back and forth independently of the moves of the operator. Thus, the compacting force may be varied by changing the angular position of the plane respective to the substrate. Simultaneously, by changing the angular position of the plane one can change the horizontal component of the compacting force, to thereby move the vibratory compactor relative to the substrate.
The above-mentioned second portion of the circular path, that is the portion between the substrate and the plane, has a semi-circular cross-section and the first portion, that is the portion located above the plane, has semi-ellipsoidal cross-section which merges into semi-circular portion. The ellipsoidal portion has the shortest half-axis equal to the constant radius of the semi-circular portion. Thus, the compacting force arrives to its maximum value when the plane is parallel to the substrate. In this case the force is directed normally to the substrate. A preferably inclination of the plane from its parallel position to the substrate is within the range of ±45°.
The guiding path is arranged on an inner circumference of a casing which is coaxial with the rotation axis. The casing is stationary. However, the casing may be turnable, particularly manually, about the rotation axis. Thus, the plane which passes through the rotation axis and which separates two differently configurated portions of the circular guiding path may be arranged substantially parallel to the substrate or at any selected acute angle relative to the substrate. The corresponding inclination of the casing may be performed by the operator, by means of a handling grip arranged on the casing.
One of the bodies may be mounted in a cage which is rotatable about the rotation axis so as to be radially shiftable relative to the rotation axis . The other body may be fixedly connected to the cage. The other body is preferably integrally connected to the cage. Such a construction of the imbalance means is particularly simple.
In another embodiment, the rotatable cage is provided with two bodies for rotation therewith, which bodies are both free to radially shift within said cage.
The cage may be formed as one-piece member, or may consist of several parts which are arranged axially adjacent one another. In this case each of the separate parts is provided with a pair of bodies which are offset relative to each other by 180° in the direction of rotation. Such an arrangement is advantageous when the masses of the bodies and height of the cage are to be kept small, or where the compacting force shall be substantially increased without increasing the masses of the bodies or the height of the cage.
The radially shiftable bodies may be spheres, balls, cylindrical bodies, rollers, cylinders, discs, etc.
The cage is coaxially arranged in a hollow cylinder which serves as a compacting plate. The hollow cylinder is constantly in contact with the substrate, so that the small transversely oriented vibrations are damped by a counterforce from the substrate to be compacted. Thus, the operator is relieved substantially from all vibrations, which factor makes it possible for the operator to easily operate the vibratory compactor. The vibratory compactor is particularly useful for compacting soil, concrete, tar, asphalt, etc.
The drive means for driving the imbalance means preferably include an internal combustion engine or an electromotor. In this case the electromotor is arranged on an arm which is firmly fixed on the casing. The drive motion may be transmitted from the motor to the cage via a belt or a chain transmission. The motor may be flanged to the casing, for instance, coaxially with the rotation axis.
The cage is fixed on a driven shaft which is fixed coaxially on the casing for rotation therewith. The hollow cylinder rotates on bearings about the casing and extends in the space between the casing and the motor arm. The handle is attached to the motor arm.
The novel features which are considered as characteristic for the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a vibratory compactor in accordance with the present invention;
FIG. 2 is a cross sectional view of the vibratory compactor shown in FIG. 1;
FIG. 3 is a sectional view taken along the line III--III in FIG. 2;
FIG. 4 is a cross-sectional view of another embodiment of the vibratory compactor shown in FIG. 1;
FIG. 5 is a sectional view taken along the line V--V in FIG. 4;
FIG. 6 is a cross-sectional view of a third embodiment of the vibratory compactor shown in FIG. 1; and
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to the drawings, and first to the FIG. 1 thereof, it may be seen that the reference numeral 1 designates a cylinder for transmitting the compacting forces onto the substrate to be compacted. A casing 3 is arranged within the interior of the cylinder 1 (see FIGS. 2 and 3). A shaft 14 is placed coaxially with the cylinder 1 and the casing 3. A cage 5 is fixedly mounted on the shaft 4 and located within the casing 3. The cage 5 receives a number of balls 6. The balls 6 rotate with the cage 5. The shaft 4 is mounted on inner bearings 7 and 8 within the casing 3 for rotation about an axis 23, which is simultaneously the central axis of the casing 3. The hollow cylinder 1 pivots relative to the casing 3 on coaxially mounted bearings 9 and 10. An arm 11 for carrying a motor 12 is flanged to the end face of the casing 3 so that the cylinder 1 pivots in the space between the arm 11 and the casing 3. The arm 11 is fixed on the shaft 4 which is provided at the corresponding end portion thereof with a driving wheel 13 which is driven via a belt 14 by a motor shaft 15 (see FIG. 1).
The cage 5 includes two axially and successively arranged identical parts 51 and 52 (see FIG. 3). Each of these parts has a pair of radial bores 16, 17 and 18, 19, respectively, which are circumferentially offset relative to each other by an angle of 180°.
The balls 6 are installed in the corresponding bores so that the balls are free to move radially along the respective bores. For this purpose the diameter of the bores slightly exceeds that of the balls, so that the balls are shiftable within the corresponding bores radially relative the rotation axis 23.
The inner surface of the casing is provided adjacent to each of the parts 51 and 52 with guides 20 and 21, respectively. The balls 6, when the cage 3 rotates centrifugally the corresponding guides 20 or 21. (See FIG. 3). The guides 20 and 21 are identical, and as shaped each of them has two differently configurated portions spaced from each other by 180° in direction of rotation of the cage 3 (see FIG. 2).
One portion is located between the substrate 2 and plane 22 which passes through the axis 23 and is normally parallel to the substrate. This portion has a circular (i.e. constant) cross-section, that is each individual point of this portion of each of the guides 20 and 21 is equally spaced from the rotation axis 23. Each of the guides 20 and 21 includes another portion of noncircular (i.e. varying) cross-section. In FIG. 2 this portion is shown above the plane 22. This section has an ellipsoidal cross-section (see FIG. 2), whose shorter axis corresponds to the diameter of the circular portion. In the direction shown by an arrow 25, the distance of the guides 20 and 21 from the rotation axis increases from the distance equal to circular radius progressively to the maximum at the end of a section of 90° from the end of the circular portion. From this maximum on the distance progressively decreases until it reaches the circular radius volume. On the level of the plane 22, both these portions join each other.
A handle 24 is mounted on the motor arm 11. The handle 24 is operative to facilitate the manipulation of the vibratory compactor by the operator. In a normal position of the vibratory compactor, both the motor arm 11 and the plane 22 are in horizontal position, that is parallel to the substrate 2. By lifting or lowering of the handle 24 one can vary angular position of the plane 22 relative to the substrate 2, to thereby achieve forward and rearward movement of the compactor along the substrate to be compacted and variation of the compacting force applied to the substrate.
The motor shaft 15 rotates via the belt 14 the shaft 4 and the cage 5. Rotation of the cage 5 causes rotation of the balls 6, which are centrifugally shifted at least partially from the corresponding bores 16, 17, 18 and 19 until they abut the corresponding guides 20 and 21.
FIGS. 4 and 5 show another embodiment of the vibratory compactor partially similar to that shown in FIGS. 2 and 3. For the sake of clearness the same parts are designated by the same reference numerals as those used in FIGS. 2 and 3, however, increased by 100.
The casing 103 and the cage 105 are mounted within the hollow cylinder 101. The motor arm 111 is located on the casing 103. Two cylindrical bodies 106 are radially movably received in the radial bores of the cage 105. The cylindrical bodies 106 have cylindrical rings 128 with bearings 126. The cylindrical body 106 remains centrifugally movable relative to the axis of rotation 123. The axes of cylindrical rings 128 are parallel to the rotation axis 123. During rotation of the cage 105, these cylindrical rings 128 are guided by the guide 120 of the casing 103. The sliding pieces 127 are radially shiftable within the radially arranged bores 116 and 117. The cage 105 (similarly to the embodiment shown in FIG. 3) may be subdivided into several parts, wherein each of these parts includes a pair of cylindrical bodies 106 which are mutually circumferentially offset from each other by an angle of 180° (see FIG. 5).
The embodiment shown in FIGS. 4 and 5 is similar to that disclosed hereabove with respect to the embodiment shown in FIGS. 2 and 3.
FIG. 6 shows a third embodiment of the vibratory compactor, which embodiment is quite similar to those shown in FIGS. 2, 3, 4 and 5. Therefore, the parts of this embodiment which are similar to those shown in FIGS. 2, 3, 4 and 5 are designated by the same reference numerals, however, increased by 200.
The hollow cylinder 201 receives the casing 203 which is provided on its inner circumference with the guide 220. The cage 205 located in the interior of the hollow cylinder 201 and the arm 211 fixed on the casing 203 are identical to the corresponding members shown in FIGS. 2 and 3 so that the entire description with regard to these elements as to the FIGS. 2 and 3 may be herewith applicable to the embodiment in FIG. 6. The cage 205 is located inside the casing 203, and includes two radial bores which are offset relative to each other by 180°, namely bores 216 and 217. The bore 216 receives the ball 206, whereas the bore 217 receives a member 226 which is stationary within the bore 217. The member 226 may be integrally connected to the cage 205. The mass of the member 226 is so selected, that the product of the mass of the member 226 and the distance of the center of gravity of this member 226 from the axis 223 is equal to that of the mass of the ball 206 and the distance of the center of gravity of the ball 206 from the axis 123 when the cage 205 rotates by 180°.
Thus, during one half of each revolution a resulting force is directed towards the substrate, to thereby compact the same. Frequency of vibration in this case is twice as small as that in the embodiment shown in FIGS. 2, 3, 4 and 5. Otherwise, construction of the embodiment shown in FIG. 6 is identical to that shown in FIG. 2. In particular, the plane 222 can be angularly displaced relative to the substrate, to thereby change the force applied thereto or to move the vibratory compactor along the substrate to be compacted.
It is to be understood that the present invention is not limited by the embodiments shown in the drawings. For example, the cylinder may be replaced by a flat compacting plate in the form of sledge which is set forth to horizontally transform motion of the vibratory compactor on to the substrate. Also, the guides do not have to be configured as in FIGS. 2, 4 and 6. Moreover, one portion of the guide does not necessarily have to be ellipsoidal. It may have any other varying cross-sectional form. The only requirement is that the spacing of the center of gravity of the balance weight increase from zero to maximum and vice versa. Also, anywhere along this portion of varying cross-section, the distance from the center of gravity to the axis of rotation should not be smaller than that anywhere along the portion with constant cross-section.
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A vibratory compactor includes a plate which is adapted to contact a substrate to be compacted, and a vibratory member which is mounted atop the plate for vibrating the same. The member includes imbalance elements mounted for rotation about an axis which is substantially parallel to the general plane of the plate. The imbalance elements are mounted for movement to and from a position which they assume once during each revolution. The compactor is further provided with a driving member for driving the imbalance elements in rotation.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method for using solid phase extraction materials to purify nucleic acid samples contaminated with proteinaceous material.
2. Background
T. Maniatis, et al. [Molecular Cloning - A Laboratory Manual, (New York: Cold Spring Harbor Laboratory, 1982), pp 458-460] describe a method of purifying nucleic acids based on the procedures described by K. S. Kirby [Biochim. J., Vol. 66, 494-504 (1957)] and J. Marmur [J. Mol. Biol , Vol. 3, 208-218 (1961)]. This method uses phenol in a liquid/liquid extraction procedure, whereby the protein contaminating an aqueous nucleic acid sample is extracted into the phenol phase, leaving the nucleic acid in the aqueous phase. This nucleic acid purification procedure may actually involve a series of liquid/liquid extractions, in which an aqueous volume of nucleic acid sample is sequentially extracted with equal volumes of liquified phenol, phenol/chloroform/isoamyl alcohol (50/48/2), and chloroform/isoamyl alcohol (96/4). After each extraction, the organic phase containing protein (and some nucleic acid) is back-extracted with an aqueous buffer to recover any nucleic acid extracted into the organic phase. The aqueous nucleic acid sample must then be exhaustively extracted with diethyl ether to remove any residual phenol, chloroform, or isoamyl alcohol. Finally, the residual diethyl ether is removed either under reduced pressure or by blowing nitrogen over the sample for ten minutes. Removal of the residual organic solvents is of paramount importance, as they would otherwise interfere in subsequent cloning or hybridization procedures in which the nucleic acid might be used.
Although phenol extraction is a very effective method for the purification of nucleic acid samples and is very widely used, the procedure is also labor-intensive and time-consuming. Other disadvantages of this technique include the hazards (chemical irritant, carcinogen, stench and flammability) associated with the use of the organic solvents (phenol, chloroform, isoamyl alcohol and diethyl ether).
A second method of nucleic acid purification is based on the preferential adsorption of nucleic acids using NENSORB 20™ Nucleic Acid Purification Cartridges (DuPont). A proteinaceous DNA sample is passed through a column of NENSORB.sup.™ particles, binding the DNA to the particles, and allowing most of the proteinaceous material to be washed from the column with an aqueous buffer. The bound nucleic acid is then desorbed from the particles by passing 20% aqueous ethyl alcohol (or 50% aqueous methyl alcohol) through the column and the DNA is collected in the column effluent Prior to use of the DNA in cloning or hybridization, the alcohol must be removed from the DNA solution by pulling a vacuum on the sample for several hours.
The use of NENSORB™ has other limitations The NENSORB™ material, besides binding nucleic acid, also binds protein to a variable extent This not only limits the capacity for quantitatively binding nucleic acid from a sample heavily contaminated with proteinaceous material (e.g., blood serum, tissue homogenate), it also affords the possibility that some loosely bound protein may elute with the nucleic acid when the latter is desorbed from the NENSORB™ by the use of aqueous alcohol. Three different solvents are needed to activate the NENSORB™ column, wash the unbound protein from the column, and then elute the nucleic acid from the column. Nucleic acid is eluted from the column in a solvent (20% ethyl alcohol or 50% methyl alcohol) that is incompatible in protocols of subsequent uses of the nucleic acid (e.g., cloning, hybridization assays, etc.). The purification procedure using NENSORB™ can be time-consuming, requiring an hour or more to purify a single sample of nucleic acid.
C. A. Thomas et al., Analytical Biochemistry, Vol. 93, 158-166 (1979), disclose the use of glass fiber filters to adsorb protein and protein-DNA complexes from aqueous DNA samples. This method suffers from the following disadvantages: (1) The aqueous sample of DNA must contain at least 300 mM NaCl for the protein to bind effectively to the glass fiber filter. This relatively high salt concentration would have to be lowered by removing the salt from the DNA sample (or diluting the solution) prior to further use of the DNA in biological reactions, such as digesting the DNA with a restriction enzyme. (2) The recovery of DNA from the filter is high only if the filter is extensively washed with an aqueous buffer. (3) The low specific surface area (approx. 2 m 2 /g) of the glass fibers results in a low protein-binding capacity of the glass fiber filter. The maximum protein-binding capacity is estimated to be 8.5 mg of bovine serum albumin (B$A) per gram of glass fiber filter.
B. Vogelstein et al., Proc. Natl. Acad. Sci. U.S.A., Vol. 26, No. 2, 615-619 (1979), disclose a method for separating DNA from agarose by binding the DNA to glass, preferably glass powder, in the presence of NaI. The DNA was removed from the glass by elution with Tris·HCl, pH7.2/0.2M NaCl/2 mM EDTA. It is also disclosed that silica gel and porous glass beads are unsuitable for DNA purification.
J. Kirkland, J. Chromatographic Sci., Vol. 9, 206-214 (1971), discloses the preparation of surface-modified silica gels by reacting silane reagents with the surface of the porous shell of Zipax™ controlled-surface chromatographic support.
J. Kohler, et al., J. Chromatography, Vol. 385, 125-150 l(1987), disclose the preparation of fully hydroxylated calcined silica by the dissolution and redeposition of silicic acid.
T. Watanabe et al., J. Solid-Phase Biochem., Vol. 3, 161-173 (1978), discloses the preparation of immobilized tannins for protein adsorption.
The object of this invention is to provide an improved solid-phase extraction procedure for removing proteinaceous contaminants for nucleic acid samples. The method should be capable of removing large proportions of proteins from minute quantities of nucleic acid and recovering the latter in a biologically active state. The method should also be rapid, convenient, provide quantitative recovery of the nucleic acid and minimize the use of hazardous materials. It should also not introduce contaminants or impurities into the nucleic acid sample that may interfere in subsequent uses of the nucleic acid.
SUMMARY OF THE INVENTION
The process for separating the proteinaceous materials from nucleic acids involves contacting a solution containing the proteinaceous materials and nucleic acids with a solid phase extraction material capable of binding proteins to form bound and unbound fractions and then isolating the unbound fraction containing the nucleic acids.
DETAILED DESCRIPTION OF THE INVENTION
The solid phase extraction materials which are useful in the claimed process for the separation of proteins and nucleic acids are particulate solid materials with very high affinities for proteinaceous materials and very low affinities for nucleic acids. The solid phase extraction materials are characterized by having large specific surface areas with high concentrations of mildly acidic surface hydroxyl groups and low surface concentrations of polyvalent cationic species.
Solid phase extraction materials with large specific surface areas are preferred due to their capacity to remove large amounts of proteins. Preferably, the specific surface area of the extraction material is at least 50 m 2 /g; more preferably, it is at least 100 m 2 /g. These high surface areas are due to the presence of pores throughout the particulate material. The pores should be >60 Å effective diameter and, though there is no upper limit on the pore diameter, a reasonable limit of 500 Å is preferred in order to maintain a high specific area. The preferred range is 60 Å to 50 Å.
High concentrations of mildly acidic hydroxyl groups on the extraction material serve both to increase the affinity of the extraction material for proteinaceous compounds and to decrease its affinity for polyanions such as nucleic acids. The minimum effective concentration of mildly acidic hydroxyl groups is 0.1 μmole/m 2 . Preferably, the concentration of mildly acidic hydroxyl groups is 1-8 μmole/m 2 ; more preferably, it is 8 μmole/m 2 .
Preferably, the pK a of the surface hydroxyl groups is between 6 and 10.
The concentration of polyvalent cationic species on the surface of the solid phase extraction material should be minimized to prevent the complexation of anionic nucleic acids by cationic surface species. Trivalent metals such as iron and aluminum are particularly deleterious to the performance of the extraction materials.
Solid phase extraction materials with the desirable properties discussed above may be prepared in a number of ways, using either a homogeneous particulate material or a core particulate material on whose surface the desired functional moieties are introduced via chemical reactions. For the former case, rehydrated silica gel has been found to possess the desired properties. Silica gel intrinsically possesses a large surface population (8 μmole/m 2 ) of mildly acidic (6<pK a <10) hydroxyl groups and thus meets the primary requirements above. It is also very effective at adsorbing proteinaceous material. However, the surface of the silica gel must be freed of polyvalent cationic species if nucleic acids are to be prevented from being adsorbed on the surface of the silica particles. This can be achieved is several ways.
The preferred method involves the rehydroxylation and purification of the surface layer of the silica particle by dissolution and reprecipitation of the surface layer of the particles according to Kohler et al., J. Chromatography, Vol. 385, 125-150 (1987). In this procedure, the outer surface of the silica particles is dissolved in a dilute solution of hydrofluoric acid at an elevated temperature. The dissolved silica is then reprecipitated onto the surface of each particle by allowing the solution containing the dissolved silica to cool to room temperature where it has a lower solubility in aqueous media. As the layer reprecipitates, contaminants present in the outer layer of silica which had been dissolved remain in the solution and an essentially pure layer of silica is formed around the core particle.
Alternatively, polyvalent metallic contaminants may be leached from the silica by treating it sequentially with moderately concentrated hydrochloric and nitric acids at elevated temperatures. This process solubilized and extracts metallic impurities on the surface of the silica gel particles, leaving a surface which is essentially pure silica.
A third method of preparing the solid phase extraction material is to polymerize a thick layer of organic material containing a large population of mildly acidic hydroxyl groups around the surface of a porous support material. This can be done by allowing an organic silane containing the desired chemical functionality to react with silica, where the silane will cross-link with itself and with the silica particles to form a thick immobilized layer of organic polymer [J. Kirkland, et al., J. Chromatographic Sci., Vol 9, 206-214 (1971)] containing the desired population of mildly acidic hydroxyl groups. Whereas the hydroxyl groups impart the surface with the ability to adsorb large quantities of proteinaceous material, they also shield the nucleic acids from any polyvalent cationic species in the core particle below the layer of organic polymer and thus prevent nucleic acids from binding to the solid phase extraction material. Numerous organic silanes could be used for this reaction. For example, use of silanes to immobilize phenol (pK a =9.9), beta-napthol (pK a 9.6) or tannin (polyhydroxycarboxylic acids) onto the surface of support particles would provide useful solid phase extraction materials. Useful support materials may include silica, cellulose, agarose and other materials which possess a large population of active surface groups.
By whatever method of preparation of the solid phase extraction material, at least two protocols can be implemented for its use in removing proteinaceous contamination from samples of nucleic acids. According to the first protocol, a quantity of the particulate solid phase extraction material is added to a volume of sample that is to be deproteinized. The mixture is gently agitated to keep the particulate material in suspension. Because of the small size and large surface area of the solid phase extraction material, diffusion and adsorption of the proteinaceous material to the solid phase extraction material is rapid (on the order of minutes). The particulate material containing the adsorbed protein is then separated from the aqueous nucleic acid sample by any convenient means, e.g., centrifugation or filtration. This protocol is most effective when a large volume (>1 mL) of sample contains small quantities of protein and thus only a small quantity of particles (e.g.,<10 mg) is required for quantitative removal of the protein.
In a second protocol, the solid phase extraction material is packed into a column and the aqueous sample is passed through the column. To accomplish this, a quantity of particles is weighed into a spin column and packed by tapping the sealed end of the column onto the bench top. The column may also be spun at high speed in a centrifuge; the centrifugal force packs the particles tightly in the bottom of the column. The column is then wetted by pipetting a volume of the appropriate buffer (a volume at least equal to the volume of particles in the column) onto the column and the buffer is then allowed to seep down into the bed of the column. The excess buffer is then removed from the column bed by spinning the column at high speed in a centrifuge for about 30 sec. Any buffer eluted from the column bed is discarded. The column is now ready to accept the sample of nucleic acid which is to be deproteinized; the sample is pipetted onto the head of the column and allowed to seep down into the bed of the column, where the proteinaceous material binds to the particles and the nucleic acids remain in solution. The column is next spun at high speed in a centrifuge to elute the aqueous phase containing the nucleic acids into a collection tube. Recovery of nucleic acid from the column is typically >80% of the quantity applied to the column. The recovery can by improved to about 95% if a small volume (typically 1/3 to 1/2 the volume of sample originally applied to the column) of the appropriate buffer is pipetted onto the head of the column and spun through at high speed in the centrifuge. This washes any trapped nucleic acid through the column bed and this wash should be added to the column effluent containing the bulk of the nucleic acid. This protocol works best for samples that are heavily contaminated with proteinaceous material, when it is necessary to use a large quantity of particles (relative to the volume of the sample). Also, this protocol is useful when a very small volume of sample (e.g., 50 μL) must be deproteinized and implementing the preceding method would be cumbersome.
Several constraints can be placed on the nature of the buffers employed in the column wetting step and in the column wash step as outlined previously. The chemical nature of the buffer does not appear to be significant, though the use of salts of polyvalent metal cations (e.g., Al, Fe, Ti, etc.) should be avoided. Standard biochemical buffers such as TE (10 mM Tris·HCl, 1 mM EDTA, pH 6.75), STE (10 mM Tris·HCl, 100 mM NaCl, 1 mM EDTA pH 7.0) or PBS (120 mM NaCl, 2.7 mM KCl, 10 mM phosphate pH 7.4) work very well. Generally, the pH of the buffer should be in the range of 6 to 7.5; at lower pH values, nucleic acid may bind to the solid phase extraction material, resulting in reduced recoveries, whereas at high pH values, the support may dissolve since silica gel has a significant solubility in alkaline solutions. By the same token, if the sample of nucleic acid has a pH outside of the above range, it must be neutralized to a pH of 6 to 7.5 prior to applying it to the column for removal of proteins. The preferred pH range for all buffers and samples would be in the range of 6.5 to 7.0.
The diameter of the pores of the solid phase extraction material should be large enough to allow entry of proteins so they may be adsorbed onto the surface of the internal pores. This will maximize the capacity of the support for removing protein from samples. Pores must also be large enough to prevent nucleic acid from becoming trapped in the pore volume. It has been found that minimum pore diameters somewhere 60 and 150 Å provide the required characteristics. There is no critical upper limit on the pore diameter, though as the pore diameter of the particle increases, the specific surface area decreases. Thus, a reasonable upper limit of 300 to 500 Å can be defined. Particles with pore diameters larger than this limit have reduced surface area and, consequently, reduced protein binding capacity.
The solid phase extraction material is useful for removing proteinaceous contaminants from a wide range of nucleic acid samples. Demonstrated uses include removal of enzymes from restriction digests, removal of alkaline phosphatase from dephosphorylation reaction mixtures and removal of kinase enzymes from labeling reaction mixtures. It is anticipated that other common enzymes such as reverse transcriptase, DNA polymerase, DNA ligase, and terminal transferase, which are commonly used in molecular biology, could also be removed from nucleic acid samples under the appropriate experimental conditions.
In addition, the solid phase extraction material has utility for the isolation and purification of nucleic acids from numerous biological samples. The material has been demonstrated for purification of DNA from organisms in samples of whole blood; it is anticipated that similar isolations from other samples of clinical interest, such as sputum, urine, feces, and tissue would be possible once the appropriate purification protocol has been developed. Such purified nucleic acid samples should be directly usable in clinical hybridization assays. Furthermore, the solid phase extraction material should have utility for the isolation and purification of nucleic acids from organisms grown in culture media expressly for the purpose of producing DNA for cloning purposes or other genetic engineering uses.
The solid phase extraction material is useful for removing proteinaceous impurities from a wide range of nucleic acids. For example, the material can be used to remove kinase enzymes which are used in the radiolabeling of mononucleotides such as dATP, dCTP, etc. The material has also been used to remove alkaline phosphatase from a mixture of DNA ranging from 125 base pairs (bp) to 21,226 bp. The material has been used extensively with pBR322 DNA (4362 bp). In addition, the material has been used with intact lambda DNA (49,000 bp) and no degradation of this DNA by mechanical shearing was observed. Larger strands of DNA may be susceptible to degradation by shear forces as they pass through the column of solid phase extraction material, though this is not known with certainty. This problem could be minimized by using a larger particle size for producing the solid phase extraction material, thereby reducing shear forces in columns packed with such particles.
The process of this invention for the deproteinization of samples containing nucleic acids has the following advantages over currently used methods:
1. Because the solid phase extraction material is essentially insoluble in appropriate aqueous buffers, it will not dissolve in the nucleic acid sample and thus subsequent procedures (e.g., extractions) to remove it are not needed as in the phenol/chloroform extractions.
2. The nucleic acid is eluted in an aqueous medium that is essentially identical (except for the removal of proteins) to the medium in which it was applied to the column. Thus, the nucleic acid is in a solvent that is compatible with subsequent biological procedures in which it is used. No contaminants (i.e., phenol, chloroform, ethanol, etc.) are present to inhibit or deactivate enzymes used in subsequent biological procedures.
3. The purification protocol using this material requires 5 to 10 min to execute for one sample, whereas procedures based on phenol/chloroform extractions or NENSORB™ can require one hour or more. In addition, processing additional samples requires two min per sample.
4. No special reagents are required to perform this procedure. TE (pH 6.75) is an acceptable buffer for wetting and washing the column and this buffer is available in all labs which work with nucleic acids. In addition, the need for toxic or dangerous reagents is obviated.
5. Recovery of nucleic acids, is high, typically 80-95%.
6. Unlike purification methods based on adsorption of DNA to a support, this method does not shear large fragments of DNA. Thus, the integrity of the sample is maintained. Shearing of DNA is possible in methods based on adsorption of the nucleic acid to a solid phase material because with long fragments of DNA (e.g., 10 kilobase pairs or more), the two ends of the strand of DNA may be adsorbed to two different particles simultaneously and when agitated, the two particles move in different directions and pull the strand of DNA into two smaller fragments. Since in the procedure of this invention, the DNA is not adsorbed to the solid phase (the protein is instead), this degradation of the DNA is not possible.
The following examples are intended to illustrate the invention.
EXAMPLES
General Methods and Reagents.
pBR322 DNA and PST restriction enzyme were obtained from Pharmacia, Inc., Piscataway, N.J. 10 x PST restriction digestion buffer contains 500 mM NaCl, 100 mM Tris HCl pH 7.5, 100 mM MgCl 2 and 10 mM dithiothreitol. Calf intestinal alkaline phosphatase was obtained from Boehringer Mannheim Biochemical, Indianapolis, Ind. BCIP (5-bromo-4-chloro-3-indolyl phosphate) was obtained from Bethesda Research Labs, Gaithersburg, Md.
Example 1
Preparation and Use of Silane-Treated Silica Gel
A. Preparation of the Silica Support.
Fractosil 500 (20.5 g, E. Merck, Darmstadt, W. Germany) was washed with three 100 mL aliquots of 25% (v/v) nitric acid at room temperature by suspending the silica particles for 10 min in the aqueous acid and then decanting the excess acid once the particles had settled to the bottom of the beaker. The acid-treated particles were exhaustively rinsed with distilled, deionized water until the supernatant had attained a pH of 5.5. The particles were then transferred to a Buchner funnel fitted with medium porosity filter paper, rinsed with high purity methanol (3×100 mL) and dried for 1 h at 80° C. (630 mm Hg).
B. Polymerization of Aminophenyltrimethoxysilane onto the Silica Support.
Aminophenyltrimethyoxysilane (4.0 mL, Petrarch Systems, Inc., Bristol, Pa.) was added to distilled, deionized water (24 mL) and isopropyl alcohol (12 mL) in a round-bottom flask fitted with a reflux condenser and a magnetic stirbar. The resulting mixture was stirred until the silane was completely dissolved. Acid-washed silica particles (6.1 g) were added to the silane solution and the mixture was refluxed for 2 h at 81° C. Glacial acetic acid (3.5 mL) was added to the flask and the mixture was refluxed for an additional hour. The suspension was allowed to cool to room temperature, after which time the silica particles had settled to the bottom of the flask. The black supernatant was decanted and the particles were exhaustively washed with high-quality methanol until the wash liquid was colorless. The aminophenyl-derivatized silica particles were then collected on a Buchner funnel and air was pulled through the particle bed to remove residual alcohol. The particles were further dried under a medium intensity lamp. Carbon and nitrogen analysis of the particles indicated a thick layer of carbonaceous material had been polymerized onto the surface of the silica particles (6.27% C., 1.13% N).
C. Diazotization of the Silane-Treated Support
The aminophenyl-derivatized silica gel (6.90 g) was added to an ice-cold solution of water (10.0 mL) and concentrated sulfuric acid (7.0 g), and the particles suspended in this solution by magnetic stirring. Finely crushed ice (approx. 17 g) was added to the above mixture and then a solution of sodium nitrite (2.24 g) in water (5.33 dropwise over a period of 8-10 min. The temperature of the mixture was maintained between 0°-5° C. during this time. The particles were allowed to settle and then the supernatant was decanted from the mixture. The particles were then washed three times by suspending them in 100 mL of cold water, allowing the particles to settle, and decanting the supernatant. The resulting particles, in which the surface amines have been converted to the corresponding diazonium salts, were used in the hydrolysis reaction described below.
D. Hydrolysis of the Diazonium Salt
Concentrated sulfuric acid (32 mL) was added to water (24 mL) and this mixture was heated to boiling (approx. 160° C.). The diazonium salt-containing particles were added slowly to the hot acid while maintaining boiling with a subdued effervescence from the nitrogen gas evolved from the decomposition of the diazonium salt. The mixture was boiled for approximately 5 min, and then placed in an ice bath to speed cooling. The acidic supernatant was decanted from the particles which were then washed with distilled, deionized water (5×200 mL). The particles were collected on a Buchner funnel fitted with medium porosity filter paper and rinsed with methanol (200 mL). Air was pulled through the particle bed to remove residual methanol and the particles were dried under a medium intensity infrared lamp. Elemental analysis revealed that the particles contained 0.55% carbon and less than 0.01% nitrogen by weight.
E. Removal of Protein Using Silane-Treated Silica Gel
The silane-treated silica gel described in part D above was tested for its effectiveness in removing a model protein (bovine serum albumin, BSA) from solution, as well as for its lack of binding to DNA (salmon sperm DNA). Aliquots of BSA were placed in various phosphate buffers (pH=5.0-7.0), the samples mixed with 250 mg of silane-treated silica gel and then the solutions separated from the silica gel by pelletizing the silica particles in a centrifuge. The initial buffered protein solution and the filtrate were analyzed by uv absorbance (200-480 nm). Comparison of the uv spectra showed that protein removal was always >90%. Similar testing using aliquots of salmon sperm DNA showed that DNA recovery was always >85%.
Example 2
Nucleic Acid Purification Using Hydrofluoric Acid-Treated Silica Gel
A. Preparation of Rehydrated Silica Gel.
Silica gel (140 g, PSM300 Zorbax, lot 9, Du Pont) was heated in a quartz crucible at 975° C. for 2 h in a muffle furnace, and then 15 g of the cooled silica gel was placed in a round bottom flask fitted with a reflux condenser. Distilled, deionized water (150 mL) containing 75 ppm HF was added to the flask and the mixture was refluxed at 110° C. for 72 h. The mixture was allowed to cool to room temperature, and then the silica gel was washed with 1 L of distilled, deionized water. The silica gel was boiled overnight in water (150 mL), washed sequentially with water (500 mL) and acetone (300 mL), and finally dried at 110° C. for 5 h.
B. Use of Rehydrated Silica Gel.
To Tube A were added 1 μg (15 μL) of pBR322 DNA, 32 units (l2 μL) of PST restrictive enzyme, 6 μL of 10 x PST restrictive digestion buffer (a low strength restrictive buffer) and 37 μL of water. The contents of this tube were mixed and incubated at 37° C. for 1.25 h. To Tube B were added reagents identical to those in Tube A. However, immediately after mixing, the contents of this tube were pipetted onto the head of a spin column containing 60 mg of hydrofluoric acid-treated silica gel. The column had been packed and wetted with 1 x PST restriction buffer immediately prior to adding the sample. The sample was allowed to seep down into the column bed and the column was spun for 5 min in an Eppendorf centrifuge (Model 5412) and the effluent was collected. An aliquot of the column effluent was removed to a third reaction tube (Tube C) and 1 μL (16 units) of PST restriction enzyme was added The contents of this tube were mixed and incubated for 1 25 h at 37° C. Aliquots of Tubes A-C were then mixed with agarose gel-loading buffer (0.25% bromophenol blue, 0.25% xylene cyanol, and 30% glycerol in water), and a portion of each was applied to a 0.7% agarose electrophoresis gel (0.105 g agarose, 14.8 mL TBE buffer containing 0.5 μg/mL ethidium bromide) in a BioRad Mini-Cell Submarine Electrophoresis Device The gel was run at 100V applied potential for about 4 h in a 0.5X TBE Buffer (0.5X TBE=0.0445M tris-borate, 0.0445M boric acid, 0.001 M EDTA, pH 8 0). Photographs of the gel were taken via transillumination with 254 nm UV light.
A linearized DNA fragment of length equal to a linearized pBR322 standard was obtained from Tube A, indicating that the PST restriction enzyme cut the circular pBR322 in one place. The DNA from Tube B ran as circular DNA; no DNA band was observed at the position on the gel corresponding to linearized pBR322, indicating that the DNA had not been cut by the enzyme, i.e., the enzyme had been removed by passage through the column. A linearized DNA fragment of length equal to a linearized pBR322 standard was also obtained from Tube C, indicating that the DNA could be cut by the restriction enzyme and that passing the DNA through the column did not alter the DNAs biological activity or remove any of the necessary buffer components (e.g., MgCl 2 ); it removed only the PST restriction enzyme.
This Example demonstrates that passage of a sample which contains DNA and proteins through a spin column containing rehydrated silica gel effectively removes those proteins, e.g. PST restriction enzyme, from the sample. It also indicates that the DNA collected in the effluent from the column is biologically active and that the column does not add impurities to the DNA that would inhibit enzymes used to modify the DNA in subsequent biological reactions.
Example 3
Removal of Eco RI Restriction Enzyme
The procedure described in Example 2 was repeated using Eco RI restriction enzyme and buffer (a medium strength buffer) in place of the PST restriction enzyme and buffer. Only circular pBR322 DNA was observed in the column effluent from tube B, indicating that passage of the mixture through the column had removed all of the Eco RI restriction enzyme before it could cut the DNA. .
Example 4
Removal of Sal I Restriction Enzyme
The procedure described in Example 2 was repeated using Sal I restriction enzyme and buffer (a high strength buffer) in place of the PST restriction enzyme and buffer. Only circular pBR322 DNA was observed in the column effluent from tube B, indicating that passage of the mixture through the column had removed all of the Sal I restriction enzyme before it could cut the DNA.
Example 5
Preparation of Rehydrated Silica Gel Using Hydrochloric and Nitric Acids
Silica gel (PSM300 Zorbax, DuPont) was first heated at 300° C. for 2 h, and then at 540° C. for 21 h in a quartz crucible in a muffle furnace. Twenty grams of this silica gel were then placed in a covered Teflon™ beaker containing 500 mL of 10% (v/v) hydrochloric acid and the mixture was heated at 100° C. for 4 h. The mixture was allowed to cool to room temperature for several hours and then filtered. The silica gel was washed with 1 L of distilled, deionized water and then transferred to a Teflon™ beaker containing 500 mL of 10% (v/v) nitric acid. The mixture was heated at 100° C. for 4 h, allowed to cool to room temperature and then filtered. The silica gel was washed with 1 L of water and then the hydrochloric and nitric acid washes were repeated. Finally, the silica gel was heated in distilled, deionized water (500 mL) for 4h at 100° C., allowed to cool to room temperature, filtered, washed with distilled, deionized water (1.5 L), rinsed with acetone (300 mL) and dried at 110° C.
A portion of this rehydrated silica gel was tested for DNA recovery as described in Example 1; 87.2% of a 1 μg sample of DNA was recovered.
Example 6
Removal of Alkaline Phosphatase from Dephosphorylation Reaction Mixtures
Linearized DNA (pBR322 DNA digested with PST restriction enzyme) was dissolved in 80 μL of dephosphorylation buffer (50 mM Tris·HCl, 1 mM EDTA, pH 8.2) and 1 μL (0.5 units) of calf intestinal alkaline phosphatase was added. The mixture was incubated at 37° C. for 30 min. A 40 μL aliquot of the reaction mixture was removed and 7.6 μL of 0.25 M HCl was added to the aliquot to adjust the pH to 6.0. The neutralized aliquot was then spun through a 40 mg column of rehydrated silica gel, prepared as in Example 2, which had previously been packed and wetted with dephosphorylation buffer (pH 6.0).
The recovered column effluent was then analyzed for active alkaline phosphatase in an enzyme assay: To the column effluent was added 10 μL of 1 M Tris·HCl (pH 8.0) to adjust the pH to 7.8. The aliquot was then added to 100 μL of assay buffer containing 0.1 M Tris HCl pH 9.5, 0.1M NaCl, 50 mM MgCl and 0.22 μg/mL BCIP, a colorless substrate for the enzyme alkaline phosphatase, which is converted by the enzyme to a colored product. The assay reaction was allowed to proceed for 2 h, and then the insoluble colored product was collected onto 2 mm diameter filters.
Control reactions which contained 0.25 units of active alkaline phosphatase yielded very strong blue colors. Dilutions of 0.0025 and 0.00025 units of alkaline phosphatase also produced blue colors. No blue precipitate was visible from the column effluent which originally contained 0 25 units prior to passing through the column, indicating that the column removed at least 99.99% of the alkaline phosphatase from the sample as it passed though the column. To insure complete removal of the enzyme, it is necessary to acidify the alkaline phosphatase dephosphorylation mixture before passing it through the column. At pH 8.2, only 99.9% of the enzyme was removed.
In a similar experiment, up to 5 units of
alkaline phosphatase were removed with >99.99% efficiency using the procedure described above.
Example 7
Purification of Bacterial DNA from Whole Blood
Whole human blood collected from healthy donors was spiked with E. coli bacteria whose DNA contained an insert of herpes simplex virus DNA (5 μg, New England Nuclear Corp., Billerica, Mass.). The spiked blood sample (10 mL) was lysed in an Isolator™ tube (Du Pont) to disrupt the red blood cells. Intact bacteria were then isolated by spinning the Isolator™ tube in a centrifuge to form a 1.5 mL layer of bacterial sediment at the bottom of the tube and removing the supernatant. The bacteria were then lysed in 2% sodium dodecyl sulfate (SDS) for 30 min at 65° C. The bacteria from the blood sample were heated to 100° C. for 10 min to coagulate the bulk of the proteinaceous material. The coagulate was then sedimented in a centrifuge for 10 min, and the supernatant was recovered. The coagulated mass was then broken up in distilled water (1 mL) to wash any DNA from the mass, and after centrifugation, the supernatant was recovered and added to the original supernatant. This process was then repeated.
At this point, the freed bacterial DNA had been isolated in 4 mL of liquid that still contained a substantial quantity of protein (>10 mg/mL) as evidenced by the rusty red color imparted to the sample by the residual heme proteins (among others). To remove this residual protein, the sample was placed on the head of a spin column packed with rehydrated silica gel (prepared as in Example 2) that had been previously wetted with 4 mL of TE (pH 6.75) buffer. The sample was flowed into the bed of the column by low-speed centrifugation, and then the centrifuge was turned to high speed to force the DNA out of the column. After the effluent had been collected (10 min), the column was washed with 1 mL of TE (pH 6.75) buffer and the wash was added to the column effluent. The purified DNA sample was reduced to dryness under vacuum and then assayed in a standard hybridization filter assay.
12 μL each of 1M NaOH and 3M NaCl were added to the dried DNA sample dissolved in 100 mL of TE (pH 6.75) buffer. The sample was heated at 95° C. for 5 min to denature the DNA, cooled and stored on ice to prevent rehybridization.
Aliquots of the denatured sample were spotted on GeneScreen Plus™ (New England Nuclear) which had previously been assembled in a Hybridot Manifold (Bethesda Research Laboratory) and wetted with 5X SSC buffer (0.75 M NaCl, 0.075 sodium citrate, pH 7.0). The samples were slowly pulled through the filter by applying a vacuum and then the spotted samples were washed by pulling 100 μL of 3M ammonium acetate through the sample spots. The filter containing the spotted samples was removed from the manifold and prehybridized for 30 min at 50° C. in 1 mL of 0.5M sodium phosphate buffer (pH 7.0) containing 2 mg/mL sonicated salmon sperm DNA (Sigma Chemical Co., St. Louis, Mo.) and 1% (w/v) sodium dodecyl sulfate (SDS) (Sigma Chemical Co.).
A 32 P-labeled pHSV106 DNA probe (200 μL, 0.15 ug, Oncor, Inc., Gaithersburg, Md.) complementary to the HSV DNA insert in the E. coli DNA was added to the hybridization mixture. The filter was heated at 60° C. for 30 min and washed at 60° C. with two 50 mL aliquots of 0.1M sodium phosphate buffer (pH 7.0) containing 1% (w/v) SDS to remove any nonhybridized DNA probe. The filter was air-dried at room temperature and then autoradiographed overnight with Kodak RP film.
The results of this experiment and an analogous experiment using a standard phenol extraction procedure indicate that intact, hybridizable DNA was recovered from the spin column with about the same efficiency as from a phenol extraction. Moreover, blank blood samples (i.e., not spiked with the E. coli DNA) which were passed through spin columns did not yield dots in the hybridization assay, indicating that the rehydrated silica gel in the spin columns did not introduce interferences or contaminants into the sample.
Recovery of DNA from Various Silica Gel Samples
The Table shows the amount of DNA recovered from nine rehydrated silica gel samples (Samples A-I), four untreated, commercially available silica gels (Samples J-N) and two rehydrated silica gels (Samples O-P) which were intentionally contaminated with various metals.
TABLE______________________________________Silica % DNA Recovered______________________________________A 90.7B 89.9C 92.5D 76.1E 87.7F 91.5G 92.9H 89.4I 91.8J 22.4K 61.2L 66.3M 26.8N 41.3O 26.6P 18.4______________________________________ Sample A = Zorbax ™ silica (PSM2000, Du Pont) pore size 2000 Å, prepared according to Example 2A. B = Zorbax ™ silica (PSM1000, Du Pont), pore size 1000 Å, prepared according to Example 2A. C = Zorbax ™ silica (PSM300, Du Pont), pore size 300 Å, heated to 925° C., then prepared according to Example 2A. D = Zorbax ™ silica (PSM300, Du Pont), pore size 300 Å, heated to 850° C., then prepared according to Example 2A.
Sample A=Zorbax™ silica (PSM2000, Du Pont) pore size 2000 Å, prepared according to Example 2A.
B=Zorbax™ silica (PSM1000, Du Pont), pore size 1000 Å, prepared according to Example 2A.
C=Zorbax™ silica (PSM300, Du Pont), pore size 300 Å, heated to 925° C., then prepared according to Example 2A.
D=Zorbax™ silica (PSM300, Du Pont), pore size 300 Å, heated to 850° C., then prepared according to Example 2A.
Sample E, F=Zorbax™ silica (PSM300, Du Pont), pore size 300 Å, heated to 975° C., then prepared according to Example 2A.
G=300 Å pore size silica prepared from tetraethylorthosilicate.
H, I=Fractosil™ 500 (E. Merck), treated
with HCl/HNO 3 as described in Example 1A.
J=Zorbax™ silica (PSM150, Du Pont), pore size 150 Å, untreated.
K=Vydac™ silica (lot 3700, The Sep/a/ra/tions Group, Hesperia, Calif.).
L=Fractosil™ 500 (E. Merck), untreated.
M=Nucleosil-100-S (Machery-Nagel), West Germany), untreated.
N=Nucleosil-300 (Machery-Nagel, West Germany), untreated.
O=Sample F, intentionally contaminated with 500 ppm each of Fe, Mg and Na.
P=Sample F, intentionally contaminated with 500 ppm Al.
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The process for separating the proteinaceous materials from nucleic acids involves contacting a solution containing the proteinaceous materials and nucleic acids with a solid phase extraction material capable of binding proteins to form bound and unbound fractions and then isolating the unbound fraction containing the nucleic acids.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The Applicants claim the benefit of their provisional application No. 60/464,810 filed on Apr. 23, 2003.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to door systems, and more particularly to automatic door safety systems which use wireless links for sending information regarding the detection of a hazard condition or the operational status of the entire wireless system and hazard detection components of a system.
[0003] Automatic door operating systems are popular in commercial or residential settings. Such doors typically include the operation of overhead door systems, elevator doors or other automatic control systems to open and close doors in various categories. Such doors also typically provide for obstruction detection to prevent the door from continuing to close when the apparatus on the door senses an obstruction in the door's path. Such obstruction sensors and obstructions switches usually include means to activate internal contacting devices within such sensors when the switch is compressed when it strikes an obstruction during the operation of a door. Such switches may include normally open, compressible door edge cells which contain internal electrical conductors which contact each other upon compression of the cell.
[0004] Present systems utilize such door edge systems usually along the leading edge of the door in a location where the system is likely to become compressed when striking an object, compressing the internal conductors together causing an electrical path to be completed thereby providing a fault signal typically communicated by a control wire to the motor controller to stop operation of the door immediately.
[0005] In many environments it is desirable to monitor the safety switches and safety sensors typically utilized with power operated doors in a wireless environment, rather than require a 2-conductor or 4-conductor wire lead to track the operation of the door as it opens and closes. It is desirable to eliminate the wear and tear on such conductor as it tracks the door through many thousands of operations. In today's environment, motor operated doors typically are expected to last ten years or more thereby placing considerable physical wear and tear on the conductors which may track the motion of the door to facilitate the connection between safety edge sensors and the controller monitoring for obstructions indicated by such sensors. Eliminating such hard-wired connections is important, but maintaining failsafe reliability systemwide is paramount. Also important is an ability to continuously monitor a system regardless of whether the door being protected is actually in operation. The systems disclosed in the prior art lack such an important combination of features.
SUMMARY OF THE INVENTION
[0006] The present invention provides an automatic door control system which utilizes wireless links between the safety edge switches which detects hazard conditions to eliminate the need for control cable conductors to communicate between door edge sensors and the control unit monitoring the sensors. Desirable safety edge sensors typically also check for internal continuity on each side of the electrical switch which comprises elongated conductor foils within a safety edge switch to assure continuity on each side of the such switch. When a hazard condition is detected, a wireless signal is sent from the vicinity of the door edge safety sensor to the controller to stop operation of the door.
[0007] Further, the present invention disclosed allows for a fault signal to be generated should there be an internal failure of the door edge safety sensor such as to require communication of that fact, wirelessly, to the same controller. At the same time the system also provides for continuous fault monitoring of the wireless link between the sensor transmitter and the receiver utilized to communicate the transmitter signal to such controller. By providing a periodic signal from the transmitter to the receiver, the receiver recognizes that the communications path between the transmitter and receiver is operating. Such periodic monitoring can prevent failure of the entire system should the radio frequency link be disturbed because of equipment failure or such other environmental conditions such as electromagnetic interference created by other apparatus or equipment within the operating environment. Such a periodic signal provides a continuous status check. Depending on the battery life desired in the transmitter, such periodic status check signals should repeat on a short time basis to be assured that failure of the link during operation of the door will be noticed by the system quickly and a fault signal provided to stop operation of the door or take other action.
[0008] The system also provides a means to determine whether the door being protected is in motion, thereby signaling the transmitter to stay in continuous operation during the door movement to provide the ability for faster signaling to the receiver if a fault condition is detected. The door motion is detected using a secondary sensor such as a mercury switch or other vibration sensing switch to indicate to the transmitter that the door is moving and the transmitter should remain in an on condition through the entire operation.
[0009] After a predetermined period of time has passed since motion of the protected door has ceased, the transmitter is commanded back to a “sleep” mode to conserve battery power while continuing to periodically check the parameters of other safety features in the system such as the integrity of a door edge switch, battery voltage condition or other system tamper indicators. Further, the transmitter polls the receiver in the system on a periodic basis, in an exemplary embodiment five minute intervals, to assure that the transmitter and receiver are in communications and that all systems are nominal prior to the next cycling of the door being protected by the system.
[0010] The disclosed system consists of one or more transmitters and a receiver which communicate in the UHF radio range. Each transmitter is connected to a safety device, typically a two- or four-wire safety edge switch such as the Miller Edge™ switch, disclosed for example in U.S. Pat. No. 5,728,984, U.S. Pat. No. 4,785,143 and U.S. Pat. No. 4,396,814. The safety device is typically installed on the leading edge of a sliding door or garage overhead door. If a transmitter senses that it has hit an object, it communicates this to the receiver. The latter then actuates the associated relay as a control signal to the motion controller. Typically, a door/gate reversal is executed at this point. Speed of response and noise immunity are the most desired design features for transmitters and receivers employed in this type of system.
[0011] The transmitter and receiver used in the present invention has a unique radio frequency channel designator set by DIP switches. In addition each transmitter and receiver has an ability to uniquely address each other in the system so that multiple systems may coexist in one location.
[0012] In the example embodiment, each transmitter has a primary and a secondary switch input. Such connections may be for edge switches which are of the Normally-Open (NO) or Normally-closed (NC) types. It is anticipated that some users will have, for example, a secondary door “break-out” signal which must be responded to in a different manner as that of the primary signal from an edge obstruction switch device. A DIP switch controls the desired NO verses NC state.
[0013] Either two- or four-wire safety devices may be connected to the system. In the former case, shorting jumpers may be installed on the transmitter board to account for this type of edge switch device. In the latter case, four-wire, a fault to any of the input lines will cause the transmitter to issue a fault indication.
[0014] The transmitters in the system are battery powered and typically each will have a 9V Lithium battery. The transmitters are designed to be highly efficient and they spend a majority of time in a dormant or inactive state. The unit automatically wakens itself on a rapid cycle. One of the fundamental trade-offs in a system employed as with the present invention is speed of response and noise immunity vs. battery longevity. While it is desired to keep the transmitter size as small as possible, it is possible to accommodate larger capacity batteries of various types if necessary for a particular application if longer life is of importance for a given application.
[0015] The transmitter checks its inputs every 18 milliseconds. It radiates a status signal every five minutes in a typical installation, even if the status is “Everything Okay.” The receiver expects to hear from each transmitter within a preprogramed amount of time, typically 2 to 5 minutes. If the receiver does not receive a signal from the transmitter, this itself is defined as a fault. The receiver can be programmed to wait a longer time to hear from the transmitter if desired to account for momentary signal loss or other temporary problem. In the event the expected signal is not received, the appropriate channel relay will then be actuated. When the transmitter detects a fault it generates a train of 24 signals to assure reception and response. This feature can be used in facilities with high EMI backgrounds.
[0016] Both transmitter and receiver are controlled by Microchip PIC parts though those skilled in the art may recognize that there could be a large amount of flexibility in modifying the design to obtain the same function using a variety of different integrated circuit designs.
[0017] The communication protocol between transmitter and receiver is simple and is designed to be as minimal as possible to speed the reaction time of the system. It is possible to support different responses for different contingencies. The communication protocol lets the receiver know exactly what the fault is, even if the end result is the same, such as a relay closure at the receiver. For example, a Maintenance-Required LED may be included which will be activated (along with the appropriate relay) to indicate a low battery situation, a tamper attempt, a secondary input sensor trip, or other fault indication.
[0018] The present transmitter design supports two different possible radio frequency design schemes. One method is based on a Micrel MICRF102 device with a quartz crystal frequency base. This method consumes more power and necessitates a careful software controlled start-up sequence. The transmitter has an LED and a connection for a buzzer as sensory outputs of operation.
[0019] The transmitter employs a low-inductance PCB-loop antenna. The receiver employs a Quarter Wavelength monopole antenna on a coaxial connector. Both transmitter and receiver are enclosed in boxes comprised of lightweight, high impact materials which are easily installed in the field.
[0020] The receiver is powered by 24 VAC, which is industry standard. In the preferred embodiment of the invention, the receiver supports up to three different channels, each with a 1A relay and a red fault LED. The same receiver may be configured to operate with only one or two relays. Each relay may be jumper-selected as NO or NC output. Additions to the receiver can support a green “Signal Received” LED as well as a yellow “Battery-Low” LED.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a block diagram of a typical installation of the various components used in the invention.
[0022] FIG. 2 is a block diagram illustrating an exemplary sequence of the operating steps of an exemplary embodiment of an automatic door safety system of the present invention.
[0023] FIG. 3 is a schematic diagram of an example of a multichannel wireless receiver utilized to practice the present invention.
[0024] FIG. 4 is a schematic diagram of a wireless transmitter utilized to practice the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0025] The following is a detailed description of the preferred embodiment of the Radio Frequency (“RF”) link system for an automatic door safety edge. The description is not intended to limit the scope, applicability or configuration of the invention in any way. However, the following description does provide a convenient illustration for implementing a preferred embodiment of the invention. Upon review of the following description it will occur to those skilled in the art that various changes may be made to the function and arrangement of the elements described in the preferred embodiment without departing from the spirit or scope of the invention as set forth herein and in the appended claims.
[0026] Referring now to FIG. 1 , a block diagram of the entire system 10 is presented. Door edge switch 12 is a membrane type switch which utilizes a door edge safety sensor in the present invention, mounted on the lower edge of an overhead garage door or some other rolling door or movable door, which may be used in a variety of applications whether commercial or residential. In a typical installation, a movable door, whether overhead or in an elevator for closing laterally, the door moves between the open and closed positions in response to a command from a door controller mechanism which itself drives the motors or chain drives to actuate the door. It is always desirable that obstructions be automatically and instantly recognized to halt operation of the door as a safety feature. Door edge switch 12 is most frequently configured to be placed along the leading edge of a movable door, such as an overhead door, to acuate the switch upon compression of switch 12 .
[0027] In conventional systems the door switch is hardwired through physical contact with a controller which, sensing actuation of the switch, signals the controller to stop motion or, as may be desired, to reverse motion and open the door. The prior art describes a variety of different systems utilized to present obstruction signaling for overhead doors or other types of doors and elevator systems, and the like, whether pneumatically or electrically controlled. It is desirable in many situations to eliminate the hardwired cabling between the door edge switch or similar control switching apparatus to the door controller such that both the wear and tear and the inconvenience of having a cable tracking the motion of an operating door can be eliminated. Over time such cables will fail from continued motion day to day and therefore either reduce the protection provided by the system or place the door out of service until the cable can be repaired or replaced.
[0028] In the present invention, system 10 , the information conveyed by switch 12 regarding obstruction detection is conveyed to a wireless transmitter 14 which itself is communicating with a receiver 16 through a radio frequency link 22 . Such transmitters and receivers have been employed in the past for a variety of different applications including, but not limited to remote control systems for car alarms, burglary systems and control of overhead doors.
[0029] In applying wireless or radio frequency techniques to present link 22 in system 10 , a problem arises regarding the assurance of reliability of the system. If transmitter 14 is signaling an obstruction condition signaled by door edge switch 12 , it would be appreciated that receiver 16 , normally placed in the vicinity of the door controller 20 , must receive information from transmitter 14 in order to command the door controller to take what action is desirable. Receiver 16 communicates to door controller 20 through path 34 normally a wired path with a connection directly from the receiver 16 to the door controller 20 . While this operation may be straightforward, in the event that transmitter 14 or receiver 16 is not functioning or, should RF link path 22 be obstructed for any reason whether temporary or permanently, it is necessary to account for such occurrences to provide the failsafe operation of system 10 . In that regard, one way to do so is to have transmitter 14 continually connected to receiver 16 through link 22 . In such fashion, receiver 16 could be programmed to take action if transmitter 14 failed or RF link 22 became ineffective. Such an “always on” condition has obvious power consequences because transmitter 14 is necessarily battery operated to take advantage of the wireless condition of mounting transmitter 14 on a particular door or other protected portal which contains switch 12 . While some systems in the prior art are designed to have a transmitter poll a receiver on a regular basis, perhaps every few seconds, the obvious consequence of battery life makes such a design undesirable. Other systems only poll the receiver while a door is actually operating and does not check the “health” of the entire system while in a standby mode.
[0030] In the present invention, system 10 provides a means to enable transmitter 14 to send information continuously upon actual operation of the rolling door or other moving door such that there is a continuous monitoring of the status of switch 12 . While in this active mode, obstructions encountered by switch 12 will be immediately conveyed from transmitter 14 to receiver 16 . To do this, transmitter 14 must be commanded to remain in an active condition only when the door is in operation. By using motion sensor 18 , transmitter 14 can be commanded to remain in the on mode, continually monitoring the condition of switch 12 , while the door being protected is in motion. To do so, it is necessary for transmitter 14 to be activated when the door is moving so that the continuous operation mode can be implemented.
[0031] Motion sensor 18 can be a variety of different mechanisms, but in the preferred embodiment the most effective means is to use a mercury switch or other switching means which are very susceptible to any vibration. A mercury switch or reed switch is in a position on the door to be protected. Placement of sensor 18 should be placed in a position on the door which is subject to the most vibration or movement during the operation of the door. Sensor 18 can continually signal transmitter 14 , through path 32 , that the transmitter should remain in an active condition transmitting its status at all times to receiver 16 through link 22 . Upon completion of the motion of the door, motion sensor 18 will cease being active and will discontinue signaling transmitter 14 through path 32 . After a preselected “time out,” normally one or two minutes, transmitter 14 can return to a standby mode by conserving transmitter battery power.
[0032] Transmitter 14 is designed to have several different features to enhance the safety of the system. First, transmitter 14 includes a tamper switch system which will signal receiver 16 when transmitter 14 is either removed, opened, or otherwise tampered with. Other such incorporated monitoring capabilities include measurement of battery voltage as well as provisions for additional secondary sensors other than motion sensor 18 . Such additional or secondary inputs could be for Infrared beam sensors, ultrasonic or RF motion sensors or other specific sensors designed for special applications. Such sensors can be integrated into the control protocol for operating the door or to stop the door upon the currents of other designed events. Further, transmitter 14 is designed to generate a signal over RF link 22 which is addressable such that the transmitter can coexist on a given channel at a given facility with other systems 10 operating nearby on other doors. In such a fashion, it can be appreciated by those skilled in the art that transmitter 14 may be selectable on a number of different operating channels such that multiple systems 10 can operate within a given facility with minimal interference between the system.
[0033] Transmitter 14 can operate on one of several channels that can be selected during installation. Further, transmitter 14 can encode defined addresses on a given channel to enable receiver 16 (which is configured to respond to a given transmitter 14 specifically configured to address a given receiver 16 ), to operate on a common frequency used by other systems within the facility. Using frequency agile transmitters, along with the system of addressable receivers for a given frequency, it can be appreciated that multiple systems 10 can operate within radio range of each other with negligible interference and without a given transmitter 14 signaling an unintended receiver 16 from a different system, even if operating on the same frequency. In the preferred embodiment as disclosed, the transmitter and receiver frequency as well as the address encoding is performed by conventional DIP switches or other methods to configure a given system 10 .
[0034] Continuing to consider FIG. 1 , one advantage of the present invention is the use of door edge switches 12 which utilize a failsafe system within the switch itself. FIG. 1 is comprised of two conductors within a compressible structure which is designed to make electrical contact upon compression of the switch material to signal contact with an obstruction. First door switch element 24 would contact second door switch element 26 as shown in FIG. 1 upon compression of the switch, thereby enabling a closed circuit, assuming that the configuration being used is a normally open switch configuration. It should be noted that the present invention can operate with a normally closed switch, a normally open switch or some other configuration because of the flexibility of the system as described below. In the preferred embodiment, a normally open switch 12 is used as suggested in FIG. 1 .
[0035] Utilizing a closed loop system on both switch element 24 and switch element 26 , it can be seen that continuity of the conductor can be measured at all times to be certain that the switch is in operating condition. From time to time it is possible that door edge switch 12 may be damaged or worn out by continual use and failure may not be detected during a normal inspection. In the event that one of the conductors within the door edge switch fails, it can be seen from FIG. 1 that continuity as measured across first switch conductor cable 28 or second switch edge conductor cable 30 would be broken. Transmitter 14 is designed to allow continuous monitoring of the continuity of switch element 24 and switch element 26 , thereby immediately being able to signal a fault condition if continuity of one side or the other side of the switch conductor is broken. Such an indication would not be possible in utilizing remote sensing or signaling systems which are configured only to work on more conventional door edge switches comprised of a single conductor on each side of the switching element.
[0036] Turning to FIG. 2 , a block diagram illustrating an exemplary sequence of the operating steps of one embodiment of the system is presented. Transmitter 14 begins in a standby mode 42 . If transmitter 14 becomes active, a decision is made whether it is because of an automatic awakening 44 or because a motion sensor for the door 18 has commanded the transmitter to an active state. If it is determined the transmitter has become active 44 , the system determines whether the preprogrammed elapse time 48 has occurred. Elapsed time 48 is programmed to be between two and five minutes depending on how frequently the user of system 10 would desire transmitter 14 to poll receiver 16 , testing both the link 22 and the general condition of the entire system. If the program elapse time 48 has occurred, transmitter 14 gets turned on as shown at 46 in FIG. 2 , and a short transmitter activation time results. If in fact the transmitter becomes active because of motion sensor 18 , evaluation of the program elapse time 48 is not necessary and the system proceeds to turn on the transmitter directly at 46 . As long as the door remains in motion at 50 the transmitter 14 remains active, checking to see if the door has hit something or encountered an obstruction 52 as well as continuing to check the system operation 54 during the period of time that the transmitter is in an active state. During this active state the transmitter conveys its status to the receiver at 56 and continues to operate through the loop as shown in FIG. 2 until the door motion is terminated. At step 50 when the door motion has terminated and the preselected time-out delay has expired, the system returns to a standby mode 42 as shown in FIG. 2 .
[0037] During the operation of the system, transmitter 14 can become active to transmit a fault condition such as low batter voltage, failure of the monitored edge sensing switches, tampering or other desired features. Transmitter 14 can be configured also to automatically awake into the active mode to convey such error or fault conditions to receiver 16 if desired to disable door controller 20 if desired. In a separate configuration, such fault conditions can present indicator outputs rather than a disabling condition. For example, both transmitter 14 and receiver 16 can provide fault indication LED light indicators showing a variety of conditions. A low battery condition on the transmitter 14 , tampering with the case of transmitter 14 , failure of door edge switch 12 continuity check, or failure of receiver 16 to be polled by transmitter 14 within a preprogrammed time period can provide fault indicator lights while at the same time disabling the operation of the door by signaling controller 20 and disabling operation until the system is inspected.
[0038] In a preferred embodiment, receiver 16 is designed to automatically signal controller 20 through path 34 if receiver 16 does not receive a signal from transmitter 14 while transmitter 14 is in the standby or inactive mode in between operation of the door. As an example, typical operation of the invention requires that receiver 16 be polled by transmitter 14 every five minutes when transmitter 14 is in the inactive or standby condition. Receiver 16 , failing to hear from transmitter 14 during preprogrammed time period would command the door controller to off or fault status shutting down system 10 until the system can be checked to determine the reason for the fault. In practice, it has been determined that receiver 16 can wait a multiple period of timed intervals to hear from transmitter 14 before determining that there has been a genuine fault in the system. It can be appreciated that the parameters to be used in a given system 10 would be dependent on the tolerance for a possible fault which the operator of the system determines is appropriate.
[0039] Turning now to FIG. 3 , a schematic diagram of a typical multichannel receiver for use in the present invention is disclosed. Receiver 60 is of conventional design and is used in the operation of system 10 in an exemplary embodiment. The illustrative design shown at 60 for receiver 16 is configured to operate with transmitter 14 in system 10 .
[0040] FIG. 4 shows the typical transmitter design which can be used effectively with receiver 60 . Particular note should be given to the design of the transmitter board 62 which incorporates a 4-conductor connection at 64 which allows connection of a 4-terminal door edge switch as shown at 12 in FIG. 1 . FIG. 1 discloses first switch conductor cable 28 and the second switch conductor cable 30 as it is configured with transmitter 14 . Such connections used on board 62 are shown at 64 , which allows for continuity checking across the entire length of a given door edge switch 12 , as discussed above. Connector 64 is integrated into the design of integrated circuit 66 which presents terminals which can be effectively used to provide sensing of the continuity switch element 24 and switch element 26 to provide a fault indication in the event that there is a loss of continuity between each side of the switch element as described in more detail above.
[0041] With the above, an automatic door system according to the various aspects of the present invention has been disclosed with reference to a particular preferred embodiment. It will be obvious to those skilled in the art that the system disclosed may be comprised of diagnostic systems that may be altered slightly to provide for specific requirements of a given installation. While the principles of the invention have been described in an illustrative embodiment, it should be apparent that many modifications of structure, arrangement, proportions, specific elements, as well as materials and components can be used in the practice of the invention. Improvements or adjustments not specifically described may be varied and in particular adapted for specific applications that warrant different operating requirements without departing from those principles as set forth above.
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An automatic door opening system utilizing wireless links to communicate from hazard or obstruction sensors to a controller to react to such conditions. The present invention allows the use of hazard, fault or obstruction switching devices which themselves utilize internal continuity monitoring in a wireless environment. Compressible hazard switch sensors which utilize internal, continuous conducting elements are continually monitored for breaks in such elements through continuity checks. A signal is generated from the wireless transmitter during door operation to indicate to the system that the link between the wireless transmitter and a wireless receiver is fully functioning at all times. The system can determine if an actual obstruction hazard is detected or if there is a loss of communications between the wireless transmitter and receiver link in the disclosed system while also allowing for wireless continuity checking between sensor switches utilized.
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CROSS REFERENCE TO RELATED APPLICATIONS AND CLAIM OF PRIORITY
[0001] This invention claims priority to the following co-pending U.S. provisional patent applications, which are incorporated herein by reference, in its entirety:
[0002] Manson et al., U.S. Provisional Patent Application Ser. No. 60/711,284, entitled “An Automated Method and Apparatus for Constructing Process Models and Managing their Synchronized Representations”. attorney docket no. 358008.00200, filed Aug. 24, 2005.
COPYRIGHT NOTICE
[0003] A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.
BACKGROUND OF THE INVENTION
Field of Invention
[0004] The present invention relates to natural language processing, the production of object models that mirror natural language, and the production of representations, such as diagrams, from natural language text descriptions. The present invention also relates to the production of textual descriptions of processes from the diagrammatic representations of the processes. The invention is more particularly related to a process modeling method for constructing a fundamental object structure from which a coordinated set of diverse representations may be uniformly generated.
SUMMARY OF THE INVENTION
[0005] The present inventors have realized the need to automate the production of a coordinated set of textual and graphical representations of processes. The present inventors have invented and developed a system for constructing a semantic object network as the fundamental structure from which these representations are uniformly generated. At a minimum, and as only one example of utility, the present invention helps identify requirements errors and provides a visual reference for understanding textual descriptions of systems, software, and other processes.
[0006] The present invention is a significant expansion of the techniques and processes described in Manson, U.S. patent application Ser. No. 09/883,693, filed Jun. 18, 2001, the contents of which are incorporated herein by reference in their entirety. The present invention is both an expansion of the syntactic and semantic representation mechanisms of Manson as well as an expansion of the utility for a user of a computer system equipped with the modeling capability. The present invention is not limited to the object model produced using Manson. Other methods of producing an object model may be utilized, including the adaptive method presented here.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
[0008] FIG. 1 is a block diagram of the components and communications within an architecture according to an embodiment of the present invention;
[0009] FIG. 2 is a screen shot of a user interface according to an embodiment of the present invention;
[0010] FIG. 3 is a screen shot of a dialog box for manual type assignment according to an embodiment of the present invention;
[0011] FIG. 4 is an illustration of a syntactic dependency structure (parse tree) according to an embodiment of the present invention;
[0012] FIG. 5 is a screenshot of a project hierarchy according to an embodiment of the present invention;
[0013] FIG. 6 is a screenshot of a project glossary according to an embodiment of the present invention;
[0014] FIG. 7 is an example of annotated text according to an embodiment of the present invention;
[0015] FIG. 8 is an example of an activity diagram according to an embodiment of the present invention;
[0016] FIG. 9 is an example of a use case diagram according to an embodiment of the present invention;
[0017] FIG. 10 is a screen shot of an object relationship diagram according to an embodiment of the present invention;
[0018] FIG. 11 is a screen shot of an object network map diagram according to an embodiment of the present invention;
[0019] FIG. 12 is a screen shot of an activity schedule diagram according to an embodiment of the present invention;
[0020] FIG. 13 is a screen shot of an action paradigm schema diagram according to an embodiment of the present invention;
[0021] FIG. 14 is a screen shot of an actor/object list diagram according to an embodiment of the present invention;
[0022] FIG. 15 is a screen shot of an object manager diagram according to an embodiment of the present invention;
[0023] FIG. 16 is a screen shot of a text/object linking diagram according to an embodiment of the present invention;
[0024] FIG. 17 is a screen shot of an object/object linking diagram according to an embodiment of the present invention;
[0025] FIGS. 18A and 18B are flow diagrams of an overview of processing according to an embodiment of the present invention;
[0026] FIGS. 19A and 19B are flow diagrams of an example interaction between a user, text processing, and lexicon manager according to an embodiment of the present invention.
[0027] FIG. 20 is a flow diagram of a syntactic processor according to an embodiment of the present invention;
[0028] FIG. 21 is a flow diagram of a semantic processor according to an embodiment of the present invention;
[0029] FIG. 22 is an example of an external processing module according to an embodiment of the present invention; and
[0030] FIG. 23 is an example of a rendering process module according to an embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] The following is a description of specific applications of a process modeling method which incorporates a sequence of discrete steps detailed in the subsections below. In summary, the described method constructs a semantic object network as the fundamental structure from which a coordinated set of textual and graphical representations are uniformly generated, and hence, automatically synchronized. Although this description is presented in a manner which strongly suggests that natural language text is an originating representation from which all other representations are constructed, it is important to realize that the method described below conforms to an MVC (Model/View/Controller) architecture, in which all of the representations (views) may be used (controlled) to manage the underlying network (model).
[0032] 1) System Architecture:
[0033] The preferred implementation of this process modeling method is manifested in a computer system called “Scenario,” which will be referenced by that name in what follows. Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts, and more particularly to FIG. 1 thereof, there is illustrated a block diagram of components and communications of an architecture according to an embodiment of the present invention (see Scenario 100 in FIG. 1 ). More specifically, Scenario 100 is functionally divided into a client component 105 (also called “Scenario Client”) and a server component 150 (also called “Scenario Server”), though this division does not necessarily entail a physical division requiring separate hardware components. From this purely functional perspective, it is possible to emphasize certain useful distinctions in system behavior such as the following: Scenario Client 105 hosts the GUI 110 (Graphical User Interface, see FIG. 2 ) functions of the system, while Scenario Server 150 hosts background processing functions such as the engine 180 and the DB 160 (DataBase).
[0034] 2) System Processing:
[0035] 2.1) Syntactic Processing:
[0036] 2.1.1) Text Editing:
[0037] In one embodiment, Scenario Client 105 provides a text editor 114 which is presented for use in a standard, windowed format (note 114 in FIG. 2 ). After a text 112 has been entered into this editor, the user activates process modeling. Scenario provides several alternatives, including:
pressing a model button 210 on the toolbar ( FIG. 2 ); selecting a model option 212 from a dropdown menu ( FIG. 2 ); and entering ctrl+m on the keyboard.
[0041] Scenario Client 105 then retrieves the entered text from the text editor 114 and forwards it to Scenario Server 150 for further syntactic and semantic processing (see engine 180 ).
[0042] 2.1.2) Text Parsing:
[0043] At the beginning of this step in a Scenario modeling process, as activated through the text view (see Sec. 2.1.1), the entered text is represented as a sequence of ASCII characters. The text parsing module 182 of Scenario Server 150 transforms this ASCII character sequence input into a coherent sequence (narrative) of token sequences (sentences) by identifying words and punctuation symbols as presented in the entered text, and then arranging these basic syntactic elements into their proper sentential contexts (i.e., making a determination of where the word and sentence boundaries are). All manner of idiomatic syntactic constructions such as abbreviations, contractions, capitalizations, hyphenations, acronyms and initialisms are handled appropriately. For example, a contraction is expanded into its two individual word elements, an initialism is identified as a special lexical type (initialism), and so on.
[0044] Scenario Server then forwards the parsed narrative for further syntactic processing (see FIG. 1 ).
[0045] 2.1.3) Basic Lexicon:
[0046] The basic lexicon 164 is an integral component of Scenario 100 . It contains a list of basic lexical terms. A lexical term is a pair consisting of a natural language token (word or punctuation symbol) and a virtual lexical type (ambiguous grammatical designation).
[0047] 2.1.4) Lexical Type Association:
[0048] As performed by Scenario Server, the process of lexical type association 184 matches each token in a narrative with its appropriate lexical type, in a manner consistent with the population of lexical terms found in the basic lexicon. This type assignment process is performed automatically for each recognized token (see Sec. 2.1.4.1), and performed manually for each unrecognized token (see Sec. 2.1.4.2).
[0049] 2.1.4.1) Automatic Type Assignment:
[0050] Scenario Server 150 recognizes a token for automatic lexical type assignment. Token recognition is performed, for example, using one of the following characterizations:
indirect morphological inference; and direct lexical reference.
[0053] Morphological inference depends on general suffix formation of a token, while lexical reference depends on specific string matching against entries in the basic lexicon. In either case, each recognized token in a narrative is paired with an appropriate virtual lexical type to form a lexical term.
[0054] 2.1.4.2) Manual Type Assignment:
[0055] If Scenario Server 150 does not recognize a token for automatic lexical type assignment, it alerts Scenario Client 105 to query the user for an appropriate lexical type assignment. In this case, Scenario Client 105 then launches the basic lexicon 116 interface, which presents the user with a dialogue box 300 (see FIG. 3 ) in which to select a type assignment for each unrecognized token in the current narrative. The choices for lexical type assignment presented in this way are limited, but generous enough in scope to cover all relevant syntactic contingencies in standard usage. The lexical type choices are, for example, verb, noun, adjective, and proper name.
[0056] Upon performing the required lexical type assignments for all tokens in the narrative being modeled, Scenario Server 150 has transformed a sequence of token sequences into a sequence of associated lexical term sequences, which it passes downstream for further syntactic processing.
[0057] 2.1.5) Syntactic Type Resolution:
[0058] Scenario Server 150 resolves each virtual lexical type in a given sequence of lexical terms (corresponding to a sentence in a processed narrative) by interweaving the subprocesses of type refinement and type reduction in the process of syntactic type resolution 186 .
[0059] 2.1.5.1) Type Refinement:
[0060] Using a weighted, smoothed metric defined on an optimally dimensioned topological space of reduction type sequences (the type sequence topology 166 ), Scenario Server 150 refines each virtual lexical type embedded in a given lexical type sequence into an actual lexical type by means of a series of local type assignments determined by the specific syntactic context constituted by the embedding type sequence. See Example 1 for a specific example of how this works. The optimal dimension for the topological space has been determined empirically.
[0061] 2.1.5.2) Type Reduction:
[0062] Using a priority scheme induced by the composition of a type rank matrix and a type order matrix operating on the space of lexical type pairs, Scenario Server 150 reduces each pair of adjacent, fully refined types appearing in a given lexical type sequence into a remaining dominant type and a suppressed subordinate type.
[0063] Example 1 shows in more detail how the matrices and topology work step by step to effect the type resolution in the preferred embodiment.
[0064] Upon performing the required type resolutions for all terms in the narrative being modeled, Scenario Server 150 has transformed a sequence of virtual type sequences into a sequence of associated resolved type sequences with complete syntactic dependency characteristics, which it passes downstream for further syntactic processing (see FIG. 1 ).
[0065] 2.1.6) Syntactic Complex Representation:
[0066] Using the complete syntactic dependency relations induced by full type resolution (see Sec. 2.1.5), Scenario Server 150 constructs a coherent syntactic complex representation of the originating narrative (see syntactic complex representation 188 ). FIG. 4 is an illustration of a syntactic dependency structure (parse tree) according to an embodiment of the present invention. As shown in FIG. 4 , the representation is conveniently displayed as a system of associated parse trees. Notice that subtle syntactic distinctions such as the appropriate grammatical categorization of each noun into verb subject, direct object, indirect object, and prepositional object are made here.
[0067] Upon constructing the syntactic complex representation of the narrative being modeled, Scenario Server 150 passes it downstream for initial semantic processing.
[0068] 2.2) Semantic Processing:
[0069] 2.2.1) Operational Hierarchy:
[0070] FIG. 5 is a screenshot of a project hierarchy according to an embodiment of the present invention. As shown in FIG. 5 , Scenario Server 150 organizes semantic object networks 500 in a nested, descending project/package/artifact hierarchy (e.g., project 510 , packages 520 , and artifacts 530 ), simply called the project hierarchy 162 for convenience. The user manages the project hierarchy 162 through the project hierarchy manager 118 . The project hierarchy manager 118 is accessible, for example, via the user interface shown in FIG. 2 .
[0071] An artifact (e.g., artifact 530 ) is either some semantic object network representation (textual or graphical) or a related miscellaneous item such as an ancillary document.
[0072] A package (e.g., package 524 ) is a collection of artifacts and subpackages (e.g., process 524 ) associated with a single semantic object network. The user manages packages through the package interface 111 .
[0073] A project 510 is a collection of packages (e.g., packages 522 / 524 ), associated with a common operational lexicon (or project glossary 550 , see Sec. 2.2.2 for further details). 2.2.2) Operational Lexicon:
[0074] Scenario Server 150 associates an operational lexicon 168 with each project. For example, the operational type association 190 makes the association (see Sec. 2.2.1). An operational lexicon contains all operational terms which appear in the associated project narratives. An operational term is a pair consisting of a natural language token and an operational type. The operational types recognized by Scenario Server are:
function; system; actor; object; modifier; and null.
[0081] A function is an action performed by some agent, which is either some system component or some other type of actor. An object is any entity upon which (or relative to which) some agent acts by means of some function. A modifier is a term which attributes special properties to an action or an object. System and actor are agents, and null is an operational type that is not any of the other types.
[0082] Note, under this definition, that any agent, whether system or actor, is an object of a special kind. It is often useful to distinguish these agents as active objects, as opposed to passive objects which are simply transferred between agents or submitted to some action by an agent.
[0083] Clearly, there is a strong correlation between syntactic terms and operational terms under which:
active verbs are cast as functions; verb subjects are cast as actors; direct, indirect, and prepositional objects are cast as objects; and adverbs and adjectives are cast as modifiers Scenario Server 150 vigorously exploits this correlation in generating the semantic connection between syntactic structure and object structure (see Sec. 2.2.3). The fundamental unit of this connection is the action paradigm, which relates an actor to its function with respect to some object in accordance with an appropriate instrumentality (direction of object flow). The basic role of a modifier here is to transform relatively simple terms into relatively complex terms, so that functions and objects (including actors) may be endowed with unlimited articulation. For example, an “application” object becomes a “loan application” object by binding the modifier “loan” to the object “application.”
[0088] 2.2.3) Operational Type Association:
[0089] Using the syntactic object representation induced by full type resolution (see Sec. 2.1.5) and the strong correlation between syntactic terms and operational terms (see Sec. 2.2.2), Scenario Server 150 determines the appropriate operational type of each token in a processed narrative, automatically assigns this type in order to form an operational term associated with that token, and enters this term in the operational lexicon associated with the project in which that narrative appears (e.g., via operational type association 190 ). In this way, a processed narrative becomes a coherent sequence of operational term sequences, and the operational lexicon becomes a specialized project glossary for that supervening project domain (e.g., see FIG. 6 , project glossary 610 ).
[0090] Under certain circumstances, the user may choose to override an automatic operational type assignment made by Scenario Server 150 , and may do so by modifying the project glossary directly through the operational lexicon interface 120 of Scenario Client 105 . A prime example of such a manual override is the promotion of a generic actor to a system agent, or the promotion of a generic object to an actor of some sort.
[0091] 2.2.4) Semantic Object Representation:
[0092] Using the relative operational term structures induced by syntactic object representations augmented by corresponding operational type assignments (see Sec. 2.2.3), Scenario Server 150 constructs a semantic object representation of a processed narrative (see semantic object representation 192 ) which includes:
static characteristics; dynamic characteristics; and logical characteristics
[0096] The static characteristics include
process actors and their attributes; process objects and their attributes; and passive relationships between process actors/objects
[0100] The dynamic characteristics include
functional relationships on/between process actor; and transfers of control/object between process actors.
[0103] The logical characteristics include:
conditional relationships on/between process actors; and faithful representations of the propositional calculus.
[0106] From a technical (model-theoretic) perspective, a semantic object representation of a narrative is basically a many-sorted first-order model of the theory comprised by the sentences of the narrative.
[0107] This local representation is stored and managed in the Scenario Server DB 160 as a substructure of the semantic object network 170 .
[0108] 2.2.5) Textual and Graphical Representation:
[0109] Using the semantic object representation (model) of a processed narrative generated in accordance with its appropriate operational term structures (see Sec. 2.2.4), Scenario Server 150 constructs various textual and graphical representations (views) of the semantic structures associated with that narrative. The diagram representation 194 performs the constructions. The representations include:
annotated text (see FIG. 7 ); activity diagram ( FIG. 8 ); use case diagram (see FIG. 9 ); object relationship diagram ( FIG. 10 ); object network map (see FIG. 11 ); activity schedule (see FIG. 12 ); action paradigm schema ( FIG. 13 ); and actor/object list ( FIG. 14 ).
[0118] Each of these representations is transferred to Scenario Client 105 for display in the GUI (e.g., diagram 124 ), and the user manages each of them through the diagram editor 122 .
[0119] It is here that the MVC architecture of Scenario becomes especially operative, in that any modification made to any of these visual representations results in a corresponding modification of the underlying semantic object network 170 , which then synchronously becomes reflected in each of the Scenario representations, textual and graphical, of that modified network.
[0120] In particular, the characteristics of any object (passive or active) in the semantic network may be effectively viewed and controlled through its appropriate representations. The internal characteristics of an object may be accessed through any of the model representations listed above. The characteristics are accessed, for example, by selecting the object as it appears in a representation and activating the object manager. FIG. 15 is a screen shot of an object manager diagram according to an embodiment of the present invention. External characteristics such as relationships may be accessed through the object relationship diagram or the object network map, in which these relationships are clearly displayed, hence easily modified.
[0121] 2.2.6) Representation Linking:
[0122] It is important to note that the underlying model from which all the textual and graphical representations are generated by Scenario (see Sec. 2.2.5) provides an effective basis upon which all entities may be automatically linked across all representations. In particular, any text fragment in a narrative is automatically linked with all of its representational components in each of these views, and the Scenario user is able to activate these links as soon as the model is generated (e.g. see FIG. 16 ). Automatic links between corresponding components in any pair of these views are similarly generated, and hence, immediately accessible (e.g. see FIG. 17 ).
[0123] FIGS. 18A and 18B are flow diagrams of an overview of processing according to an embodiment of the present invention. The user 1800 enters text 1802 , and the text processor 1810 creates a sequence of lexical terms 1812 . The sequence of lexical terms 1812 are resolved into operational types 1822 and iterated 1824 to produce a sequence of syntactic processes. The semantic processor 1830 creates object representations 1832 . An external processing module 1840 prepares and sends diagram specific files 1842 to the renderer 1850 which displays graphic diagrams on screen 1852 to the user 1800 .
[0124] FIGS. 19A and 19B are flow diagrams of an example interaction between a user, text processing, lexicon manager, and syntactic processor according to an embodiment of the present invention. The text processing is, for example, the text processor discussed above. The text processor 1810 parses the received text into sequences of tokens which are sent to the basic lexicon manager 1900 . The basic lexicon manager iterates over all tokens in given sequences 1910 . Recognized tokens are assigned an appropriate type 1912 . Unrecognized tokens may be recognized via a suffix of the token 1916 ; if so, a type assignment is made based on the suffix 1920 . Unrecognized tokens with unrecognized suffixes are sent to a manual assignment method. In this example, the manual assignment method is requesting the user 1922 to assign a lexical term 1850 to the unrecognized token. Upon iteration over all tokens, the text processor 1810 sends the sequences of lexical terms to the syntactic processor 2000 .
[0125] FIG. 20 is a flow diagram of a syntactic process according to an embodiment of the present invention. Upon receipt of the sequences of lexical terms, the syntactic processor performs a number of sub-processes as shown in the flow chart. A sequence of syntactic complexes is created which are forwarded for semantic processing (to semantic processor 2100 ).
[0126] FIG. 21 is a flow diagram of a semantic process according to an embodiment of the present invention. A semantic processor 2100 receives syntactic complexes from syntactic processor 2000 and creates an object representation 2110 , which is forwarded to, for example, an external processing module 2200 .
[0127] FIG. 22 is an example of external processing according to an embodiment of the present invention. An external processing module 2200 constructs a file for each type of diagram 2210 , and for each target 2220 . The constructed files are forwarded to a renderer 2300 .
[0128] FIG. 23 is an example of a rendering process according to an embodiment of the present invention. The renderer 2300 stores the files for later export 2310 if not diagrammed. Otherwise, the file is converted into an appropriate graphic diagram 2320 which are sent to the user 2330 for display as graphic diagrams 1862 .
[0129] Thus, the present invention provides various techniques and processes for preparing diagrams from text and modifying text by changing diagrams. In one embodiment, the present invention comprises a method, comprising the step of generating graphical representations of an object model. The object model is, for example, created from natural language text via an adaptive syntactic pattern recognition scheme. In one alternative embodiment, the method includes the step of constructing the graphical representations of an object model via a semantic object representation method. The semantic object representation model, for example, comprises, preparing a semantic object representation comprising a prepared syntactic complex augmented by an operational type association method comprising, determining an operational type assignment method based on a lexical type signature of a given token of an operational lexicon, and performing an operational type association comprising forming an operational term by applying the determined operational type assignment method.
[0130] Various alternative embodiments include the step of automatically linking correlated object elements across all representations generated, and/or any of linking object elements in graphical representations produced by a semantic object representation method, linking object elements in textual representations produced from an object model as produced by a semantic object representation method, and linking object elements in graphical representations produced by a semantic object representation method with correlated object elements in textual representations produced from an object model as produced by a semantic object representation method.
[0131] Other alternative embodiments include the step of interactively presenting the graphical and textual representations as views, wherein the graphical and textual representations comprise an underlying semantic object model; and controlling the graphical representation by direct manipulation of the object model. The underlying semantic object model is produced, for example, by preparing a semantic object representation comprising a prepared syntactic complex augmented by an operational type association method, and the operational type association method comprises, for example, determining an operational type assignment method based on a lexical type signature of a given token of an operational lexicon, and performing an operational type association comprising forming the operational term by applying the operational type assignment method.
[0132] In various embodiments, graphical representations comprise, for example, any of an activity diagram, a use case diagram, an object relationship diagram, an object network map, an activity schedule, an action paradigm schema, and an action/object list.
[0133] In another embodiment, the present invention alternative embodiment, the invention is a method comprising the step of generating graphical representations of an object model, wherein the object model is created from natural language text via an adaptive syntactic pattern recognition scheme. The invention may also include the steps of, creating syntactic type representations of the natural language text, and storing the syntactic type representations in a remodeling cache.
[0134] In various embodiments, the invention may include, for example, the step of exporting the representations of the object model, wherein the exported representations are formatted in any of XMI, XML, BPEL, and Microsoft Visio protocols. The various embodiments may also alternatively include the steps of, displaying the representations of the object model in Microsoft Visio, and exporting the representations of the object model, wherein the exported representations are formatted in, for example, Microsoft Visio or another protocol. The exported representations of the object model may be formatted, for example, in any of.bmp, .jpg, gif, .png, .tiff, .exif, .wmf, and .emf protocols.
[0135] In another embodiment, the present invention is a method, comprising the step of generating textual representations of an object model. The object model is, for example, created from natural language text via an adaptive syntactic pattern recognition scheme. In one embodiment, the method includes the step of constructing the textual representations from an object model produced by a semantic object representation method. The textual representations comprise, for example, an annotated text, with graphical marking of tokens indicating proper operational type associations. The proper operational type associations comprise, for example, determining an operational type assignment method based on a lexical type signature of a given token of the operational lexicon, and performing an operational type association comprising forming the operational term by applying the operational type assignment method.
[0136] In another embodiment, the present invention is a method comprising the step of creating a basic lexicon. The basic lexicon is, for example, a lexicographically ordered list of lexical terms, where a lexical term is a pair consisting of an admissible token and an associated lexical type, a token is a string of ASCII characters, an admissible token is a token which is either a word or a punctuation symbol in a natural language, and a lexical type is a syntactic designation which specifies the possible grammatical roles its associated token can assume in a sentential context relative to that natural language. In one alternative, the method includes the steps of viewing a lexical term in the basic lexicon, inserting a lexical term into the basic lexicon, editing a lexical term in the basic lexicon, deleting a lexical term from a basic lexicon. In another alternative, the method may include a step of assigning a lexical type, which forms one of the lexical terms, using a submethod of direct lexical reference to the basic lexicon or a submethod of indirect morphological inference on token suffix formation or a submethod of manual selection from a list of lexical types or by applying an appropriate lexical type assignment method. An appropriate assignment method is, for example, determined by a character string signature of a given token.
[0137] In another embodiment, the present invention in a method for lexical type resolution comprising the step of transforming a virtual type occurring in a lexical type sequence into an actual type, where a virtual lexical type is an ambiguous designation of grammatical role allowing for a number of possible outcomes in sentential context, and an actual lexical type is a fixed designation of grammatical role.
[0138] In another embodiment, the present invention is a method comprising the step of creating a type reduction rank matrix, which is a reduction priority structure operating on the space of pairs of actual lexical types. In another embodiment, the present invention is a method comprising the step of creating a type reduction order matrix, which is a reduction dominance structure operating on the space of pairs of actual lexical types.
[0139] In another embodiment, the present invention is a method comprising the step of defining a metric on a type sequence space by discrete convolution over at least one of a type reduction rank matrix, which is a reduction priority structure operating on the space of pairs of actual lexical types, and a type reduction order matrix, which is a reduction dominance structure operating on the space of pairs of actual lexical types, wherein a type sequence space is a set of lexical type sequences. The method includes, for example, the step of creating a type sequence topology of a space of lexical type sequences on which the metric has been defined. The method may further include the step of correlating any element of the type sequence topology with an associated lexical type, wherein the associated lexical type is the relative resolution value of the correlated element. In one alternative, the method further includes the step of performing syntactic refinement, by assigning a relatively resolved lexical type to an unresolved lexical type in a type sequence, and using a type correlation specifically determined by an optimization over the created type sequence topology.
[0140] In another embodiment, the present invention is a method for syntactic type reduction, comprising the steps of, selecting an adjacent pair of fully resolved types according to the type reduction rank matrix, and transforming the adjacent pair of fully resolved types in a type sequence into a remaining dominant type and a suppressed subordinate type, wherein the transformation is based on a type reduction rank matrix comprising a reduction priority structure operating on the space of pairs of actual lexical types.
[0141] In one alternative, the present invention includes the step of, performing lexical type sequence resolution by iterated lexical type resolution, incorporating submethods comprising, performing syntactic refinement, by, assigning a relatively resolved lexical type to an unresolved lexical type in a type sequence, and using a type correlation specifically determined by an optimization over the created type sequence topology, performing syntactic type reduction, comprising the steps of, selecting an adjacent pair of fully resolved types according to a type reduction rank matrix, and transforming the adjacent pair of fully resolved types in a type sequence into a remaining dominant type and a suppressed subordinate type, wherein the transformation is based on the type reduction rank matrix comprising a reduction priority structure operating on a space of pairs of actual lexical types, and wherein lexical type sequence resolution by iterated lexical type resolution in an interwoven application which transforms any sequence of lexical types into a correlated sequence of actual types. And may also include the step of preparing a syntactic complex representation, which represents an actual lexical type sequence, where the syntactic complex is a syntactic dependency structure represented as a parse tree that encodes syntactic information required to perform further semantic processing.
[0142] In one embodiment, the present invention is a method comprising the step of creating an operational lexicon. The operational lexicon is, for example, a lexicographically ordered list of operational terms, where an operational term is a pair consisting of an operational token and an associated operational type, an operational token is an admissible token comprising either a word or a punctuation symbol in a natural language, and an operational type is a semantic designation which specifies the operative role its associated token plays. The method may include, for example, the step of managing the operational lexicon by any of viewing an operational term in the operational lexicon, and/or inserting an operational term into the operational lexicon, and/or editing an operational term in the operational lexicon, and/or deleting an operational term from the operational lexicon. The step of managing may also include one or more of submethods such as direct lexical reference to the operational lexicon, indirect syntactic inference on a lexical type of a given token, manual selection from a list of operational types, based on lexical type signature of a given token. The invention may also include selecting between the various submethods based on any criteria and applying the selected submethod.
[0143] The present invention may also include, for example, preparing a semantic object representation comprising the prepared syntactic complex augmented by an operational type association method. In one alternative, the operational type association method comprises, determining an operational type assignment method based on a lexical type signature of a given token of the operational lexicon, and performing an operational type association comprising forming the operational term by applying the operational type assignment method. The operational type association method may include for example a step any of, for example, assigning static characteristics of an operative scenario, such as actors, objects, and passive relationships between actors and/or objects and other actors and/or objects, assigning dynamic characteristics of an operative scenario, such as functional relationships on and/or between actors, and transfers of control and/or objects between actors, and assigning logical characteristics of an operative scenario, such as conditional relationships on and/or between actors, and faithful representations of the propositional calculus.
[0144] In one embodiment, the present invention is a method for editing text, comprising, interactively displaying linking between the text and a diagram representation of the text. The diagram representation is, for example, a representation generated from graphical representations of an object model of the text. The graphical representations of an object model are produced, for example, by a semantic object representation method. The diagram representations comprise, for example, automatically linking object elements in graphical representations produced by a semantic object representation method with correlated object elements in textual representations produced from an object model of the text.
[0145] In another embodiment, the method for editing text comprises the step of interactively controlling representations from a text view as provided by a diagram representation method. The diagram representation method includes, for example, constructing graphical representations of an object model as produced by a semantic object representation method. In one embodiment, the text is annotated text. Any of the text editing methods may include, for example, the steps of interactively viewing the text, and interactively managing graphical representations as produced by the diagram representation method. Other steps that may be included are, for example, interactively displaying linking between diagrams and other representations as produced by the diagram representation method, and interactively controlling all representations from a diagrammatic view as provided by the diagram representation method.
[0146] In one embodiment, the present invention is a method, comprising the step of creating a project hierarchy. The project hierarchy is, for example, a nested data structure which organizes object model artifacts into packages, and packages into projects. The method may include, for example, the step of associating a basic lexicon with the project, and associating an operational lexicon with the project. Other steps may include, for example, the step of displaying graphical representations of projects, packages contained in the projects, and the artifacts of the packages, in a nested arrangement determined by the project hierarchy, the step of inserting a package into a project in the hierarchy, and the step of saving an existing package in a project in the hierarchy. An existing package may, for example, be renamed in a project in the hierarchy, moved to another project in the hierarchy, and/or deleted. The method may include, for example, the step of displaying artifacts of a selected package in the hierarchy may be displayed in graphical representations.
[0147] In another embodiment, the present invention is a method, comprising the steps of managing a package, comprising, for example, displaying artifacts of the package in graphical representations. The method may include, for example, any of the displaying a natural language text artifact of the package, displaying an activity diagram artifact of the package, displaying a use case diagram artifact of the package, displaying an object relationship diagram artifact of the package, displaying an object network map artifact of the package, displaying an activity schedule artifact of the package, displaying an action paradigm schema artifact of the package, displaying an actor/object list artifact of the package, displaying an annotated text artifact of the package, and modifying artifact graphical representations of the package, The modified artifact graphical representation is, for example, a natural language text artifact of the package, that includes any of an activity diagram artifact of the package, a use case diagram artifact of the package, an object relation diagram artifact of the package, an object network map artifact of the package, an activity schedule artifact of the package, an action paradigm schema artifact of the package, an actor/object list artifact of the package, and an annotated text artifact of the package.
[0148] In another embodiment, the present invention is a method comprising the step of managing a package. The step of managing comprises, for example, saving artifacts of the package in the project hierarchy, including any of natural language text artifacts, activity diagram artifacts, use case diagram artifacts, object relationship diagram artifacts, object network map artifacts, activity schedule artifacts, action paradigm schema artifacts, actor/object list artifacts, and annotated text artifacts.
[0149] In one embodiment, managing a package comprises the step of modifying a representation of an object model associated with the package. The method may include, for example, the step of modifying characteristics of the object model from a natural language text artifact of the package. The modified characteristics include, for example, any of characteristics of the object model from an activity diagram artifact of the package, characteristics of the object model from a use case diagram artifact of the package, characteristics of the object model from an object relationship diagram artifact of the package, characteristics of the object model from an object network map artifact of the package, characteristics of the object model from an activity schedule artifact of the package, characteristics of the object model from an action paradigm schema artifact of the package, characteristics of the object model from an actor/object list artifact of the package, and characteristics of the object model from an annotated text artifact of the package. The method may also include, for example, the step of displaying automated links between artifacts of the package. The automated links include, for example, links between graphical artifacts of the package, links between textual artifacts of the package, and/or links between graphical and textual artifacts of the package.
[0150] In various embodiments, a displayed activity diagram and/or artifacts thereof may be viewed in a zoomable mode. Various embodiments may also include where the displayed artifacts comprise an activity diagram artifact of the package displayed in a pannable mode. Other modes include a scrollable mode, a pinned actor heading mode, a sequential presentation mode. In various embodiments, the same modes are applied to use case diagrams and their related artifacts, object network map artifacts (and may also include global mode, and a local, star topology mode), object relationship diagram artifacts of the package displayed in a zoomable mode (and may also include global and local, expanded attribute/method mode modes). The example also includes the step of printing each of the artifacts of the package as displayed, which may include, for example, the step of sizing panels of the printed artifacts such that a printed copy occupies sized panels and/or the provision of header/trimmer options to be used in the step of printing.
[0151] Various embodiments may also include the step of modifying an object model associated with a package according to a modification of any of the natural language text artifact of the package, the activity diagram artifact of the package, the use case diagram artifact of the package, the object relationship diagram artifact of the package, the object network artifact of the package, the activity schedule artifact of the package, the action paradigm artifact of the package, the action/object list artifact of the package, and the annotated text artifact of the package.
[0152] In other embodiments, links are utilized (e.g., automated linking), and the links are, for example, are activated and displayed.
[0153] In another embodiment, the present invention is a method, comprising the step of, diagramming natural language text, wherein the text is displayed and editable via a word processor, and resultant diagrams are displayed and editable via a diagram program. In one embodiment, the word processor comprises Word. In one embodiment, the diagramming program comprises Visio. In yet another embodiment, the diagrams are displayed and edited by a Microsoft Windows graphics interface.
[0154] [[175]]. The method according to Claim [[48]], further comprising the step of retrieving a user selection for visual characteristics of annotation markings for the annotated text.
[0155] Various embodiments of the present invention further include, for example, any of, typographically marking fragments of text according to a representational status of the fragments, and/or contextually associating modeling help information with fragments of text as marked. The various embodiments may also include, for example, displaying modeling help information, and associating the help information with fragments of text, wherein the associations between the help information and the fragments of text are contextual and manifest in the displayed help information and text fragments.
[0156] Various embodiments of the invention may also include displaying the project hierarchy, wherein graphical signatures of package artifacts of the project hierarchy are presented in a photo album format. The photo album format may also be utilized, for example, for graphical signatures for any of activity diagram artifacts, case diagram artifacts, object relationship diagram artifacts, object network map artifacts, and/or other artifacts of packages of the project hierarchy.
[0157] In another embodiment, the present invention is a method, comprising the step of, associating modeling error traits with graphical representations of an object model; and may further comprise the step of displaying the modeling error traits. In one alternative, the associated traits are manifest in an activity diagram presentation.
[0158] Various embodiments of the present invention include the step of creating a hyperlink, and or activating a hyperlink, and/or displaying an activated hyperlink, between any pair of packages in the project hierarchy. The hyperlinks are, for example, between any of any package in the project hierarchy and any artifact stored in the project hierarchy, any package in the project hierarchy and any element of an artifact stored in the project hierarchy, any artifact in a package stored in the project hierarchy and any element of an artifact in a package stored in the project hierarchy, any element of an artifact in a package stored in the project hierarchy any other element of any artifact in a package stored in the project hierarchy, any pair of packages in the project hierarchy, any package in the project hierarchy and any artifact in a package of the project hierarchy, any package in the project hierarchy and any element of any artifact in a package in the project hierarchy.
[0159] In various embodiments, the present invention includes the step of accessing, and/or displaying, and/or modifying characteristics of an element of an object model from graphical representations of the present invention. The graphical representations include, for example, any of an activity diagram, a use case diagram, an object relationship diagram, an object network map diagram, an activity schedule, an action paradigm diagram, an actor/object list, or other representations.
[0160] In various embodiments, the step of accessing characteristics of any element of the object model may be performed from textual representations created from the object model. The textual representations comprise, for example, annotated text, and the accessed characteristics are, for example, displayed, modified.
[0161] In various embodiments, the invention includes, for example, a step of accessing, and/or displaying, and/or modifying relationships between any elements of the object model from certain of the graphical representations. The graphical relationships include, for example, any of, an object relationship diagram, object network map, or other representations.
[0162] In various embodiments, the present invention includes the step of creating a remodeling cache, in which a syntactic representation of a natural language text upon which the remodeling cache is based is stored in a rapidly accessible format. The remodeling cache is, for example, used to generate appropriate syntactic representations of previously modeled portions of the natural language text.
[0163] In describing preferred embodiments of the present invention illustrated in the drawings, specific terminology is employed for the sake of clarity. However, the present invention is not intended to be limited to the specific terminology so selected, and it is to be understood that each specific element includes all technical equivalents which operate in a similar manner. For example, when describing lexicons, hierarchies, topologies, or any other processes or features of the present invention, that any other equivalent device, or a device having an equivalent function or capability, whether or not listed herein, may be substituted therewith. Furthermore, the inventors recognize that newly developed technologies not now known may also be substituted for the described parts and still not depart from the scope of the present invention. All described items, including, but not limited to type resolutions, syntactic representations, semantic processing or representations, diagram representations, views, linking management, etc. should also be considered in light of any and all available equivalents.
[0164] Portions of the present invention may be conveniently implemented using a conventional general purpose or a specialized digital computer or microprocessor programmed according to the teachings of the present disclosure, as will be apparent to those skilled in the computer art.
[0165] Appropriate software coding can readily be prepared by skilled programmers based on the teachings of the present disclosure, as will be apparent to those skilled in the software art. The invention may also be implemented by the preparation of application specific integrated circuits or by interconnecting an appropriate network of conventional component circuits, as will be readily apparent to those skilled in the art based on the present disclosure.
[0166] The present invention includes a computer program product which is a storage medium (media) having instructions stored thereon/in which can be used to control, or cause, a computer to perform any of the processes of the present invention. The storage medium can include, but is not limited to, any type of disk including floppy disks, mini disks (MD's), optical discs, DVD, CD-ROMS, CDRW+/−, micro-drive, and magneto-optical disks, ROMs, RAMs, EPROMs, EEPROMs, DRAMs, VRAMs, flash memory devices (including flash cards, memory sticks), magnetic or optical cards, MEMS, nanosystems (including molecular memory ICs), RAID devices, remote data storage/archive/warehousing, or any type of media or device suitable for storing instructions and/or data.
[0167] Stored on any one of the computer readable medium (media), the present invention includes software for controlling both the hardware of the general purpose/specialized computer or microprocessor, and for enabling the computer or microprocessor to interact with a human user or other mechanism utilizing the results of the present invention. Such software may include, but is not limited to, device drivers, operating systems, and user applications. Ultimately, such computer readable media further includes software for performing the present invention, as described above.
[0168] Included in the programming (software) of the general/specialized computer or microprocessor are software modules for implementing the teachings of the present invention, including, but not limited to, text entry and editing, parsing, creating object models (e.g., from natural language text), diagramming text based on object models, syntactic pattern recognition, creating textual representations of an object model, pairing tokens and lexical types, managing lexicons, linking representations in any of text, graphics, hierarchies, etc., inserting terms into lexicons, performing morphological inferences, type reduction processes, refinements, assignments, or any other processes described herein, and the display, storage, or communication of results according to the processes of the present invention.
[0169] The present invention may suitably comprise, consist of, or consist essentially of, any of the elements (the various parts or features of the invention) and their equivalents as described herein. Further, the present invention illustratively disclosed herein may be practiced in the absence of any element, whether or not specifically disclosed herein. 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.
EXAMPLE 1
Syntactic Type Resolution
[0170]
originating text:
“The Scenario engine transforms informal natural language text into
formal object
representations.”
parsed token sequence:
the Scenario engine transforms informal natural language text into
formal object
representations.
initial lexical type sequence:
ajd xim xom xax xjx xjq xom xom xyv xjx xox xom trm
where the listed types are
ajd: definite article
xim: pni/mbj
xom: obj/mbj
xax: act/xom
xjx: adj/obj
xjq: xjv/obj
xyv: xyp/adv
xox: xom/act
trm: terminator
with each virtual type (i.e. any type designated by an initial ‘x’ in
its 3-letter code) defined by its refinement pair over the actual types
act: active verb
obj: object noun
adj: adjective
adv: adverb
mbj: object modifier
pni: inanimate proper name
and the further virtual types
xjv: adj/adv
xyp: xuq/xpq
xuq: imd/mim
xpq: prp/mpr
over the actual types
prp: preposition
imd: instrumental
mpr: meta-preposition
mim: meta-instrumental
initial reduction type sequence:
ajd xom xom xax xjx xjq xom xom xyv xjx xox xom trm
initial reduction type pairings/rankings:
11) (representations,.) / (xom,trm) // 20 / −1 <--
10) (object,representations) / (xox,xom) // 0 / −1 <--
9) (formal,object) / (xjx,xox) // 1 / −1
8) (into,formal) / (xyv,xjx) // 0 / −1
7) (text,into) / (xom,xyv) // 4 / −1
6) (language,text) / (xom,xom) // 0 / −1
5) (natural,language) / (xjq,xom) // 0 / −1
4) (informal,natural) / (xjx,xjq) // 1 / −1
3) (transforms,informal) / (xax,xjx) // 1 / −1
2) (engine,transforms) / (xom,xax) // 0 / −1
1) (Scenario,engine) / (xom,xom) // 0 / −1
0) (the,Scenario) / (ajd,xom) // 1 / −1
presented in the format
index) (token,token) / (type,type) // rank / order
where
index is a reduction pair index for iteration reference
token is a sentence token
type is a reduction type
rank is a type reduction priority ranking (0 = high, 21 = low)
order is a type reduction dominance ordering (0 = first, 1 = second,
−1 = neither)
[interwoven processes of type refinement and type reduction, repeatedly
executed here, produce the following intermediate results:]
intermediate reduction type pairings/rankings:
11) (representations,.) / (obj,trm) // 21 / 0 <--
10) (object,representations) / (mbj,obj) // 1 / 1 <--
9) (formal,object) / (adj,mbj) // 1 / 1
8) (into,formal) / (xyv,adj) // 0 / −1 <--
7) (text,into) / (xom,xyv) // 4 / −1
6) (language,text) / (xom,xom) // 0 / −1
5) (natural,language) / (xjq,xom) // 0 / −1
4) (informal,natural) / (xjx,xjq) // 1 / −1
3) (transforms,informal) / (xax,xjx) // 1 / −1
2) (engine,transforms) / (xom,xax) // 0 / −1
1) (Scenario,engine) / (xom,xom) // 0 / −1
0) (the,Scenario) / (ajd,xom) // 1 / −1
type refinement sequence:
xom xax xjx xjq xom xom [xyv] adj mbj obj trm nul nul
type refinement branch: xyv -> xyp/adv
estimated type sequence:
xom xox xax ajd xjx xom [xyv] ajd mbj obj trm nul nul -> xyp
minimizing type refinement metric:
8.66 8.79 8.70 8.32 7.62 6.53 [5.28] 3.86 2.52 1.47 0.69 0.22
0.00 -> 40.07
type refinement sequence:
xom xax xjx xjq xom xom [xyp] adj mbj obj trm nul nul
type refinement branch: xyp -> xuq/xpq
estimated type sequence:
xax aji xap xtj xom xjq [xyp] ajd mbj obj trm nul nul -> xuq
minimizing type refinement metric:
8.92 8.90 8.35 7.84 7.17 6.04 [4.81] 3.60 2.38 1.36 0.64 0.22
0.00 -> 38.01
type refinement sequence:
xom xax xjx xjq xom xom [xuq] adj mbj obj trm nul nul
type refinement branch: xuq -> imd/mim
estimated type sequence:
xom xax xux xpg xjx xom [xuq] adj mbj obj trm nul nul -> mim
minimizing type refinement metric:
8.32 8.42 8.16 7.54 6.67 5.40 [3.95] 2.55 1.50 0.69 0.16 0.00
0.00 -> 34.60
intermediate reduction type pairings/rankings:
11) (representations,.) / (obj,trm) // 21 / 0 <--
10) (object,representations) / (mbj,obj) // 1 / 1 <--
9) (formal,object) / (adj,mbj) // 1 / 1
8) (into,formal) / (mim,adj) // 5 / 0
10) (representations,.) / (obj,trm) // 21 / 0 <--
9) (formal,representations) / (adj,obj) // 1 / 1 <--
8) (into,formal) / (mim,adj) // 5 / 0
9) (representations,.) / (obj,trm) // 21 / 0 <--
8) (into,representations) / (mim,obj) // 14 / 0 <--
8) (into,.) / (mim,trm) // 21 / 0 <--
7) (text,into) / (obj,mim) // 15 / 0 <--
6) (language,text) / (xom,obj) // 1 / −1 <--
5) (natural,language) / (xjq,xom) // 0 / −1 <--
4) (informal,natural) / (xjx,xjq) // 1 / −1
3) (transforms,informal) / (xax,xjx) // 1 / −1
2) (engine,transforms) / (xom,xax) // 0 / −1
1) (Scenario,engine) / (xom,xom) // 0 / −1
0) (the,Scenario) / (ajd,xom) // 1 / −1
[continued interwoven processes of type refinement and type reduction,
repeatedly executed here, produce the following final results:]
final reduction type sequence:
ajd mbj obj act adj adv mbj obj mim adj mbj obj trm
final syntactic dependency tree:
->(transforms) [act]
|-#(text) [obd]
| |-*(language) [mbj]
| | |-{circumflex over ( )}(natural) [adv]
| |-*(informal) [adj]
|-%(into) [imd]
| |-#(representations) [obq]
| | |-*(object) [mbj]
| | |-*(formal) [adj]
|-#(engine) [obs]
| |-*(Scenario) [mbj]
| |-*(the) [ajd]
|-.(.) [trm]
|
The primary component of the present invention is an automated method for transforming any suitably well-formed textual description of a process into a series of diagrammatic representations of that process. The secondary component of this invention is an automated method for transforming any of these diagrammatic representations into a corresponding textual description. These complementary methods are specific implementations of a more fundamental process modeling method for constructing a fundamental object structure from which a coordinated set of diverse representations may be uniformly generated, and hence, automatically synchronized. This fundamental process modeling method derives directly from the underlying mechanisms of syntactic and semantic representation provided by metaScript, a software technology presented in a previous patent application (Ser. No. 09/883,693: “Computer System With Natural Language To Machine Language Translator”).
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method for manufacturing a photographic paper support having a resin coating thereon. More particularly, it relates to a method of making a resin coated photographic paper having improved adhesion between the resin layer and the paper surface.
2. Description of Related Art
In order to keep the processing solution from penetrating photographic paper base during the development steps, synthetic resins of the polyolefin type such as polyethylene and polypropylene are coated on paper. The side to be coated with photographic emulsion has inorganic fillers such as titanium dioxide to provide white background. The opposite side has generally a blend of low density and high density polyethylene for curl control purpose. Since polyolefins are nonpolar by nature, extra steps are required to promote good bond between a polyolefin and paper surface. One method is to oxidize the molten polyolefin curtain prior to the coating. Polymer melt temperature is kept as high as 338° C. (640° F.) to promote oxidation. But the high melt temperature produces unwelcome results such as polymer degradation and crosslinked gel formation. The distance between the die lip and the lamination nip can be adjusted to provide longer oxidation time. But too great distance can hurt oxidation because it will lower the melt temperature. The coating line speed can be reduced to allow more time for oxidation. But this is not attractive from the cost point of view.
Another method is to precoat paper with adhesion promoting chemical primers. However, because the photographic paper is a rather porous substrate, the priming solution soaks through the paper rather than staying on the surface. Also photosensitivity of chemical primers is another concern.
There are other means of treating substrate surfaces. U.S. Pat. Nos. 5,147,678; 3,892,573; 4,135,932; 4,729,945; 4,186,018; and 4,128,426 describe treating polymeric surface using flame, corona, or ozone to improve on adhesion. U.S. Pat. No. 4,481,289 describes treating paper surface with corona discharge and oxidizing the polyolefin melt curtain using ozone and air mixture. It claimed that, by this method, improved adhesion was observed at 183 m/min (600 FPM) line speed. A line speed of 183 m/min is rather slow in today's environment. There is a great need to increase the line speed to 457 m/min (1,500 FPM) or beyond.
SUMMARY OF THE INVENTION
The invention contemplates a method of making resin coated photographic paper which comprises providing a paper base, subjecting the paper base to a flame treatment and a corona discharge treatment, providing a polyolefin melt curtain, treating the polyolefin resin melt curtain with a mixture of ozone and air and bringing the paper base in contact with the polyolefin melt curtain to provide a uniform layer of polyolefin resin on the paper base. The paper base may, in addition, be treated with a corona discharge. Significant improvement in adhesion between a polyolefin resin and paper is achieved in accordance with this invention.
The process in accordance with this invention provides excellent adhesion of the polyolefin resin to the paper substrate at speeds greatly exceeding that heretofore known.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic representation of an apparatus for practicing the process of this invention;
FIG. 2 is a diagrammatic view of an apparatus for conducting the corona discharge treatment in accordance with this invention;
FIG. 3 is a diagrammatic view of an apparatus for conducting the flame treatment in accordance with this invention;
FIG. 4 is a partial perspective view of an apparatus for conducting the ozone treatment in accordance with this invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
Without being bound by any particular mechanism, it is believed that surface moisture in the paper substrate is an important factor influencing adhesion. When the hot polymer melt contacts the paper surface, it raises the paper surface temperature well above the boiling point. The surface moisture then evaporates causing delamination of polyolefin layer from the paper surface. This moisture effect can be minimized by pretreating paper with flame.
Further, by exposing the paper surface to different surface treatments, flame and corona discharge, it is believed that more specific and unique chemical groups are formed which are not formed by corona discharge alone.
Referring to FIG. 1, photographic paper sheet 10 is moving in the direction shown by the horizontal arrow through a first corona discharge treatment zone 12, through a flame treatment zone 14, and then through a second corona discharge treatment zone 16 followed by passing around nip roller 18 and between nip roller 18 and chill roller 20. Chill roller 20 is provided with a matte finish and the pressure applied by rollers 18 and 20 is about 0.4 MPa (60 PSI). The molten polyolefin resin is conveyed in a molten sheet 22 from curtain coating device 24 to impinge upon the paper substrate 10 near the nip of rollers 18 and 20. Ozone coating station 26 is positioned just prior to the entrance of the curtain of molten polyolefin in order that the ozone treats the polyolefin sheet.
In the coating line of FIG. 1, the first corona discharge zone may embody a single horse shoe type electrode, 10.2 centimeters (4 inches) wide and 81.3 centimeters (32 inches) long and a dielectric coated roll. The first corona discharge treatment may be one provided by Pillar Technology, rated at 110 kHz and 12 kW. The second corona discharge treatment zone is located about 91.4 centimeters (3 feet) away from the first nip pressure roll 18 and has 6 electrodes with a bare roll. A suitable device of this type is supplied by Enercon and is rated at a 110 kHz and 12 kW.
A typical configuration for corona discharge treating at positions 12 or 16, in accordance with this invention is shown schematically in FIG. 2. The paper substrate 10, to be treated, passes over a grounded roll 30, which roll 30 may or may not be coated with a dielectric material 32. A generator 34, such as a high frequency spark generator supplies a high voltage to electrode 36 which jumps the gap between the electrode 36 and the substrate 10 causing a corona discharge 38 upon the surface of the substrate 10. The circuit is completed by the connection of the metal roll 30 to ground 40 and then through resistor 42 back to the generator.
The high voltage fields cause the oxygen molecules to break up into ions and electrons which react with the surface of the substrate. Those that do not react, recombine into molecules with either two atoms (normal oxygen) or three atoms (unstable reactive ozone).
Power input for the surface treatment is defined by watt density formula.
Wd=PS/(WE×LS×NST)
Where:
Wd=Watt Density (watts/sq. meter/minute)
PS=Power Supply (watts)
LS=Line Speed (meters/minute)
NST=Number of Sides Treated
WE=Width of Electrode
Watt density can range from 0.18 to 11 watts/m 2 /min. (0.017 to 1.0 watts/sq. ft./min.), preferably 1.5 to 6.2 watts/m 2 /min. (0.143 to 0.57 watts/sq. ft./min.).
FIG. 3 is a diagrammatic representation of a suitable apparatus for conducting the flame treatment in accordance with this invention. The flame treating zone 14 receives the continuous substrate 10 from the first corona discharge treating zone 12 in FIG. 1 and the substrate 10 passes over roll 50 where it is held under tention by means of tention rolls 52. The surface of the paper substrate 10 is treated with flame 54, which treatment takes place under an exhaust hood 56. The paper after passing over roll 50 and being subjected to the flame then moves continuously to the next station, which is shown in FIG. 1 is the second corona discharge treatment zone 16. While two corona treating stations are preferred, the corona treatment is optional in this invention.
In flame treating, the high temperature of the combustion gases causes the molecules of oxygen to come apart to form free oxygen atoms that are chemically very reactive. They also lose electrons to become positively charged oxygen ions. The electrically neutral gas made up of equal amounts of positively charged particles and negatively charged particles is known as "plasma." In flame treating, these high speed, energetic, very reactive oxygen ions and free electrons bombard the substrate surface and react with the molecules. This process can be said to oxidize the surface, and requires an oxidizing flame which is a flame with excess oxygen.
The quality of air can vary from time to time. There is a significant reduction of oxygen and an increase in water vapor in the air when the relative humidity is higher. The quality of commercially available gas can vary also due to changes in composition of the supply source. It can also change if the gas company adds propane and air to natural gas at peak loads. The type of gas can be natural gas, propane, or any other hydrocarbon gas. The moving paper web 10 carries with it a boundary layer of air. At high speeds, the flame 54 tends to mix with the boundary layer of air. To compensate for this extra air, the air/gas mixture should be richer in gas at higher line speeds than would be optimal at slow speeds in order to end up at proper plasma readings. For consistency of flame, a flame plasma analyzer is used. A small continuous sample of air/gas mixture was taken and burned into a controlled flame in a closed chamber within the analyzer. The flame plasma produces an electrical signal which is processed to produce the plasma value. The plasma value is an accurate, reproducible measure of the treating ability of an air/gas mixture. Depending on the web speed, the plasma value should be kept from 30 to 80, preferably 45 to 60. The lower the plasma value, the leaner air/gas mixture becomes.
The output of the burner must be increased as the speed of the web is increased to 914 M/min. (3,000 FPM) or higher in order to achieve the same level of treat. The output can range from 1 to 3970 Kg-cal/cm (10 to 40,000 Btu/inch), preferably 3.97 Kg-cal/cm to 1990K (40 to 20,000 Btu/inch). The burner/web gap should be increased with increased burner output so that the plasma portion of the flame, which is just beyond the unburnt cones of air/gas mixture, is just at the web surface.
The distance between the tip of the cone and the moving web can be 0-10.2 cm (0 to 4 inches), preferably 0.254 cm to 5.08 cm (0.1 to 2 inches). The angle at which the tip of the cone contacts the moving web can be 30 to 90 degrees, preferably 45 to 90 degrees. The triple slot design ribbon burners were used, but any other types of commercially available burner can be used. A suitable flame treating device supplied by Wise Corporation has double burner heads (triple slots).
A suitable configuration for the application of ozone to the polyolefin melt is shown in FIG. 4. The paper substrate 10 which exits the second corona discharge treatment zone 16 passes over nip roll 18 and through the nip provided by roll 18 and chill roll 20. Polyolefin curtain coating extrusion die 24 provides a continuous sheet of molten polyolefin into the nip provided by rolls 18 and 20. The extrusion die 24 has a die gap of 0.076 cm (0.03 inch). Immediately above the nip is situated an ozone applicator 26 which treats the surface of the extruded polymer melt curtain with an ozone air mixture. The polyolefin-coated paper exits this zone in the direction shown by the arrow.
Ozone (O 3 ) is a three atom allotrope of oxygen (O 2 ), which is typically formed from oxygen by either electrical discharge (as during lightning) or UV irradiation at specific wavelengths. The basic equation for the formation of ozone is
3 O.sub.2 ⃡2 O.sub.3 ΔH=68 K cal
This is an endothermic process and therefore the equilibrium between O 2 and O 3 is shifted towards O 2 with increased temperature. The rate of ozone being generated in an ozonator decreases as temperature, pressure, and flow rate of incoming feed stock of air increases. Ozone oxidizes and decomposes organic and inorganic substances at a higher rate than other reagents. Ozone is the second most powerful oxidant after fluorine. This powerful oxidation nature is being used to treat the polymer melt curtain for improved adhesion.
Ozone is a very unstable compound. Its half life at 21° C. and 1 atmospheric pressure (70° F./14.7 psi) is about 20 minutes. It will be totally degraded at 220° C. (428° F.). The temperature of the ozone-containing gas applied to the polymer melt curtain should be closely controlled to be within the range between 25° and 205° C. (80° and 400° F.), preferably 37.8° C. and 121° C. (100° and 250° F.). If the gas temperature exceeds 204° C. (400° F.), the decomposition of ozone will be accelerated, whereas if it is below 26.6° C. (80° F.), it will decrease the temperature of the polymer melt curtain. In both cases, the efficiency of treatment deteriorates significantly.
The distance between the ozone/air applicator and the extruded polymer melt curtain can be kept from 0.254 cm to 7.62 cm (0.1 to 3.0 inches), preferably 0.50 cm to 2.54 cm (0.2 to 1.0 inches). If the distance is too short, it will affect melt curtain stability, while if the distance is too great, the efficiency of treatment drops significantly. The amount of ozone applied to the polymer melt curtain can range from 2 to 323 mg/m 2 (0.2 to 30 mg per square feet), preferably 10.8-108 mg/m 2 (1 to 10 mg per square feet). If the amount is too low, degree of oxidation deteriorates, while if it exceeds 30 mg, the excess ozone in the ambient air can become health hazards to operating personnel.
A suitable ozonator is provided by Enercon Industries Corporation. An Enercon Compack 2,000 supplied power to the generator (input: 230/460 vac; 10/5 amps, 115 vac; 20 amps, output: 0 to 2 kW). A 2.54 cm (1 inch) diameter pipe with holes along the lengthwise direction (FIG. 4) was installed about 5.08 cm (2 inches) away from the laminator nip. A piece of plastic tubing running between the pipe and the ozonator carried the ozone/air mixture to the nip area.
In order to determine the efficiencies of the two CDT units, raw stock paper was first resin coated, and then it was passed through the line a second time with only one CDT unit turned on at a time. Using the dyne solutions, surface energies were checked: 46 dynes/cm from corona treatment 12 and 58 dynes/cm from corona treatment 16.
The invention is further illustrated by the following examples:
EXAMPLE 1
In this example, a base paper sheet, Kodak Coloredge photographic paper, 48.98 Kg/279 m 2 (108 lb./3,000 sq. ft. in basis weight), was extrusion coated with NA 219 (LDPE by Quantum Chemicals, 0.923 gms/cc, 10 MI). The melt temperature was kept at 288° C. (550° F.). The line speed was at 305 m/min. (1,000 FPM). Different modes of surface treatment were applied. Neither corona discharge treatment (CDT) on paper alone, nor CDT on paper along with ozone/air treatment of polyethylene melt produced any bond at all. However, an excellent bond was achieved when the paper was treated with both CDT and flame, and the polyethylene melt curtain was treated with ozone/air mixture.
__________________________________________________________________________ LineSample Melt Speed Air Gap Coverage SurfaceNo. Resin Paper Temp. °C. (m/min.) (cm) (Kg/92.9 m.sup.2) Treatments Adhesion__________________________________________________________________________1 NA219 A 288 304.8 22.9 3.6 #2 CDT, Exc. Flame, Ozone2 " " " " " " #2 CDT, No Ozone3 " " " " " " #1 CDT, No Ozone4 " " " " " " #1 CDT No5 " " " " " " #2 CDT No6 " " " " " " #2 CDT, Exc. Flame, Ozone__________________________________________________________________________
EXAMPLE 2
A medium density polyethylene was prepared by blending 54 parts using LDPE and 46 part using HDPE. The melt temperature was raised to 315.6° C. (600° F.) in order to maintain melt curtain stability. In order to see the effect of flame treatment, it was turned on and off during the experiment. When the flame treater was turned off, the adhesion went from "excellent" to "no-bond."
__________________________________________________________________________ LineSample Melt Speed Air Gap Coverage SurfaceNo. Resin Paper Temp. °C. (m/min.) (cm) (Kg/92.9 m.sup.2) Treatments Adhesion__________________________________________________________________________7 LDPE/ A 315.6 311 21.59 2.8 #1 CDT, Exc. HDPE Flame, Ozone8 LDPE/ " " " " " #1 CDT, No HDPE Ozone__________________________________________________________________________
EXAMPLE 3
With the same resin used in Example 2, different line speed trials were made using a little heavier basis weight paper, type `B`. This time, the CDT unit was turned on and off during the run. Shutting the CDT, increased line speed from 335.3 m/min. to 427 m/min. (1,100 FPM to 1,400 FPM), and lowering coverage from 4.54 Kg/92.9 m 2 (10 lb./1,000 sq. ft.) to 3.86 Kg/92.9 m 2 (8.5 lb./1,000 sq. ft.) did not affect the adhesion. The bond remained "excellent."
__________________________________________________________________________ LineSample Melt Speed Air Gap Coverage SurfaceNo. Resin Paper Temp. °C. (m/min.) (cm) (Kg/92.9 m.sup.2) Treatments Adhesion__________________________________________________________________________ 9 LDPE/ B 329.4 335.3 21.59 4.54 #2 CDT, Exc. HDPE Flame, Ozone10 LDPE/ " " 426.7 " 3.86 Flame, Exc HDPE Ozone__________________________________________________________________________
EXAMPLE 4
With the same resin used in Example 2, different line speed trials were made using type `A` paper 48.98 Kg/279 m 2 (108 lb./3,000 sq. ft. basis weight). The melt temperature was 329.4° C. (625° F.). All three treatment devices (CDT, flame and ozone/air) were kept turned on during the experiment. Excellent bond was achieved at 426.7 m/min. (1,400 FPM) line speed. Much higher line speed was possible.
__________________________________________________________________________ LineSample Melt Speed Air Gap Coverage SurfaceNo. Resin Paper Temp. °C. (m/min.) (cm) (Kg/92.9 m.sup.2) Treatments Adhesion__________________________________________________________________________11 LDPE/ A 315.6 365.8 21.59 4.3 #2 CDT, Exc. HDPE Flame, Ozone12 LDPE/ " 329.4 426.7 " 3.18 #2 CDT, " HDPE Flame, Ozone__________________________________________________________________________
|
A method of making resin coated photographic paper which comprises providing a paper base, subjecting the paper base to a flame treatment and a corona discharge treatment, providing a polyolefin melt curtain, treating the polyolefin resin melt curtain with a mixture of ozone and air and bringing the paper base in contact with the polyolefin melt curtain to provide a uniform layer of polyolefin resin on the paper base.
| 3
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FIELD OF THE INVENTION
The present invention relates to frame hardware for panel-type doors and, more particularly, to an improved retainer and stile for holding the stile onto a door panel.
BACKGROUND OF THE INVENTION
Panel-type doors consisting of a single, generally flat door panel, appropriate frame hardware surrounding the panel and corner connectors holding the edge frame members together. Hinges connecting one side of the door to a doorway, or upper and lower tracks on which the door slides or rolls are typically used for opening mechanisms. Double doors are constructed in which one door slides to one side in front of or in back of another adjacent door, or in which the two doors are connected together by hinges so that they open by folding. This invention is primarily useful for the by-pass type sliding or rolling doors. It may also be used with swing doors or pocket doors.
The frame hardware for such panel-type doors includes horizontal rails and vertical stiles fitted onto the ends and sides respectively of the panel. The rails and stiles each have a channel that receives the edge of the panel and are interconnected at each corner by corner connectors positioned in back of the panel.
The stiles of such door panels must be stiff enough to minimize any twisting or bending that could release the panel from the stile. Any force exerted on the stile in a direction away from the panel such as to open or close a panel may pull the stile away from the panel. This may result in the panel coming out of the corresponding channel in the stile or in the stile becoming bowed. This problem is accentuated by heavy panels such as glass or mirror panels because the forces acting on the framing hardware are greater.
There is a need for stiles and rails to grip the panels firmly enough to prevent the panel from slipping out of the channel and also to add to the stiffness and rigidity of the overall door. This is partly aesthetic and partly functional. Since many panel-type doors are assembled by hand from purchased frame hardware and separately purchased panels, there is also a need for these doors to be quickly and easily assembled without any special tools and to be inexpensive and simple to construct.
BRIEF SUMMARY OF THE INVENTION
In one embodiment, the invention comprises a panel door stile and spring panel retainer in the stile for bearing against the back of a panel inserted into the stile and retaining the stile on the edge of the panel. The stile has a panel receiving channel adjacent to its front wall and a retainer channel behind the panel receiving channel. An elongated spring retainer fits in the retainer channel. The spring retainer has a portion which bears against two spaced apart portions of the back of the stile and a deflection arm having an end opposite a position between the spaced apart portions for bearing against the back face of a panel inserted into the panel receiving channel. Preferably the flattened generally C-shaped retainer has tongues which engage a shoulder inside the retainer channel for holding the retainer in the channel.
More specifically, the edge stile has a side wall, a front wall along the front edge of the side wall and a generally U-shaped channel formed from two internal walls extending substantially normal to the side wall One of the internal channel walls is spaced apart from the front wall enough to allow a door panel to be received in the space between the front wall and the channel wall. A retainer has a mounting end for inserting into the bight of the channel and a resilient deflection arm which extends from the retainer mounting end toward the front wall into the space between the front wall and the channel. The deflection arm resiliently engages a door panel inserted in the space between the front wall and the channel wall for retaining the door panel in place. The channel has a shoulder and the retainer has a resilient tongue for engaging the shoulder. The channel also has a heel protruding from the channel wall which is furthest from the front wall for contacting and supporting the retainer. The back of the edge stile has a support edge for supporting the other end of the retainer and supporting it against movement away from the space between the front wall and the channel.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features and advantages of the present invention will be better understood by reference to the following Detailed Description, when considered in conjunction with the accompanying drawings, wherein:
FIG. 1 is a face view of the back of a panel-type door incorporating the present invention;
FIG. 2 is a cross-sectional view of a stile, retainer and door panel taken along line 2--2 in FIG. 1;
FIG. 3 is an exploded view of the components shown in FIG. 2;
FIG. 4 is a perspective view of a portion of the retainer of FIG. 2 showing the tongue; and
FIG. 5 is a view similar to that of FIG. 4 showing an alternate embodiment of the tongue.
DETAILED DESCRIPTION
The present invention is primarily intended for use on panel-type doors such as that illustrated in FIG. 1. Such a door has a vertical stile 10 at either side, a horizontal rail 12 at the top and bottom of the door and a door panel 14 such as a mirror. The stiles and rails are held together by corner connectors 16 illustrated schematically at each corner. A stile, rail and corner connector construction in part suitable for use with the present invention is shown, for example, in U.S. Pat. No. 3,750,337 to Brydolf et al. or U.S. Pat. No. 4,631,894 to Jerila.
The stiles and rails are preferably extruded from aluminum, while the corner connectors are stamped steel. The door panel can be constructed of a variety of materials, including wood, glass and plastic, and the door is typically intended for use as an interior door for a closet, or for a wardrobe or armoire. However, a great variety of other applications are possible with minor adaptations to the embodiments shown. In addition, the particular panel material selected can vary according to the application. For a typical sliding closet door, the corner connectors incorporate track guides at the top and rollers at the bottom to allow the door to slide and handle flanges 18 on each stile to allow the door to be grasped and moved to different positions.
Referring to the transverse cross section in FIG. 2, the stile 10 has a rigid outer side wall 20 with a felt strip 22 to cushion the impact of the sliding door against the door jamb. A front wall 24 extends perpendicularly from or normal to the side wall and ends with the handle flange 18. This front wall provides a visual frame, as well as an actual frame for the door panel and is preferably as narrow as possible to reduce the visual impact of the frame on the door panel. A variety of decorative features may be incorporated in the front wall of the stile and the austere stile shown in the drawings is merely exemplary.
A pair of secondary interior walls 26, 28 also extend perpendicularly from the side wall and are spaced a distance away from the front wall 24. The two interior walls 26 and 28 define a channel 30 for receiving a mounting end 32 of a spring retainer 34. The space between the front interior wall 28 and the front wall 24 forms a second door panel channel which is large enough to allow a door panel 14 to slide into the space between the front wall and the retainer channel 30. The front wall preferably has a stop 62, an elongated edge running the length of the stile, against which the door panel rests when in position.
Inside the retainer channel is a heel 36 and a flange or shoulder 38 which interact with the retainer 34 when pressed fully into the bight of the channel, as will be described below.
The retainer is preferably formed from a roll formed sheet of steel to give it significant resilient spring-like properties and is elongated along the same axis as the stile. For a typical approximately 200 cm tall sliding closet door, a set of three elongated retainers are preferably used in each stile, each retainer measuring approximately 40 cm long. Three retainers are used for obtaining a desired spring retention force against the back of a panel with retainers having a length less than the total length of the stile.
Each retainer has a mounting end 32 and a deflection arm 40. The mounting end has a first substantially flat surface 42 which ends in a bent U-shaped surface 44 which winds up nearest the outer edge of the stile. A second, substantially flat surface 46 parallel to the first flat surface extends from the opposite end of the bent U-shaped surface back in the opposite direction. A tongue 48 extends outward from this second surface away from the first surface.
The deflection arm 40 extends from the first flat surface 42. The flat surface of the deflection arm ends in a curved portion 52 which is also U-shaped but does not form a complete 180 degree turn like the U-shaped surface of the mounting end. Instead, it forms a lesser turn and leads into a third flat surface 54. This third flat surface extends outward away from the U-shaped surface 52 and back towards the mounting end of the retainer. At the end of the second flat surface is a rounded contact edge 56 which again is substantially U-shaped, preferably forming a complete 180 degree turn back toward the U-shaped section 52 of the deflection arm.
As can be seen by comparing FIGS. 2 and 3, the retainer is resilient and is deformed somewhat when installed into the stile. The retainer is easily installed into the stile by pressing the mounting end 32 into the channel. This causes the first or central flat surface 42 of the mounting end 32 to contact the raised heel 36 in the retainer channel 30. Just as the flat surface is an elongated surface, the heel is an elongated edge shown in cross section in FIGS. 2 and 3. As the mounting end is pressed still further into the channel, the tongue 48 comes in contact with the outside of shoulder 38 in the channel and is depressed downwardly, bending the tongue and the second flat surface of the mounting end towards the first surface. As the mounting end is pressed still further, the tongue passes the flange and springs back upward into the position shown in FIG. 2.
At this point, the U-shaped surface 44 of the mounting end is in contact with or in close proximity to the bottom of the channel. The flange, heel and channel bottom cooperate to hold the retainer firmly in place inside the channel.
For manufacturing convenience, when the stile is extruded, the shoulder 38 is preferably an elongated edge which runs the entire length of the stile. The tongues on the spring retainer, however, are only stamped out along portions of the length of each retainer (see e.g. FIGS. 4 and 5). If the tongues are made too long along the length of the retainer, then the retainer becomes difficult to insert into the channel. If the tongues are made too short, then they will not be strong enough to hold the retainer in place. For a 40-cm long stamped steel retainer for use in an extruded aluminum stile, it is presently preferred that there be three tongues equally spaced apart from each other, each approximately 15 mm wide. The retainer is preferably insertable into the channel with a push of the hand or a rubber mallet, and an audible click is preferably heard when the tongue passes the shoulder, locking the retainer in place.
The stile has a fourth or rear wall 58 which also extends substantially perpendicular from the side wall 20 and has a curve which ends in a support edge 60 spaced a distance away from the top of the retainer channel. Preferably, as shown in FIGS. 2 and 3, the support edge 60 is further away from the side wall than the width of the retainer from the bottom of the retainer channel in the stile. The support edge 60 supports the first flat surface of the retainer so that the retainer cannot move away from the front wall when a door panel is pushed into position.
After the retainer is pushed into the retainer channel, the stile is pushed onto a door panel. Actually, the spring force may be high enough that it is difficult to push the stile on by hand and a rubber mallet may be used against the edge of the stile to force it on the panel. The door panel slides between the resilient deflection arm's rounded edge 56 into the channel formed by the front wall 24 and the front interior wall 28. The stile is pushed onto the edge of the panel until the panel engages the stop 62 inside the stile. As the stile is pushed into position, the door panel deflects the deflection arm away from the front wall toward the support edge 60. The resilient deflection arm presses outwardly from the retainer against the back wall of the door panel to hold the door panel in place, i.e. to hold the stile on the panel. The door panel can be removed simply by pulling the door panel and stile away from each other with sufficient force. The retainer can then be removed from the stile, if desired, by pushing it along the retainer channel out one end of the stile.
The force with which the deflection arm pushes the door panel against the front wall is determined by the angle of the deflection arm's second flat portion with respect to the first flat portion of the retainer, the thickness of the steel and the width of the deflection arm. It is presently preferred that this angle be between 10° and 25°. A smaller angle, for example 15°, allows the door panel to be installed and removed more easily, while a greater angle of, for example, 20° requires significantly more force. The particular angle selected may depend on the door panel material and thickness, the retainer material and thickness and the intended application for the finished door. The rounded edge 56 at the end of the deflection arm prevents the retainer from significantly marring the back surface of the door panel 14.
As can be seen in FIG. 2, when a door panel is installed in the frame assembly, the retainer is held in position at three points: the heel 36, the support edge 60 and the back of the door panel which contacts the end of the deflection arm 56. This three-point (actually three line) contact assures that the clip is well aligned and retained in a fixed position, even if the manufacturing tolerances of the parts are not great, significantly eliminating shaking and wobbling. The spring friction of the retainer against the panel contributes to the stiffness of the stile and prevents it from bowing when the handle is used to pull a door.
Thus, the retainer has a flattened generally C-shaped cross section with one end of the C extending into the retainer channel and the other end being outside the retainer channel. The retainer is positively held in the channel by the tongues engaging the internal shoulder on the stile. The deflection arm of the retainer has an edge outside the retainer channel extending across a portion of the panel receiving channel for engaging the back face of a panel and retaining it securely in the stile, i.e., retaining the stile on the panel.
The tongue which retains the retainer in its channel can be formed in a variety of ways. As illustrated in FIG. 4, the tongue may be formed by bending an edge portion of the second flat surface outwardly away from the first flat surface of the mounting end and cutting off the excess. In the embodiment illustrated in FIG. 5, the tongue is stamped and bent from a square panel in the material of the second flat surface.
A variety of other modifications and adaptations are possible without departing from the spirit and scope of the present invention. The door panels, stile and retainer may be constructed from a variety of materials, although it is preferred that the retainer be resilient. The heel, shoulder and tongue may be dispensed with, although it is preferred that some provision be made to hold the retainer into its channel until the door panel is slipped into position. The heel provides a certain location for the bearing of the retainer against the rearward portion of the stile, easing manufacturing tolerances and enhancing uniformity of the spring force applied by the retainer against the back of a panel.
The shape and configuration of the stile can be varied in many different ways, particularly for variations in appearance. Also, the stile may be provided with a second retainer channel and a flat rear wall to allow a second door panel to be mounted to the back surface of the stile so that opposite sides of the door present a different door panel surface. Although described for a panel door stile, the retainer may also be used in a rail, or for engaging panels in other frame and panel constructions. It is not intended to limit the scope of the present invention to the embodiment described above, but only by the claims below.
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A frame assembly for fastening a stile onto a door panel comprises an edge frame member and a spring retainer. The edge frame member has a door panel channel which receives a door panel and a retainer channel which receives a retainer. The retainer channel has a heel and a shoulder projecting inwardly into the channel from opposite walls. The edge frame member also has a support edge which faces the door panel channel. The retainer has a U-shaped mounting end which snaps into the retainer channel, engaging the heel and the flange. A resilient deflection arm extends out of the channel away from the mounting end, contacts the supporting edge and bends outward into the door panel channel so that when a door panel is pressed into the door panel channel, it is resiliently engaged by the deflection arm which retains it in the door panel channel. A tongue on the mounting end locks into place behind the shoulder in the retainer channel to hold the retainer in the retainer channel.
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GOVERNMENT RIGHTS
This invention was made with United States government support under Grant CA-02817 from the United States Public Health Service. The United States government may have certain rights in the present invention.
This is a division of application Ser. No. 07/403,533, filed Sep. 6, 1989, now U.S. Pat. No. 5,101,072.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is directed to novel sulfonylhydrazines and their use as antineoplastic agents. The present invention also concerns methylating agents, especially N-methyl-N-sulfonylhydrazines, and their use as antineoplastic and trypanocidal agents.
2. Background Information
The synthesis and anticancer activity of a series of 1,2-bis(sulfonyl)-1-methylhydrazines was reported in K. Shyam, R. T. Hrubiec, R. Furubayashi, L. A. Cosby and A. C. Sartorelli, J. Med. Chem., 30, 2157-2161 (1987). Base-catalyzed decomposition to generate the putative methylating species RSO 2 N═NMe was hypothesized to account for the observed biological activity.
Trypanosomes of the brucei group are flagellated protozoa which produce lethal infections in humans and domestic mammals throughout much of sub-Saharan Africa. (M. Katz, D. D. Despommier and R. W. Gwadz, Parasitic Diseases, Springer-Verlag, New York (1982); R. Allsopp, D. Hall and T. Jones, New Scientist, 7, 41-43 (1985); C. A. Hoare, Adv. Parasitol., 5, 47-91 (1967)). With the exception of alpha-difluoromethylornithine (DFMO), the trypanocidal drugs currently in use have been available for 25 to 80 years. Current treatment of early-stage infections consists of suramin for T. rhodesiense and pentamidine for T. gambiense (S. R. Meshnick, "The Chemotherapy of African Trypanosomiasis", In: Parasitic Diseases, J. M. Mansfield, ed., Marcel Dekker, Inc., New York (1984); F.I.C. Apted, Manson's Tropical Diseases, 18th edition, Bailliere Tindall, Eastbourne (1983), pp. 72-92; W. E. Gutteridge and G. H. Coombs, The Biochemistry of Parasitic Protozoa, Macmillan, London (1977), pp. 1-25).
These therapies require approximately six weeks of hospitalization due to drug toxicity. The only drug available for late-stage sleeping sickness is melarsoprol (S. R. Meshnick, supra). This drug has serious side-effects and up to 5% of patients die due to drug toxicity. Suramin, pentamidine and melarsoprol are all administered by intravenous injection. Recently, DFMO has been shown to be effective against early-stage sleeping sickness in man and animals. However, there are doubts as to its efficacy in late-stage disease unless it is used in combination with other less desirable agents such as bleomycin (P. P. McCann, G. J. Bacchi, A. B. Clarkson, Jr., J. R. Seed, H. C. Nathan, B. O. Amole, S. H. Hutner and A. Sjoerdsma, Medical Biol., 59, 434-440 (1983); A. B. Clarkson, Jr., C. J. Bacchi, G. H. Mellow, H. C. Nathan, P. P. McCann and A. Sjoerdsma, Proc. Natl. Acad. Sci. USA, 80, 5729-5733 (1983)). Therefore, better drugs are needed to treat trypanosomiasis.
SUMMARY OF THE INVENTION
The present invention concerns sulfonylhydrazine compounds of the formula RSO 2 N(CH 2 CH 2 X)N(SO 2 CH 3 ) 2 , wherein R is an alkyl having 1 to 10 carbon atoms, preferably 1 to 6 carbon atoms and preferably methyl, ethyl, n-propyl, i-butyl or n-butyl, cycloalkyl, preferably having 3 to 6 carbon atoms, or an aryl, preferably having 6 to 12 carbon atoms, for example, phenyl, 4-tolyl, 4-methoxyphenyl, 4-chlorophenyl, 4-bromophenyl, 4-nitrophenyl, naphthyl or biphenyl and X is a halogen selected from the group consisting of F, Cl, Br and I, especially Cl, Br or I, or OSO 2 Y, wherein Y is an unsubstituted or substituted alkyl having 1 to 10 carbon atoms or an unsubstituted or substituted aryl. Y is preferably methyl, but non-limiting examples of Y also include ethyl, propyl, isopropyl, trichloromethyl, trifluoromethyl, phenyl, p-tolyl, p-methoxyphenyl, p-chlorophenyl and other substituted phenyls. A preferred compound is CH 3 SO 2 N(CH 2 CH 2 Cl)N(SO 2 CH 3 ) 2 .
The present invention also relates to a method of treating cancer (e.g., leukemias, lymphomas, breast carcinoma, colon carcinoma and lung carcinoma), in a warm-blooded animal patient, e.g., a human, by administering to such patient an antineoplastic effective amount of the aforesaid sulfonylhydrazine.
The present invention is also directed to the following two classes of methylating agents:
(1) R'SO 2 N(CH 3 )N(SO 2 CH 3 ) 2 , namely 1,2,2-tris(sulfonyl)-1-methylydrazines, wherein R' is an alkyl having 1 to 10 carbon atoms, preferably 1 to 6 carbon atoms and preferably methyl, ethyl, n-propyl, i-propyl, n-butyl or i-butyl, cycloalkyl, preferably having 3 to 6 carbon atoms, or an aryl, preferably having 6 to 12 carbon atoms, for example, phenyl, 4-tolyl, 4-methoxyphenyl, 4-chlorophenyl, 4-bromophenyl, 4-nitrophenyl, naphthyl or biphenyl.
(2) R"SO 2 N(CH 3 )N(CH 3 )SO 2 R", namely 1,2-bis(sulfonyl)-1,2-dimethylhydrazines, wherein R" is an alkyl having 1 to 10 carbon atoms, preferably 1 to 6 carbon atoms and preferably methyl, ethyl, n-propyl, i-propyl, n-butyl or i-butyl, cycloalkyl, preferably having 3 to 6 carbon atoms, or an aryl, preferably having 6 to 12 carbon atoms, for example, phenyl, 4-tolyl, 4-methoxyphenyl, 4-chlorophenyl, 4-bromophenyl, 4-nitrophenyl, naphthyl or biphenyl.
The present invention further relates to a method of treating trypanosomiasis in patients, e.g., warm-blooded animals, such as humans, horses, sheep, goats, swine, camels or cattle, by administering to such patients a trypanocidal effective amount of a methylating agent as described above.
The present invention also concerns a method of treating trypansomiasis in a warm-blooded animal patient comprising administering to said patient a trypanocidal effective amount of a compound capable of generating a methylating agent of the formula CH 3 N=NX', wherein X' is a leaving group, e.g., OH or SO 2 R'", wherein R'" is an alkyl or an aryl, more particularly an unsubstituted or substituted alkyl having 1 to 10, preferably 1 to 6, carbon atoms or an unsubstituted or substituted aryl, including other species capable of generating methyl radicals (CH 3 •), diazomethane (CH 2 N 2 ) or methyldiazonium (CH 3 N 2 + ). Non-limiting examples of such compounds which generate CH 3 N═NX' include N-methyl-N-nitrosourea, 5-(3,3-dimethyl-1-triazenyl)-1H-imidazole-4-carboxamide, streptozotocin and 1,2-bis(sulfonyl)-1-methylhydrazines.
Typical substituents for the substituted alkyl and substituted aryl for R', R" and R'" in the above formulas include halogen, e.g., chlorine, fluorine or bromine, hydroxy and nitro. Furthermore, the aryl can be substituted by C 1 -C 10 alkyl or C 1 -C 10 alkoxy.
The present invention is also directed to a method of treating cancer in a warm-blooded animal patient, e.g., human patient, comprising administering to such patient an antineoplastic effective amount of a methylating agent selected from the group consisting of
(a) R'SO 2 N(CH 3 )N(SO 2 CH 3 ) 2 , wherein R' is an alkyl having 1 to 10 carbon atoms or an aryl, for example, phenyl, 4-tolyl, 4-methoxyphenyl, 4-chlorophenyl, 4-bromophenyl, 4-nitrophenyl, naphthyl or biphenyl, and
(b) R"SO 2 N(CH 3 )N(CH 3 )SO 2 R", wherein R" is an alkyl having 1 to 10 carbon atoms or an aryl, for example phenyl, 4-tolyl, 4-methoxyphenyl, 4-chlorophenyl, 4-bromophenyl, 4-nitrophenyl, naphthyl or biphenyl.
DETAILED DESCRIPTION OF THE INVENTION
Synthesis
1-Methyl-1,2,2-tris(methylsulfonyl)hydrazine was synthesized by reacting methylhydrazine with an excess of methanesulfonyl chloride in pyridine.
1,2-Bis(methylsulfonyl)-1,2-dimethylhydrazine was prepared by reacting methanesulfonyl chloride with 1,2-dimethylhydrazine dihydrochloride in approximately a 2:1 molar ratio in pyridine. 1-(2-Chloroethyl)-1,2,2-tris(methylsulfonyl)hydrazine was synthesized as shown in the following reaction scheme: ##STR1##
The use of lithium bromide and potassium iodide in lieu of lithium chloride in the second step gave the 2-bromoethyl and the 2-iodoethyl analogues, respectively. 1-Arylsulfonyl-1-(2-chloroethyl)-2,2-bis(methylsulfonyl)hydrazines were synthesized by reacting the corresponding 1-arylsulfonyl-1-(2-methylsulfonyloxy)ethyl-2,2-bis(methylsulfonyl)hydrazine with lithium chloride in acetone. The (methylsulfonyloxy)ethyl compound, in turn, was prepared by reacting the appropriate 1-arylsulfonyl-1-(2-hydroxyethyl)hydrazide with an excess of methanesulfonyl chloride in pyridine. The 1-arylsulfonyl-1-(2-hydroxyethyl)hydrazides were prepared by methodology analogous to that described by K. Shyam, R. T. Hrubiec, R. Furubayashi, L. A. Cosby and A. C. Sartorelli, J. Med. Chem., 30, 2157-2161 (1987).
Mechanisms of Activation
The 1,2,2-tris(sulfonyl)-1-methylhydrazines are believed to undergo spontaneous hydrolysis in aqueous solutions at neutral pH to generate 1,2-bis(sulfonyl)-1-methylhydrazines as shown below. ##STR2##
In the case of 1,2,2-tris(methylsulfonyl)-1-methylhydrazine, this reaction occurs slowly. A 50 μM solution of this compound hydrolyzes at an initial rate of 1% per minute in phosphate buffered saline (pH 7.6) at 37° C.
Hydrolysis is expected to occur preferentially at N-2 to generate the 1,2-bis(sulfonyl)-1-methylhydrazine. The sulfonic acid and 1,2-bis(sulfonyl)-1-methylhydrazine that are generated are both ionized under these conditions. The release of protons can be used to follow the decomposition of these and related compounds. The release of protons can be assayed by following the decrease in absorbance at 560 nm of a weakly buffered (1 mM potassium phosphate) phenol red (21 mg/l) solution; initial pH 7.6 at 37° C. The assay can be calibrated using HCl standards.
The 1,2-bis(sulfonyl)-1-methylhydrazine anions are believed to decompose under these conditions by a two-step process, generating the putative alkylating species RSO 2 N═NCH 3 as an intermediate. The intermediate can methylate nucleophiles, such as water and other biomolecules as shown below.
RSO.sub.2 e,ovs/N/ --N(CH.sub.3)SO.sub.2 R→RSO.sub.2 N═NCH.sub.3 +RSO.sub.2.sup.-
RSO.sub.2 N═NCH.sub.3 +H.sub.2 O→RSO.sub.2.sup.- +N.sub.2 +CH.sub.3 OH+H.sup.+
The reaction of 1,2-bis(sulfonyl)-1-methylhydrazine with water at pH 7.4-7.6 at 37° C. can be followed by proton release and/or methanol generation. Methanol generation can be assayed using alcohol oxidase and measuring the resultant O 2 consumption using a Gilson oxygraph. This assay can be calibrated using methanol standards. The reaction of 1,2-bis(sulfonyl)-1-methylhydrazine with water is relatively fast [a 50 μM solution of 1,2-bis(methylsulfonyl)-1-methylhydrazine decomposes at an initial rate of 12-15% per minute in phosphate buffered saline (pH 7.6) at 37° C.] compared to the hydrolysis of 1,2,2-tris(methylsulfonyl)-1-methylhydrazine. RSO 2 N═NMe may also decompose by a free radical mechanism to a smaller extent and methylate by the generation of methyl radicals.
The 1-(2-chloroethyl)-1,2,2-tris(methylsulfonyl)hydrazine would be expected to undergo hydrolysis and base-catalyzed elimination in a manner analogous to the 1,2,2-tris(sulfonyl)-1-methylhydrazines. The chloroethylating species generated in this case, ClCH 2 CH 2 N═NSO 2 CH 3 , would be expected to act as a bifunctional alkylating agent as shown below. ##STR3## wherein Nu and Nu' are biological nucleophiles, e.g., primary or secondary amines, sulfhydryl groups or carboxy groups.
Compounds of the general structure R"SO 2 N(CH 3 )N(CH 3 )SO 2 R" may act as methylating agents by several mechanisms including:
(i) hydrolysis to generate 1,2-dimethylhydrazine followed by oxidation to give 1,2-dimethyldiazene as follows:
RSO.sub.2 N(CH.sub.3)N(CH.sub.3)SO.sub.2 R→CH.sub.3 NHNHCH.sub.3 →CH.sub.3 N═NCH.sub.3
CH.sub.3 N═NCH.sub.3 →CH.sub.3.sup.• +N.sub.2 +CH.sub.3.sup.•
(ii) N-demethylation to give 1,2-bis(sulfonyl)-1-methylhydrazine.
Formulations and Modes of Administration
The invention further provides pharmecutical compositions containing as an active ingredient the aforementioned sulfonylhydrazines, the aforementioned 1,2,2-tris(sulfonyl)-1-methylhydrazine, or the aforementioned 1,2-bis(sulfonyl)-1,2-dimethylhydrazine in the form of a sterile and/or physiologically isotonic aqueous solution.
The invention also provides a medicament in dosage unit form comprising the aforementioned sulfonylhydrazines, the aforementioned 1,2,2-tris(sulfonyl)-1-methylhydrazine, or the aforementioned 1,2-bis(sulfonyl)-1,2-dimethylhydrazine, all hereinafter referred to as the "active ingredient" or "active compound".
The invention also provides a medicament in the form of tablets (including lozenges and granules), caplets, dragees, capsules, pills, ampoules or suppositories comprising the aforementioned sulfonylhydrazine, the aforementioned 1,2,2-tris(sulfonyl)-1-methylhydrazine or the aforementioned 1,2-bis(sulfonyl)-1,2-dimethylhydrazine, all hereinafter referred to as the "active ingredient" or "active compound".
"Medicament" as used herein means physically discrete coherent portions suitable for medical administration. "Medicament in dosage unit form" as used herein means physically discrete coherent units suitable for medical administration, each containing a daily dose or a multiple (up to four times) or a sub-multiple (down to a fortieth) of a daily dose of an active compound of the invention in association with a carrier and/or enclosed within an envelope. Whether the medicament contains a daily dose, or for example, a half, a third, or a quarter of a daily dose will depend on whether the medicament is to be administered once, or for example, twice, three times, or four times a day, respectively.
The pharmaceutical compositions according to the invention may, for example, take the form of suspensions, solutions and emulsions of the active ingredient in aqueous or non-aqueous diluents, syrups, granulates, or powders.
The diluents to be used in pharmaceutical compositions (e.g., granulates) adapted to be formed into tablets, dragees, capsules and pills may include one or more of the following: (a) fillers and extenders, e.g., starch, sugars, mannitol and silicic acid; (b) binding agents, e.g., carboxymethyl cellulose and other cellulose derivatives, aliginates, gelatine and polyvinyl pyrrolidone; (c) moisturizing agents, e.g., glycerol; (d) disintegrating agents, e.g., agar-agar, calcium carbonate and sodium bicarbonate; (e) agents for retarding dissolution, e.g., paraffin; (f) resorption accelerators, e.g., quaternary ammonium compounds; (g) surface active agents, e.g., cetyl alcohol, glycerol monostearate; (h) adsorptive carriers, e.g., kaolin and bentonite; (i) lubricants, e.g., talc, calcium and magnesium stearate and solid polyethylene glycols.
The tablets, dragees, capsules, caplets and pills formed from the pharmaceutical compositions of the invention can have the customary coatings, envelopes and protective matrices, which may contain opacifiers. They can be so constituted that they release the active ingredient only or preferably in a particular part of the intestinal tract, possibly over a period of time. The coatings, envelopes and protective matrices may be made, for example, from polymeric substances or waxes.
The active ingredient can also be made up in microencapsulated form together with one or several of the above-mentioned diluents.
The diluents to be used in pharmaceutical compositions adapted to be formed into suppositories can, for example, be the usual water-soluble diluents, such as polyethylene glycols and fats (e.g., cocoa oil and high esters, [e.g., C 14 -alcohol with C 16 -fatty acid]) or mixtures of these diluents.
The pharmaceutical compositions which are solutions and emulsions can, for example, contain the customary diluents such as solvents, solubilizing agents and emulsifiers. Specific non-limiting examples of such diluents are water, ethyl alcohol, isopropyl alcohol, ethyl carbonate, ethyl acetate, benzyl alcohol, benzyl benzoate, propylene glycol, 1,3-butylene glycol, dimethylformamide, oils (for example, ground nut oil), glycerol, tetrahydrofuryl alcohol, polyethylene glycols and fatty acid esters of sorbitol or mixtures thereof.
For parenteral administration, solutions and emulsions should be sterile and, if appropriate, blood-isotonic.
The pharmaceutical compositions which are suspensions can contain the usual diluents, such as liquid diluents, e.g., water, ethyl alcohol, propylene glycol, surface-active agents (e.g., ethoxylated isostearyl alcohols, polyoxyethylene sorbite and sorbitane esters), microcrystalline cellulose, aluminum metahydroxide, bentonite, agar-agar and tragacanth or mixtures thereof.
All the pharmaceutical compositions according to the invention can also contain coloring agents and preservatives, as well as perfumes and flavoring additives (e.g., peppermint oil and eucalyptus oil) and sweetening agents (e.g., saccharin and aspartame).
The pharmaceutical compositions according to the invention generally contain from 0.5 to 90% of the active ingredient by weight of the total composition.
The pharmaceutical compositions and medicaments according to the invention can also contain other pharmaceutically active compounds.
The discrete coherent portions constituting a medicament according to the invention will generally be adapted by virtue of their shape or packaging for medical administration and may be, for example, any of the following: tablets (including lozenges and granulates), pills, dragees, capsules, suppositories and ampoules. Some of these forms may be made up for delayed release of the active ingredient. Some, such as capsules, may include a protective envelope which renders the portions of the medicament physically discrete and coherent.
The preferred daily dose for administration of the medicaments of the invention is 60 to 600 mg/square meter of body surface per day of active ingredient. Nevertheless, it can at times be necessary to deviate from these dosage levels, and in particular to do so as a function of the nature of the human or animal subject to be treated, the individual reaction of this subject to the treatment, the type of formulation in which the active ingredient is administered, the mode in which the administration is carried out and the point in the progress of the disease or interval at which it is to be administered. Thus, it may in some cases suffice to use less than the above-mentioned minimum dosage rate, while in other cases the upper limit mentioned must be exceeded to achieve the desired results. Where larger amounts are administered, it may be advisable to divide these into several individual administrations over the course of a day.
The production of the above-mentioned pharmaceutical compositions and medicaments is carried out by any method known in the art, for example, by mixing the active ingredient(s) with the diluent(s) to form a pharmaceutical composition (e.g., a granulate) and then forming the composition into the medicament (e.g., tablets).
This invention provides a method for treating the above-mentioned diseases in warm-blooded animals, which comprises administering to the animals an active compound of the invention alone or in admixture with a diluent or in the form of a medicament according to the invention.
It is envisaged that the active compounds will be administered perorally, parenterally (e.g., intramuscularly, intraperitoneally, subcutaneously, or intravenously), rectally, or locally, preferably orally or parenterally, especially perlingually or intravenously. Preferred pharmaceutical compositions and medicaments are, therefore, those adapted for administration, such as oral or parenteral administration. Administration in the methods of the invention are preferably oral administration or parenteral administration.
Treatment of Trypanosomiasis
One aspect of the present invention is the treatment of trypanosomiasis by administration of methylating agents. Such methylating agents are effective against T.rhodesiense and T.gambiense, which cause fatal diseases in man, and also against T.brucei, T.evansi and T.equiperdum, which are of veterinary importance (C. A. Hoare, Adv. Parasitol., 5, 47-91 (1967)).
Some methylating agents for use in the present invention are described in K. Shyam, R. T. Hrubiec, R. Furubayashi, L. A. Cosby and A. C. Sartorelli, J. Med. Chem., 30, 2157-2161 (1987).
Non-limiting examples of methylating agents for use in the present invention include CH 3 NHNH 2 , CH 3 NHNHCH 3 , CH 3 SO 2 N(CH 3 )NHSO 2 CH 3 , CH 3 SO 2 N(CH 3 )NHSO 2 C 6 H 4 --p--OCH 3 , (CH 3 ) 2 SO 4 , CH 3 SO 2 OCH 3 , N-methyl-N-nitrosourea, procarbazine, 5-(3,3-dimethyl-1-triazenyl)-1H-imidazole-4-carboxamide and streptozotocin.
Thirty-day "cures" of mice bearing T.rhodesiense were obtained with some of these agents at single dose levels which produced no overt signs of toxicity.
In general, compounds lacking a reactive methyl group, but structurally identical to the corresponding N-methyl analogues in all other respects, or containing the methyl group, but lacking good leaving groups, are inactive as trypanocides (see Table III hereinbelow). The kinetics of the loss of activity of methylating agents upon the "aging" of an aqueous solution correlates well with the kinetics of methanol generation, a measure of the spontaneous breakdown of these agents to generate the reactive methyl group. These findings provide strong evidence that methylation is essential for the observed biological activity of these compounds.
Methylating agents appear to have two major effects on trypanosomes, depending upon the dose level. At high levels, cytokinesis appears to be inhibited almost immediately and the cells are transformed into transitional forms containing multiple nuclei and kinetoplasts. These cells disappear from the bloodstream in 48 to 72 hours. When administered at repetitive low doses, methylating agents induce the entire population to differentiate into short-stumpy forms (short-stumpy forms cannot differentiate further unless they are taken up by a feeding tsetse fly or placed in appropriate culture conditions), as judged by morphology, NADH diaphorase positivity and other biochemical and physiological criteria. Short-stumpy forms are non-dividing differentiated cells and are not infective to the mammalian host. The latter property may make these agents useful biochemical tools in the study of differentiation in trypanosomes, since, with these compounds, it is possible to induce the entire population of trypanosomes to differentiate in a moderately synchronous manner and through this approach early events in the differentiation process can be studied. Both single high dose regimens and repetitive low doses can result in cures using a number of the methylating agents described herein.
DFMO has also been shown to induce differentiation in T. brucei (B. F. Giffin, P. P. McCann, A. J. Bitanti and C. J. Bacchi, J. Protozool., 33, 238-243 (1986)). This effect is generally attributed to the depletion of polyamines. DFMO, however, also causes a 1000-fold increase in decarboxylated S-adenosylmethionine (DSAM) and S-adenosylmethionine (SAM) (A. H. Fairlamb, G. B. Henderson, C. J. Bacchi and A. Cerami, Mol. Biochem. Parasitol. 7, 209-225 (1983)). These latter metabolites are weak chemical methylating agents and, therefore, may be in part responsible for the differentiating action of DFMO. The depletion of polyamines and trypanothione as a result of the DFMO treatment may potentiate the actions of SAM and DSAM as methylating agents by decreasing the levels of competing nucleophiles. Depletion of polyamines may also make the nucleic acids more susceptible to methylation (R. L. Wurdeman and B. Gold, Chemical. Res. Toxicol., 1, 146-147 (1988)). SAM is also the methyl donor used by many methylases; therefore, enzymatically mediated methylation reactions may also be affected.
Orally active trypanocidal agents are desirable, since in areas where trypanosomiasis is endemic, other routes of drug administration frequently present problems. Although methylating agents in general are mutagenic, in cases of multi-drug resistant trypanosomiasis which have failed to respond to existing therapies, these compounds may be extremely effective.
The distinct advantages of methylating agents over existing trypanocides include (a) high therapeutic indices, (b) oral activity, (c) novel mechanism of action, (d) broad-spectrum antitrypanosomal activity, and (e) favorable pharmacokinetics which make these compounds candidates for both agricultural and clinical development.
The invention will now be described with reference to the following non-limiting examples.
EXAMPLES
Melting points were determined on a Thomas-Hoover capillary melting point apparatus and are uncorrected. Proton magnetic resonance spectra were recorded on a Varian EM-390 spectrometer with Me 4 Si as an internal standard. Elemental analyses were performed by the Baron Consulting Co. (Orange, CT.) and the data were within 0.4% of the theoretical values.
EXAMPLES 1 to 6
A. 1-(2-Methylsulfonyloxy)ethyl-1,2,2-tris(sulfonyl)hydrazines
Example 1
Preparation of 1-(2-methylsulfonyloxy)ethyl-1,2,2-tris(methylsulfonyl)hydrazine
To an ice-cold stirred solution of 2-hydroxyethylhydrazine (6.08 g, 0.08 mol) in dry pyridine (40 ml) was added methanesulfonyl chloride (41.2 g, 0.36 mol) dropwise, while maintaining the temperature between 0° and 5° C. After keeping the reaction mixture stirred at this temperature range for an additional 3 hours, it was left in a freezer (-10° C.) for 48 hours. It was then triturated with a mixture of ice and concentrated hydrochloric acid (100 ml, 1:1, v/v). A thick semi-solid separated and settled at the bottom of the flask. Sometimes a solid separated, which was filtered and treated as described below. The clear supernatant was carefully decanted and the semi-solid was warmed to 60° C. in glacial acetic acid (150 ml) and was cooled to 5° C. The solid that separated was filtered, washed with cold glacial acetic acid (20 ml), dried and recrystallized from ethanol-acetone (1:3, v/v) using Norit A as a decolorizing agent to give 9.6 g (31%) of the title compound: m.p. 160°-162° C.; anal.(C 6 H 16 N 2 O 9 S 4 ) C,H,N: 1 H NMR (acetone-d 6 ) δ 4.5 and 4.1 (2t, 4H, CH 2 CH 2 ), 3.6 [s, 6H, N 2 (SO 2 CH 3 ) 2 ], 3.3 [s, 3H, N 1 SO 2 CH 3 ], 3.2 [s, 3H, OSO 2 CH 3 ].
Example 2
Preparation of 2,2-bis(methylsulfonyl)-1-(2-methylsulfonyloxy)ethyl-1-(4-toluenesulfonyl)hydrazine
To an ice-cold stirred mixture of 1-(2-hydroxyethyl)-1-(4-toluenesulfonyl)hydrazide (6.9 g, 0.03 mol) and dry pyridine (12 ml) was added methanesulfonyl chloride (14.1 g, 0.12 mol) dropwise, while maintaining the temperature between 0° and 10° C. After an additional 3 hours of stirring at this temperature range, the reaction mixture was left in a freezer (-10° C.) for 48 hours. It was then triturated with a mixture of ice and concentrated hydrochloric acid (100 ml, 1:1, v/v). A thick semi-solid separated and settled to the bottom of the flask. The clear supernatant was carefully decanted and the residue was boiled with ethanol (100 ml). A solid separated that was filtered while the ethanol mixture was still hot, washed with ethanol and dried. It was recrystallized from a mixture of ethanol and acetone (Norit A) to give 4.7 g (34%) of the title compound: m.p. 153°-155° C.; anal. (C 12 H 20 N 2 O 9 S 4 ) C,H,N; 1 H NMR (acetone-d 6 ) δ 7.9 and 7.4 (2d, 4H, aromatic H), 4.4 and 4.0 (2t, 4H, CH 2 CH 2 ), 3.6 [s, 6H, N(SO 2 CH 3 ) 2 ], 3.0 [s, 3H, OSO 2 CH 3 ] and 2.4 [s, 3H, ArCH 3 ].
Example 3
Preparation of 2,2-bis(methylsulfonyl)-1-(2-methylsulfonyloxy)ethyl-1-phenylsulfonylhydrazine
1-(2-Hydroxyethyl)-1-phenylsulfonylhydrazide (10.8 g, 0.05 mol) and methanesulfonyl chloride (29.6 g, 0.26 mol were reacted in dry pyridine (25 ml) and the product was isolated in a manner identical to that described for 2,2-bis(methylsulfonyl)-1-(2-methylsulfonyloxy)ethyl-1-(4-toluenesulfonyl)hydrazine (see Example 2 above): yield, 3.1 g (14%); m.p. 107°-108° C.; anal. (C 11 H 18 N 2 O 9 S 4 ) C,H,N; 1 H NMR (acetone-d 6 ) δ 8.0 and 7.7 (d and m, 5H, aromatic H), 4.3 and 4.0 (2t, 4H, CH 2 CH 2 ), 3.6 [s, 6H, N(SO 2 CH 3 ) 2 ], 3.0 (s, 3H, OSO 2 CH 3 ).
Example 4
Preparation of 2,2-bis(methylsulfonyl))-1-(2-methylsulfonyloxy)ethyl-1-[(4-methoxyphenyl)sulfonyl]hydrazine
To an ice-cold stirred mixture of 1-(2-hydroxyethyl)-1-[4-methoxyphenyl)sulfonyl]hydrazide (10.0 g, 0.04 mol) and dry pyridine (25 ml) was added methanesulfonyl chloride (29.6 g, 0.26 mol) in portions, while maintaining the temperature between 0° and 5° C. After an additional 2 hours of stirring at this temperature range, the reaction mixture was left in a freezer (-10° C.) for 48 hours. It was then triturated with a mixture of ice and concentrated hydrochloric acid (100 ml, 1:1, v/v), the clear supernatant was decanted and the thick semi-solid that separated was boiled with ethanol (100 ml) and cooled to 5° C. A yellow solid separated that was stirred with methylene chloride (200 ml) and filtered. The filtrate was evaporated to dryness in vacuo to give the crude title compound, which was recrystallized from a mixture of ethanol and acetone (Norit A): yield, 6.7 g (34%); m.p. 144°-145° C.; anal. (C 12 H 20 N 2 O 10 S 4 ) C,H,N; 1 H NMR (acetone-d 6 ) δ 7.9 and 7.1 (2d, 4H, aromatic H), 4.3 and 4.0 (2t, 4H, CH 2 CH 2 ), 3.9 [s, 3H, OCH 3 ], 3.6 [s, 6H, N(SO 2 CH 3 ) 2 ], 3.0 [s, 3H, OSO 2 CH 3 ].
Example 5
Preparation of 2,2-bis(methylsulfonyl)-1-[(4-chlorophenyl)sulfonyl]-1-(2-methylsulfonyloxy)ethylhydrazine
To an ice-cold stirred mixture of 1-[(4-chlorophenyl)sulfonyl]-1-(2-hydroxyethyl)hydrazide (12.5 g, 0.05 mol) in dry pyridine (20 ml) was added methanesulfonyl chloride (23.68 g, 0.21 mol) dropwise, while maintaining the temperature between 0° and 10° C. After an additional 2 hours of stirring at this temperature range, the reaction mixture was left in the freezer (-10° C.) for 48 hours. It was then triturated with a mixture of ice and concentrated hydrochloric acid (100 ml, 1:1, v/v). The solid that separated was filtered, stirred with chloroform (300 ml) for 10 minutes, treated with Norit A and filtered. On evaporation of the filtrate to dryness in vacuo a solid was obtained that was recrystallized from ethyl acetate-petroleum ether (Norit A) to give 6.3 g (26%) of the title compound: m.p. 152°-153° C.; anal. (C 11 H 17 ClN 2 O 9 S 4 ) C,H,N: 1 H NMR (acetone-d 6 ) δ 8.1 and 7.7 (2d, 4H, aromatic H), 4.5 and 4.1 (2t, 4H, CH 2 CH 2 ), 3.6 [s, 6H, N(SO 2 CH 3 ) 2 ], 3.1 [s, 3H, OSO 2 CH 3 ].
Example 6
Preparation of 2,2-bis(methylsulfonyl)-1-[(4-bromophenyl)sulfonyl]-1-(2-methylsulfonyloxy)ethylhydrazine
This compound was prepared by reacting 1-[(4-bromophenyl)sulfonyl]-1-(2-hydroxyethyl)hydrazide (5.2 g, 0.018 mol) with methanesulfonyl chloride (9.0 g, 0.079 mol) in dry pyridine (15 ml) in a manner analogous to that described for 2,2-bis(methylsulfonyl)-1-[(4--chlorophenyl)sulfonyl]-1-(2-methylsulfonyloxy)ethylhydrazine (Example 5): yield, 2.5 g, (27%); m.p. 154°-155° C.; anal. (C 11 H 17 BrN 2 O 9 S 4 ) C,H,N; 1 H NMR (acetone-d 6 ) δ 7.9-8.0 (2d, 4H, aromatic H), 4.4 and 4.1 (2t, 4H, CH 2 CH 2 ), 3.6 [s, 6H, N(SO 2 CH 3 ) 2 ], 3.0 [s, 3H, OSO 2 CH 3 ].
EXAMPLES 7 TO 14
B. 1-(2-Haloethyl)-1,2,2-tris(sulfonyl)hydrazines
Example 7
Preparation of 1-(2-chloroethyl)-1,2,2-tris(methylsulfonyl)hydrazine
A mixture of 1-(2-methylsulfonyloxy)ethyl-1,2,2-tris(methylsulfonyl)hydrazine (2,0 g, 0.005 mol), lithium chloride (2.0 g, 0.047 mol) and dry acetone (50 ml) was heated under reflux for 96 hours. The reaction mixture was cooled to room temperature, filtered and the filtrate evaporated to dryness in vacuo. The residue was warmed with chloroform (100 ml) to 50° C., filtered and the filtrate was evaporated to dryness in vacuo. Recrystallization of the residue from ethanol gave 1.1 g (65%) of the title compound: m.p. 154°-155° C.; anal. (C 5 H 13 ClN 2 O 6 S 3 ) C,H,N; 1 H NMR (CDCl 3 ) δ 3.6-4.0 (m, 4H, CH 2 CH 2 ), 3.5 [s, 6H, N 2 (SO 2 CH 3 ) 2 ], 3.2 (s, 3H, N 1 SO 2 CH 3 ).
Example 8
Preparation of 1-(2-bromoethyl)-1,2,2-tris(methylsulfonyl)hydrazine
1-(2-Bromoethyl)-1,2,2-tris(methylsulfonyl)hydrazine was prepared in a manner analogous to that of the corresponding 2-chloroethyl analogue by reacting 1(2-methylsulfonyloxy)ethyl-1,2,2-tris(methylsulfonyl)hydrazine with lithium bromide in acetone for 48 hours: yield, 35%; m.p. 147°-148° C.; anal. (C 5 H 13 BrN 2 O 6 S 3 ) C,H,N; 1 H NMR (CDCl 3 ) δ 4.0 and 3.6 (2t, 4H, CH 2 CH 2 ), 3.5 [s, 6H, N 2 (SO 2 CH 3 ) 2 ] and 3.2 [s, 3H, N 1 SO 2 CH 3 ].
Example 9
Preparation of 1-(2-iodoethyl)-1,2,2-tris(methylsulfonyl)hydrazine
1-(2-Iodoethyl)-1,2,2-tris(methylsulfonyl)hydrazine was prepared in a manner analogous to that of the corresponding 2-chloroethyl analogue by reacting 1-(2-methylsulfonyloxy)ethyl-1,2,2-tris(methylsulfonyl)hydrazine with potassium iodide in acetone for 48 hours: yield, 66%; m.p. 136°-138° C.; anal. (C 5 H 13 IN 2 O 6 S 3 ) C,H,N; 1 H NMR (CDCl 3 ) δ 4.0 and 3.4 (2t, 4H, CH 2 CH 2 ), 3.5 [s, 6H, N 2 (SO 2 CH 3 ) 2 ] and 3.2 [s, 3H, N 1 SO 2 CH 3 ].
Example 10
Preparation of 2,2-bis(methylsulfonyl)-1-(2-chloroethyl)-1-(4-toluenesulfonyl)hydrazine
A mixture of 2,2-bis(methylsulfonyl)-1-(2-methylsulfonyloxy)ethyl-1-(4-toluenesulfonyl)hydrazine (2.0 g, 0.0043 mol), dry lithium chloride (2.0 g, 0.047 mol) and dry acetone (50 ml) was heated under reflux for 4 days. The reaction mixture was filtered and the filtrate was evaporated to dryness in vacuo. The residue was warmed with chloroform (100 ml) to 40° C., filtered and the filtrate was evaporated to dryness. The residue was boiled with ethanol (150 ml) and cooled to 10° C. The unreacted sulfonate which crystallized was removed by filtration and the filtrate was evaporated to dryness in vacuo. The residue thus obtained was recrystallized from chloroform-petroleum ether (Norit A) to give 1.2 g (69%) of the title compound: m.p. 99°-101° C.; anal. (C 11 H 17 ClN 2 O 6 S 3 ) C,H,N; 1 H NMR (CDCl 3 ) δ 7.9 and 7.4 (2d, 4H, aromatic H), 3.6-3.9 (m, 4 H, CH 2 CH 2 ), 3.5 [s, 6H, (SO 2 CH 3 ) 2 ] and 2.4 [s, 3H, ArCH 3 ].
Example 11
Preparation of 2,2-bis(methylsulfonyl)-1-(2-chloroethyl)-1-phenylsulfonylhydrazine
A mixture of 2,2-bis(methylsulfonyl)-1-(2-methylsulfonyloxy)ethyl-1-phenylsulfonylhydrazine (2.0 g, 0.0044 mol), dry lithium chloride (2.0 g, 0.047 mol) and dry acetone (50 ml) was heated under reflux for 5 days. The reaction mixture was filtered and the filtrate was evaporated to dryness in vacuo. To the residue was added chloroform (100 ml) and the mixture was stirred for 10 minutes and filtered. The filtrate was evaporated to dryness and the semi-solid residue obtained was dissolved by boiling in a minimum quantity of ethanol and was filtered. On cooling, the title compound was obtained as white crystals: yield, 0.68 g (39%); m.p. 114°-115° C.; anal. (C 10 H 15 ClN 2 O 6 S 3 ) C,H,N; 1 H NMR (acetone-d 6 ) δ 8.0 and 7.7 (d and m, 5H, aromatic H), 3.6-4.0 (m, 4H, CH 2 CH 2 ) and 3.6 [s, 6H, 2CH 3 ].
EXAMPLES 12 TO 14
The following 1-(2-chloroethyl)-1,2,2-tris(sulfonyl)hydrazines were synthesized using procedures similar to those described above:
Example 12
2,2-Bis(methylsulfonyl)-1-(2-chloroethyl)-1-[(4-methoxyphenyl)sulfonyl]hydrazine
Yield, 68%; m.p. 109°-110° C.; anal. (C 11 H 17 ClN 2 O 7 S 3 ) C,H,N: 1 H NMR (CDCl 3 ) δ 7.9 and 7.0 (2d, 4H, aromatic H), 3.9 (s, 3H, OCH 3 ), 3.5-3.8 (m, 4H, CH 2 CH 2 ) and 3.5 [s, 6H, (SO 2 CH 3 ) 2 ].
Example 13
2,2-Bis(methylsulfonyl)-1-(2-chloroethyl)-1-[(4-chlorophenyl)sulfonyl]hydrazine
Yield, 69%; m.p. 122°-123° C.; anal. (C 10 H 14 Cl 2 N 2 O 6 S 3 ) C,H,N; 1 H NMR (CDCl 3 ) δ 7.9 and 7.5 (2d, 4H, aromatic H), 3.6-4.0 (m, 4H, CH 2 CH 2 ) and 3.5 [s, 6H, 2CH 3 ].
Example 14
2,2-Bis(methylsulfonyl)-1-[(4-bromophenyl)sulfonyl]-1-(2-chloroethyl)hydrazine
Yield, 45%; m.p. 117°-118° C.; anal. (C 10 H 14 BrClN 2 O 6 S 3 ) C,H,N; 1 H NMR (acetone-d 6 ) δ 7.9-8.0 (2d, 4H, aromatic H), 3.7-4.1 (m, 4H, CH 2 CH 2 ) and 3.6 [s, 6H, 2CH 3 ].
Example 15
C. 1,2-Bis(methylsulfonyl)-1,2-dimethylhydrazine
1,2-Dimethylhydrazine dihydrochloride (2.6 g, 0.02 mol) was suspended in ice-cold dry pyridine (6 ml) and the mixture was stirred for 10 minutes. Methanesulfonyl chloride (5.0 g, 0.043 mol) was added in portions to this mixture, while maintaining the temperature between 0° and 10° C. After an additional 1 hour of stirring at 0° to 5° C., the reaction mixture was left in a freezer (-10° C.) overnight. The pH of the reaction mixture was adjusted to pH 1 with cold dilute hydrochloric acid. The solid that separated was filtered and recrystallized from ethanol (Norit A) to give 1.4 g (32%) of the title compound: m.p. 168°-169° C.; anal. (C 4 H 12 N 2 O 4 S 2 ) C,H,N; 1 H NMR (CDCl 3 ) δ 3.1 [2s, 12H, 2(CH 3 SO 2 NCH 3 )].
Example 16
D. 1-Methyl- 1,2,2-tris(methylsulfonyl)hydrazine
To an ice-cold stirred solution of methylhydrazine (4.6 g, 0.1 mol) in dry pyridine (30 ml) was added methanesulfonyl chloride (44.6 g, 0.39 mol) dropwise, while maintaining the temperature between 0° and 10° C. The reaction mixture was left in a freezer (-10° C.) for 2 days. It was then triturated with a mixture of ice and concentrated hydrochloric acid (1:1, v/v, 100 ml). The precipitate that formed was collected, washed with cold water and dried. This product was stirred with chloroform (200 ml) and filtered. The undissolved material, consisting mainly of 1,2-bis(methylsulfonyl)-1-methylhydrazine, was discarded and the filtrate was treated with decolorizing carbon, filtered and evaporated to dryness in vacuo to give a yellow solid, which was crystallized twice from ethanol (Norit A) to give 5.1 g (18%) of the title compound: m.p. 123°-124° C.; anal. (C 4 H 12 N 2 O 6 S 3 ) C,H,N; 1 H NMR (acetone-d 6 ) δ 3.6 [s, 6H, N 2 (SO 2 CH 3 ) 2 ], 3.5 (s, 3H, N--CH 3 ), 3.2 (s, 3H, N 1 SO 2 CH 3 ).
Example 17
Antineoplastic Activity
The tumor-inhibitory properties of several compounds, e.g., 1,2-bis(methylsulfonyl)-1-methylhydrazine, 1-methyl-1,2,2-tris(methylsulfonyl)hydrazine, 1,2-bis(methylsulfonyl)-1,2-dimethylhydrazine and 1-(2-chloroethyl)-1,2,2-tris(methylsulfonyl)hydrazine were determined by measuring the effects of these agents on the survival time of mice bearing the L1210 leukemia as described by K. Shyam, L. A. Cosby, and A. C. Sartorelli, J. Med. Chem., 28, 525-527 (1985). The results are summarized in Table I.
TABLE I__________________________________________________________________________Effects of Sulfonylhydrazine Derivatives on theSurvival Time of Mice Bearing the L1210 Leukemia Optimum effectiveCompound Daily Dose, mg/kg.sup.a AvΔ Wt, %.sup.b % T/C.sup.c 60-day cures,__________________________________________________________________________ %MeSO.sub.2 N(Me)N(SO.sub.2 Me).sub.2 150 -7.7 186 0MeSO.sub.2 N(Me)N(Me)SO.sub.2 Me 20 -11.3 158 0MeSO.sub.2 N(Me)NHSO.sub.2 Me 40 -10.7 180 0MeSO.sub.2 N(CH.sub.2 CH.sub.2 Cl)N(SO.sub.2 Me).sub.2.sup.d 60 -7.2 -- 100MeSO.sub.2 N(CH.sub.2 CH.sub.2 Br)N(SO.sub.2 Me).sub.2 150 -2.0 213 0MeSO.sub.2 N(CH.sub.2 CH.sub.2 OSO.sub.2 Me)N(SO.sub.2 Me).sub.2 100 -4.2 198 0MeSO.sub.2 N(CH.sub.2 CH.sub.2 I)N(SO.sub.2 Me).sub.2 150 +8.0 110 0C.sub.6 H.sub.5 SO.sub.2 N(CH.sub.2 CH.sub.2 Cl)N(SO.sub.2 Me).sub.2 150 +0.5 187 40MeO--4--C.sub.6 H.sub.4 SO.sub.2 N(CH.sub.2 CH.sub.2 Cl)N(SO.sub.2Me).sub.2 200 +5.9 -- 100Me--4--C.sub.6 H.sub.4 SO.sub.2 N(CH.sub. 2 CH.sub.2 Cl)N(SO.sub.2Me).sub.2 150 -12.0 215 60Cl--4--C.sub.6 H.sub.4 SO.sub.2 N(CH.sub.2 CH.sub.2 Cl)N(SO.sub.2Me).sub.2 200 -3.4 203 60Br--4--C.sub.6 H.sub.4 SO.sub.2 N(CH.sub.2 CH.sub.2 Cl)N(SO.sub.2Me).sub.2 150 +0.9 241 60__________________________________________________________________________ .sup.a Administered once daily for 6 consecutive days, beginning 24 hours after tumor transplantation with 5-10 animals being used per group. .sup.b Average change in body weight from onset to termination of therapy .sup.c % T/C = average survival time of treated/control animals × 100. .sup.d % T/C vs. P388 leukemia = 218 (80% 60day cures) at 60 mg/kg/day
The methylating agents displayed considerable activity against this tumor and the chloroethylating agent [MeSO 2 N(CH 2 CH 2 Cl)N(SO 2 Me) 2 ] was exceedingly active, giving 60-day "cures" of the L1210 leukemia at levels of 40 and 60 mg/kg per day x 6. Replacement of the chloroethyl group in MeSO 2 N(CH 2 CH 2 Cl)N(SO 2 Me) 2 by bromoethyl or methylsulfonyloxyethyl resulted in retention of activity against the L1210 leukemia, the compounds giving maximum % T/C values of 213 and 198 percent, respectively. Activity was abolished when the chloroethyl group was replaced by iodoethyl.
A single intraperitoneal dose of 1.2 g/kg or six daily intraperitoneal doses of 200 mg/kg of MeSO 2 N(CH 2 CH 2 Cl)N(SO 2 Me) 2 produced no lethality in normal mice. Thus, the relatively great efficacy of this compound against the L1210 and P-388 leukemias and its relative lack of toxicity makes it an agent of significant promise.
Example 18
Trypanocidal Activity
The trypanocidal properties of several methylating agents including MeSO 2 N(Me)N(SO 2 Me) 2 and MeSO 2 N(Me)N(Me)SO 2 Me were determined by measuring their effects on the survival time of CD-1 mice infected with T. rhodesiense (Y Tat 1.1), a pleiomorphic strain that produces a non-replapsing disease in mice. The level of parasites in the bloodstream and body fluids increases by approximately 10-fold per day and the animals die when the parasite burden exceeds 1 to 2×10 9 cells/ml. Infection with a single viable parasite will kill a mouse in approximately 9 to 10 days.
Mice were infected ip with approximately 10 6 trypanosomes/mouse in phosphate buffered saline containing glucose. This level of parasites produces death in 4 days post-infection. These mice were treated (ip) with a single dose of drug dissolved in the appropriate vehicle 3 days after infection, when the parasitemia was 1 to 3×10 8 cells/ml of blood and the mice, if untreated, would survive for only 24 additional hours. The number of days the mice survived beyond that of the untreated controls was used as a measure of trypanocidal activity. The level of parasitemia in treated mice was measured at regular intervals to distinguish between parasite-related and drug toxicity-related deaths. No toxic deaths were observed. Mice that survived for 30 days without detectable parasitemias were considered cured. The effects of a single dose of various methylating agents on the survival time of trypanosome-bearing mice are summarized in Table II.
TABLE II______________________________________Effects of Methylating and Ethylating Agents onthe Survival Time of Mice Bearing T. rhodesiense Dose Mean ExtensionCompound (mmol/kg) of Life (Days)______________________________________MeNHNH.sub.2 .sup.a 0.5 1MeNHNHMe.sup.a 0.2 4.3EtNHNHEt.sup.a 0.2 0MeSO.sub.2 N(Me)NHSO.sub.2 Me.sup.b 0.2 11.8MeSO.sub.2 N(Me)NHSO.sub.2 C.sub.6 H.sub.4 -p-OMe.sup.b 0.2 4.5PhSO.sub.2 N(Me)NHSO.sub.2 Ph.sup.b 0.2 5.0MeSO.sub.2 N(Me)N(SO.sub.2 Me).sub.2 .sup.b 0.2 7.7 1.0 100% cureMeSO.sub.2 N(Me)N(Me)SO.sub.2 Me.sup.b 0.2 25% cure 9.7 for relapsing animalsMe.sub.2 SO.sub.4.sup.b 0.2 3.0Et.sub.2 SO.sub.4.sup.b 0.2 0MeSO.sub.2 OME.sup.b 0.2 1.0N-Methyl-N-nitrosourea.sup.b 0.2 8.0Procarbazine.sup.a 0.2 5.0DTIC.sup.a 0.2 6.0Streptozotocin.sup.a 0.2 4.3______________________________________ .sup.a Drug that was administered was dissolved in 0.5 ml of phosphate buffered saline containing glucose. .sup.b Drug that was administered was dissolved in 0.05 ml of DMSO.
As mentioned above, compounds lacking a reactive methyl group(s), but structurally identical in all other respects, or containing the reactive methyl group(s) but lacking good leaving groups, were inactive and failed to generate methanol in phosphate buffered saline (Table III).
TABLE III______________________________________Structural Requirements for Antitrypanosomal ActivityCompoundAdministered in Mean Extension Relative Methanol0.05 ml of DMSO of Life (Days) Generation in vitro______________________________________PhSO.sub.2 N(Me)NHSO.sub.2 Ph 5 1.0PhSO.sub.2 NHNHSO.sub.2 Ph 0 0PhCON(Me)NHCOPh 0 0______________________________________
Methanol was produced by these agents in aqueous solutions free from strong competing nucleophiles. Formation of this alcohol was used as a measure of the rate of spontaneous breakdown of these compounds to generate reactive methyl groups. When aqueous buffered (pH 7.6) solutions of 1,2-bis(methylsulfonyl)-1-methylhydrazine were assayed over time for the formation of methanol, no further alcohol was generated after 15 minutes, indicating that decomposition was complete within this time period. This result correlated with the loss of biological activity upon aging of equivalent solutions, where essentially all antiparasitic activity was lost after aging for 15 minutes, (i.e., 0, 21, 73 and 97% of the antitrypanosomal activity was lost after 0, 1, 5 and 15 minutes of aging, respectively). These findings provide strong evidence that methylation is essential for the observed biological activity of these compounds. In support of this hypothesis, a number of structurally unrelated methylating agents, but not ethylating agents were found to have significant biological activity (Table II).
The absence of clear-cut structure-activity relationships is probably due to the large number of variables introduced in vivo test systems and may reflect variation in parameters other than stability and rate of generation of the alkylating species.
A representative agent, 1,2-bis(methylsulfonyl)-1-methylhydrazine, was also tested against several other trypanosoma species. Activity has been demonstrated against T. gambiense which, like T. rhodesiense, causes a fatal disease in man, and against I. brucei brucei, T. evansi and T. equiperdum, which are species of veterinary importance.
The therapeutic indices of some of the invented compounds are significantly greater than that of the antineoplastic agents tested for antitrypanosomal activity; for example, cures are obtained with 1,2,2-tris(methylsulfonyl)-1-methylhydrazine at approximately 10% of the LD 50 , whereas animals given streptozotocin at 50% of the published LD 50 survived for only 4 to 5 days longer than the control animals. Preliminary results indicate that 1,2-bis(methylsulfonyl)-1-methylhydrazine, 1,2,2-tris(methylsulfonyl)-1-methylhydrazine and 1,2-bis(methylsulfonyl)-1,2-dimethylhydrazine have comparable activity to that reported in Table II when administered orally in aqueous solutions. The decomposition of 1,2-bis(methylsulfonyl)-1-methylhydrazine in aqueous solutions can be inhibited by dosing in acidified solutions. Orally active trypanocidal agents are desirable since, in areas where trypanosomiasis is endemic, other routes of drug administration frequently present problems.
It will be appreciated that the instant specification and claims are set forth by way of illustration and not limitation, and that various modifications and changes may be made without departing from the spirit and scope of the present invention.
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Sulfonylhydrazines of the formula RSO 2 N(CH 2 CH 2 X)N(SO 2 CH 3 ) 2 , wherein R is an alkyl or an aryl and X is a halogen or OSO 2 Y, wherein Y is an alkyl or an aryl. Such sulfonylhydrazines are useful in treating cancer.
Methylating agents of the formula
(a) R'SO 2 N(CH 3 )N(SO 2 CH 3 ) 2 , wherein R' is an alkyl or an aryl and
(b) R"SO 2 N(CH 3 )N(CH 3 )SO 2 R", wherein R" is an alkyl or an aryl.
Such methylating agents are useful as antitrypanosomal and anticancer agents.
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CROSS-REFERENCE TO RELATED APPLICATION
This is a continuation-in-part of application Ser. No. 171,731, filed July 24, 1980 now U.S. Pat. No. 4,330,972.
SUMMARY OF THE INVENTION
This invention relates to a frame assembly used in fastening windows or pre-hung doors to an opening of an existing structure.
Heretofore the usual method for mounting a window or pre-hung door has been to drive fasteners through the side frame of the door or window and into the jamb of the structure. When a door or window is not properly positioned, the fasteners are removed and the door or window is reset. This creates mars on the frame or leaves holes that must be filled or covered to preserve the aesthetic appearance of the frame. This was necessary because the fastening devices were located in visible portions of the frame. Since the door and window frames of the prior art are usually from wood, they have to be painted and maintained to keep their appearance. Also, when resetting a frame made of wood, the wood often has a tendency to split as a result of drying or curing.
The door or window frame of this application includes an extruded outer frame which is formed to accommodate a wooden frame support member which fits into the outer frame. The outer frame is secured to the support member with screws or other means turned or driven into the support frame. The connected wooden support member and outer frame are fitted into an opening with attachment means such as screws turned through an anchor flange of the outer frame and into the jambs and header sides and top of the door or window opening. The screws are then covered by a strip decorative member which snaps into place between ridges in the anchor flange of the outer frame.
This construction accommodates the resetting of a door or window. The resetting can be easily accomplished by removing the decorative member and removing the fastening means driven through the anchor flange of the outer frame. Since the fastening means are covered by the decorative member when in place, there is no need to be concerned about visibly marring or defacing the frame when resetting the door or window. This method of attaching the frame also allows for easy removal of a door or window if it must be replaced. By making the outer frame of extruded metal or plastic material and the decorative member of vinyl or other molded material, the frame is essentially maintenance free.
Another advantage provided by this invention is that the production cost is less than the cost of producing an all-wood door or window frame. Also, the metal-wood or plastic-wood combination provides a frost barrier which is conducive to better insulation of the interior of the structure to which the door or window is attached.
Accordingly, it is an object of this invention to provide a novel frame for windows or pre-hung doors.
Another object of this invention is to provide a door or window frame which may be easily removed or adjusted.
It is another object of this invention to provide a door or window frame which has means hidden from sight for attaching it to the jambs of a wall.
Still another object of this invention is to provide a door or window frame which is essentially maintenance free.
Another object of this invention is to provide a door or window frame which provides a frost barrier as an inherent part of its construction.
Still another object of this invention is to provide a window frame which may accommodate many different styles of windows.
Further objects will become obvious upon a reading of the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the door assembly.
FIG. 2 is a front elevational view of the door assembly with a fragment of a decorative member illustrated therein.
FIG. 3 is a sectional view taken along line 3--3 of FIG. 2.
FIG. 4 is a sectional view of the metal door frame and wooden support frame.
FIG. 5 is a perspective view of the window assembly.
FIG. 6 is a fragmentary sectional view taken along line 6--6.
FIG. 7 is a front perspective view of the window assembly in sectionalized form with the cover member removed for purposes of illustration.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiments illustrated are not intended to be exhaustive nor to limit the invention to the precise forms disclosed. They are chosen and described in order to explain the principles of the invention and its applications and practical uses to thereby enable others skilled in the art to best utilize the invention.
The door frame assembly 8 of this invention, as shown in FIGS. 1-4, includes a three-sided outer frame 10, a corresponding wooden inner frame 12 and a decorative or cover member 14. A threshold of conventional design may be used with assembly 8.
The outer frame 10 is preferably made of an extruded material and is of the uniform cross section as shown in FIGS. 3 and 4. Outer frame 10 is configured to receive the inner frame 12 which fits snugly into it. Inner frame 12 is preferably secured to the outer frame 10 by screws 17 and 18 or other attachment means. Screws 17 are turned through inner frame 12 and anchor into inturned return flange 21 of the outer frame 10. Screws 18 are driven through one wall 11 of a U-shaped portion 13 of the outer frame 10 and are anchored in inner frame 12. Screws 17 and 18 remain hidden from view when the door frame assembly is in position against the existing wall structure 20 which defines the door opening.
The door frame assembly 8 is secured to the sides and top of the door opening in an existing structure 20 by use of screws 22 or other means turned through an outturned flange or wall 23 of portion 13 of the outer frame 10 and anchored in the existing structure 20. Wall 23 terminates in a longitudinal lip 24 which preferably extends perpendicularly outwardly from the margin thereof. A flange 25 projects substantially perpendicularly from wall 11 and preferably terminates in a groove part 26.
The walls 11 and 23 are covered by the decorative member 14 which is generally L-shaped. Decorative member 14 includes a longitudinal marginal U-shaped part 27 which fits around the lip 24 and an opposite longitudinal marginal hook part 28 which anchors in groove part 26. Decorative member 14 is retained in place by U-shaped margin 27 straddling lip 24 and the snap interlock of hook part 28 with groove 26, covering screws 22 turned into the underlying structure 20. When the door frame assembly is anchored to door opening structure 20 and decorative members 14 are applied, no means of attachment to the opening structure is visible. The frame assembly can be easily adjusted within the existing door opening by the simple removal and replacement of screws 22.
The inturned return flange 21 of the outer frame 10 provides a stop for the door 34 and is provided with a U-shaped longitudinal channel 30 whose mouth is defined by inturned ribs 31. Channel 30 receives with a snap fit a molded enlargement 32 of strip 33, preferably formed of rubber or other suitable flexible material, which is engaged by the margin of door 34 and serves as a seal or weather strip.
A second embodiment of this invention describes a window frame assembly 40 which is shown in FIGS. 5-7. Frame assembly 40 includes an outer frame member 42, inner frame member 44 and cover member 46. The outer frame 42 is made of extruded metal or plastic material and is configured to receive inner frame 44, which fits snugly into it.
Frame assembly 40 is secured to the sides of the window opening in underlying structure 80 by fasteners, such as screws 63. Screws 63 are turned through mounting holes 62 in wall 43 of outturned flange 49 and anchored in wall 80. Wall 43 terminates in a longitudinal lip 60 which preferably extends perpendicularly outward from the margin thereof. A flange 47 projects perpendicularly from wall 45 and terminates in a groove part 58.
Walls 43 and 45 are enclosed by a cover member 46 which is generally L-shaped. Cover member 46 includes a longitudinal marginal U-shaped part 54 which fits around lip 60 and an opposite marginal hook part 56 which attaches to groove part 58. Cover member 46 is retained in place by U-shaped part 54 straddling lip 60 and the interlock of hook part 56 with groove part 58 with screws 63 being hidden from view. Frame assembly 40 is easily adjusted within the opening by simple removal and replacement of screws 63.
Outer frame 42 provides for a longitudinal U-shaped channel part 57 which secures window glazing panel 64 in place by use of a gasket 59. A second window glazing panel 66 is configured to be set in preformed grooves which run horizontally along the top and bottom of frame assembly 40. Panel 66 is secured in channel part 53 within a gasket 59' and may be slid horizontally, relative to panel 64. Channel part 53 is configured to receive felt weather stripping member 48 providing an insulative function when panel 66 slides relative to panel 64. In addition, outer frame 42 is constructed to provide for a thermal barrier window 68 in periods of colder weather. Window 68 is fitted into a channel part 52 which is connected to outer frame 42.
It is to be understood that the above description of the glazing panels is merely for purposes of illustration, and is not intended to limit the structure defined therein. Frame assembly 40 may be adapted to accommodate other types of windows such as double hung, awning and casement windows.
It is understood that the invention is not to be limited to the above description but may be modified within the scope of the appended claims.
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A frame which is for mounting windows or pre-hung doors in openings of an existing structure and which includes an extruded metal or plastic outer frame, a wooden frame for the support of the extruded outer frame, fasteners which are used for attaching the outer frame at a window or door opening, and a molded cover which is secured to the outer frame and conceals the fasteners attaching the frame to the structure.
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BACKGROUND OF THE INVENTION
The invention relates to a road marking machine having at least one spray gun for a pumpable marking substance, such as paint, and a combination of two displacement pumps for dosably supplying the marking substance to the spray gun, wherein the combination of the two displacement pumps is driven in proportion with the traveling speed of the road marking machine.
Such a road marking machine is known from German patent application DE 30 07 116 C2. A serious disadvantage of that machine is the branched guiding of the paint streams after leaving the supply chambers of the pump, with the stream guided by valves. The 3/2-port-valves must be positively controlled in that their functional principle is for dividing the interrupted paint streams discharged from the supply chambers into a pulse free paint stream for the using units, and an interrupted remaining paint stream to be recycled to the reservoir. These valves are subject to high wear, in particular with abrasive paints. Furthermore, the valves are complicated and expensive with increasing operating pressures.
Besides the disadvantage associated with recycling a part of the paint stream to the reservoir, it is an additional disadvantage that this part paint stream has to be guided through a throttle, and the resistance of the throttle has to be adjusted to the resistance of the spray gun. Positively controlled valves for the control of paint streams are subject to high wear, in particular when the paints contain solid particles, and are complicated and expensive for high pressures. The same is true for the throttle.
It is a further disadvantage that the pump has to be driven even when the marking lines are interrupted, and that during the interruption the paint stream dedicated for the spray gun has to be recycled back to the reservoir through a valve to be opened and a throttle adjusted to the resistance of the spray gun.
This constant pumping is necessary to have the required spray pressure ready when the spray gun is opened again when a new part of the marking line is started.
The branched guidance of the paint with many paint contacting members is also a disadvantage when the unit has to be designed in stainless steel for paints being aggressive for normal steel, which again will greatly increase the manufacturing costs.
The process known from the patent document cited above has the further disadvantage that the two displacement members are mechanically driven through cam plates. The economic transfer of forces in this manner is limited for the sizes of the utilized pumps. Pumps of this type have been known only for the low pressure range with spray pressures up to 15 bar. For the high pressure range with pressures up to 200 bar, such a mechanical drive would be very heavy, very complicated, and costly for the higher forces involved.
SUMMARY OF THE INVENTION
It is an object of the invention to further develop a generic road marking machine, such that with a simplified construction of the pump combination, a trouble free and almost maintenance free operation is provided. This object is attained with a generic road marking machine in which a pump combination is provided comprising two single oscillating displacement pumps, wherein the single pumps, each after starting the positive displacement operation thereof, which starts during the supply operation of the corresponding other displacement pump, pre-compresses the paint with an outlet valve closed up to a pressure close or equal to the supply pressure of the supplying displacement pump, then stops while holding the pre-compression final pressure reached, and continues the displacement operation while supplying the paint only when the corresponding other displacement pump ends its supply. The term positive displacement in this context is a movement of the displacing element decreasing the volume of the pump supply chamber. The pulsing, when transferring the supply from the one single pump through the other pump, therein depends on the difference between supply pressure and the end pressure reached at the pre-compression, and is very small. The term marking substance includes various substances, but as a specific example useful in an embodiment of the invention described herein, the term paint will be used throughout this disclosure, not in a limiting sense, but rather merely as a specific example.
The control for attaining a low pulse supply is attained at the drive side of the displacing members with pumps of such a supply operation. The total paint volume leaving the pump supply chambers is pumped to the spray pistol or may be reserved for the spray pistol, respectively. The paint flow path system is simple. Other than the check valves associated with the pump supply chambers, no further control valves, which are complicated and subject to wear for deviating the paint streams, are required, and no throttles for influencing the pressure are required either. The number and complexity of the paint contacting construction members is small, leading to lower cost when adapting the materials to the requirements of the paint.
The pumps of the road marking machine are driven such that the supply volume, when changing the traveling speed, will vary in the same ratio as the traveling speed. With varying paint volumes, the supply pressure will also vary, as the outlet cross-section of the spray pistol remains the same. With varying supply pressure, the difference between supply pressure and fixedly adjusted pre-compression final pressure will also vary, and thereby the amplitude of the supply volume pulse when transferring the supply from the one pump supply chamber to the other will vary. Pulses, however, generate thin areas or interruptions in the marking line to be generated and have to be avoided for this reason.
According to the invention, an automatic adaption of the pre-compression final pressure to the supply pressure is attained.
By means of the supply pressure of the currently supplying single pump, up to the end of the displacing operation thereof, the end pressure of the pre-compression of the other single pump is controlled to a value in proportion with the supply pressure.
According to the invention, the supply pressure of the single pump currently supplying to the spray gun is used as a control value for the device which interrupts the displacement operation of the other single pump as it reaches a pre-compression pressure, defined by the supply pressure, while holding this pressure.
During the interruption of a line, i.e., with a closed spray gun, the paint pressure has to be held at a pressure which corresponds to the spraying pressure of an opened spray gun during the application of a line, in order to have the spray pressure ready, which is required for a good spray quality at the beginning of the spraying at the start of a further line part. This is attained, according to an embodiment of the invention, such that when the spray gun is closed, the oil stream for driving the pump finds a side exit open through which the oil stream is guided into the oil reservoir through a throttle generating the required pressure, wherein the pump will be stopped. The counter-pressure generated by the throttle therein is depending on the size of the oil stream being in proportion to the traveling speed, in the same manner as the paint pressure generated during the pump operation through the nozzle of the spraying gun is dependent on the size of the paint stream being in proportion with the traveling speed.
The invention is now further explained referring to a drawing depicting the example of a combination of two displacement pumps wherein the positive and negative displacement is attained by rigid displacing members displaceable in cylinders.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically illustrates the total design of the road marking machine, in principle.
FIG. 2 schematically illustrates the construction of the pump combination from FIG. 1, in principle.
FIG. 3 illustrates a side sectional view of one of the two pressure controllers of FIG. 2 for one of the two hydraulic streams to the hydraulic cylinders.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, displacement pumps 1a and 1b combined in a pump combination 100, are driven by two oil streams through ducts 108a and 108b, with the oil streams, in the size thereof, proportional with the traveling speed and equal with each other. The generation of these two oil streams from one oil stream, supplied by a hydraulic pump 104 driven by an internal combustion engine 103, is attained in a control unit 105, which is not further explained, while supplying a traveling speed signal which, e.g., is derived from a wheel 106 rolling on a road.
The backstream of the hydraulic oil from the pump combination 100 to an oil tank 107 is attained through a duct 15. A side outlet duct 109a or 109b, respectively, is connected to the ducts 108a and 108b to the pump combination 100, with the side outlet lines leading to 2/2-port-valves 110a or 110b, respectively, wherefrom again ducts lead to throttles preferably to adjustable throttles 111a or 111b, respectively. The outlet sides of these throttle valves are connected with the duct 15.
The pump combination 100 sucks paint from a reservoir 112 and supplies it through a duct 8 to a spray gun 113. Simultaneously with the closing of the spray gun 113 the valves 110a and 110b are opened. After closing the spray gun, when the pump combination 100 stands still, the oil streams being supplied through the ducts 108a and 108b now are discharged through the ducts 109a or 109b, respectively, through the opened valves 110a or 110b, respectively, and subsequently through the throttles 111a or 111b, respectively, to the oil tank 107. The throttles must be adjusted in such a way that the oil pressure acting in the ducts 109a or 109b, respectively, and therefore in the non-actuated pump combination 100, corresponds to the oil pressure which occurs when the spray gun 113 is open and the pump combination 100 is working.
Referring to FIG. 2, the pump combination 100 of FIG. 1, comprising the two displacement pumps 1a and 1b, is explained:
The displacement pumps 1a, 1b comprise displacing members 2a, 2b which are connected with pistons 3a, 3b of hydraulic cylinders 4a, 4b, such that a movement of the hydraulic pistons 3a, 3b is transferred to the displacing members 2a, 2b. With a movement of the pistons 3a, 3b, because of oil supply to cylinder chambers 5a, 5b, the paint which is contained in the pump chambers 6a, 6b is compressed, and after reaching the pressure acting in the duct 8 to the spray gun 113, is pressed through an outlet valve 7a, 7b into the duct 8. The hydraulic oil is fed to the cylinder chambers 5a, 5b through ducts 9a, 9b. For accomplishing the suction stroke, the hydraulic oil is supplied to cylinder chambers 10a, 10b. The control of the oil streams to the cylinder chambers is accomplished by means of valves 11a, 11b which are fed with the oil through ducts 108a, 108b. Each of the two displacement-piston-combinations 2a, 3a and 2b, 3b oscillates between an upper and a lower reverse position. Switches or sensors 18a, 18b and 19a, 19b in the reverse position sense the position of the corresponding displacement-piston-combination and control the oil streams by switching the corresponding hydraulic valves 11a, 11b such that the stroke is reversed. The upwards stroke is the pressure or supply stroke, respectively. The downward stroke is the suction stroke.
Ducts 12a, 12b are connected with the ducts 9a, 9b. The ducts 12a, 12b lead to pressure controllers 14a, 14b and then to the common duct 15 through connection ducts 15a, 15b back to the oil tank 107. The pressure controllers 14a, 14b are designed such that an oil stream is passed only when a certain pressure is reached, with the pressure defined by the pressure in the cylinder chambers 5a or 5b, respectively, of the pump 1a or 1b, respectively, supplying just into the duct 8. For this reason the pressure controllers 14a, 14b are connected with control pressure ducts 17a, 17b to the cylinder chambers 5a, 5b.
The pressure controller 14a associated with the pump 1a is connected with the cylinder chamber 5b of the pump 1b through the duct 17a, and the pressure controller 14b of the pump 1b is connected with the cylinder chamber 5a of the pump 1a through the duct 17b.
Shortly prior to the switch 19a, 19b enacting the reverse of the supply stroke to the suction stroke, there is a further switch 20a, 20b. The object of this switch is to enact an interruption of the oil stream through the ducts 12a or 12b, respectively, to the oil tank, and that of the other pump standing still at the end of the pre-compression stroke. Therefore, the switch 20a is dedicated for the interruption of the oil stream through the duct 12b, and the switch 20b is dedicated for the interruption of the oil stream through the duct 12a.
The pump 1b is illustrated in the supply operation, i.e., it supplies paint through the opened outlet valve 7b into the duct 8 to the spray gun 113. The pressure acting in the cylinder chamber 5b and therefore in the ducts 9b, 12b and 17a depends on the pressure of the paint in the pump chamber 6b.
The pump 1a is illustrated standing still after the pre-compression stroke is finished. The pressure controller 14a is in the opened position such that the hydraulic oil streaming into the duct 9a is discharged through the duct 12a to the duct 15. Therein, the pressure in the duct 9a, and therefore in the cylinder chamber 5a, and also the pressure in the pump chamber 6a, is maintained at a value by the pressure controller 14a which is defined by the geometric design in the pressure controller 14a and by the pressure of the cylinder chamber 5b of the pump 1b acting as a control pressure through the duct 17a onto the pressure controller.
When the displacing member 2b, during the supply stroke, reaches the switch or sensor 20b, this switch or sensor enacts the interruption of the oil stream through the duct 12a. This may be accomplished by different means, e.g., by check valves in the ducts 12a, 12b. In the example illustrated, this is accomplished by enacting an additional force onto the valve slider of the pressure controller 14a, whereby the pressure controller is closed. Thereupon, the displacing member 2a continues its pressure stroke now as a supply stroke, wherein paint is pressed or forced through the opening outlet valve 7a into the duct 8 to the spray gun 113.
When the displacing member 2b, at the end of the supply stroke thereof, reaches the lower dead point, the suction stroke is triggered by the switch 19b, whereupon the outlet valve 7b closes and the paint streams through an opening inlet valve 21b (or 21 a in the left pump 1a) into the chamber 6b.
By means of adjusting the distance between the switches 20b and 19b, a lag between the switch signal and completed valve switch may be compensated such that a continuous supply stroke of the pump 1a, to the ending supply stroke of the pump 1b, is accomplished.
When the displacing member 2a is in the supply stroke, the displacing member 2b enacts the suction stroke because the supply of hydraulic oil into the cylinder chamber 12b, with the velocity of the suction stroke, is larger than that of the pressure stroke. The switch or sensor 18b, respectively, enacts the completion of the suction stroke, and a transfer to the pressure stroke, which begins with the pre-compression of the paint. The oil pressure resulting in the duct 9b to the cylinder chamber 5b is also present in the pressure controller 14b through the duct 12b. The pressure controller remains closed up to reaching the opening pressure because the oil pressure from the cylinder chamber 5a of the pump 1a enacting the supply stroke with the oil pressure being the control pressure acting on the pressure controller through the duct 17b. The size of the opening pressure, as has been explained before, is defined by the geometric design in the pressure controller and by the control pressure. After opening the pressure controller 14b, the hydraulic oil supplied through the duct 9b streams through the duct 15 to the oil tank 107, while holding the opening pressure.
In FIG. 3, one of the two pressure controllers which have the same function is illustrated, in an example of the pressure controller 14a. In a housing 25a there is a slider 26a containing, at the end thereof, a conical closing member 27a. This conical member closes an opening 28a, with a cross section A 2 , which is connected with the duct 12a and thereby with the hydraulic cylinder chamber 5a. In direction towards the closing member 27a, the opening 28a is enlarged to form a chamber 29a. The chamber 29a is connected with the duct 15 leading to the oil tank 107. The end of the slider 26a facing away from the closing member 27a has an effective cross-section A, and together with the housing 25a forms a chamber 30a. This chamber 30a is connected with the duct 17a and thereby with the hydraulic cylinder chamber 5b of the pump 1b, with the pump supplying paint into the duct 8 to the spray gun 113.
Furthermore, the housing 25a comprises a chamber 31a with a piston 32a. The latter is connected with a piston rod 33a which projects in a sealing fashion towards the housing 25a into the chamber 30a and presses onto the front face of the slider 26a when the chamber 31a is under pressure. The hydraulic oil is supplied to the chamber 31a through a duct 34a.
By the oil pressure in the chamber 30a, a force F 1 equaling A 1 ×p.sub.(5b) acts on the slider 26a, wherein P.sub.(5b) is the hydraulic pressure of the cylinder chamber 5b. In the opening 28a, a force F 2 , equaling A 2 ×p.sub.(5a), in direction opposite to F 1 acts on the slider, wherein p.sub.(5a) is the hydraulic pressure of the cylinder chamber 5a of the pump 1a accomplishing the pre-compression stroke. While the force F/ 2 increases from zero with increasing pre-compression in the pump chamber 6a, and therefore with correspondingly increasing hydraulic pressure p.sub.(5a), the force F 1 has a constant value. When the force F 1 is equal to F 2 , the closing force for the opening 28ais zero and the hydraulic oil begins to stream or flow from the opening 28a through the chamber 29a to the duct 15a when the closing member 27a opens. The accomplished oil pressure corresponds to the end pressure of the pre-compression of the paint in the pump chamber 6a. Now the piston displacement combination 3a, 2a comes to a standstill. The furthermore streaming oil through the duct 9a will then stream through the pressure controller 14a to the duct 15, wherein the oil pressure in the opening 28a is held constant by the force F 1 acting on the opening. The ratio of the pre-compression end pressure of the pump 1a to the supply pressure of the pump 1b is defined by the area ratio A 1 :A 2 and is not dependent on the value of the supply pressure.
When the oil stream through the opening 28a has to be stopped, the pressure control chamber 31a is impinged with pressure by the switch 20b through the duct 34a, such that an additional force results which is required for closing the opening 28a. The piston displacement combination 3a, 2a then enacts the pressure stroke as a supply stroke beginning from the stand-still situation. By a control, which is not further illustrated, the impingement of the pressure control chamber 31a with pressure is held at least up to the end of the supply stroke.
When the outlet valves 7a, 7b are designed as automatically opening valves, e.g., as illustrated as check valves by means of the area ratio A 1 :A 2 , the pre-compression end pressure has to be selected smaller than the supply pressure. Otherwise the valves 7a, 7b would be opened against the supply pressure acting in the duct 8 as a consequence of the pre-compression pressure increasing above the supply pressure. This would mean that in this case both pumps would supply into the duct 8. In the case that the outlet valves 7a, 7b are provided as positively controlled valves with the control enacted by additional energy, or, when with an additional energy, an additional closing force has to be provided, then the pre-compression end pressure has to be selected equal to or larger than the supply pressure.
As is apparent from the foregoing specification, the invention is susceptible of being embodied with various alterations and modifications which may differ particularly from those that have been described in the preceding specification and description. It should be understood that I wish to embody within the scope of the patent warranted hereon all such modifications as reasonably and properly come within the scope of my contribution to the art.
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A road marking machine comprising a spray gun and a combination of two displacement pumps for supplying the marking substance to the spray gun, wherein the combination is driven in proportion with the traveling speed and wherein the pumps, each after starting the positive displacement operation thereof, which starts during the supply operation of the corresponding other displacement pump, pre-compress the marking substance, then stops and continues the pressure stroke when the other displacement pump ends its supply, with hydraulic cylinders for driving the displacement pumps.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention generally relates to methods for manufacturing plastic products, and more particularly, to a method for manufacturing small plastic products by means of an injection molding apparatus.
[0003] 2. Description of Related Art
[0004] Nowadays, electronic devices such as mobile phones and digital cameras are widely used and bring convenience to our lives. In order to attract customer, producers of these products are increasingly concentrating on the appearance of the electronic devices. Since some small parts, e.g., covers for protecting camera lenses, infrared windows, keys, are generally mounted on an outside surface of an electronic device, these small parts might effect the appearance of the electronic device. These small parts are generally formed in an injection molding apparatus, and gate is formed at the same time. In order to achieve final product, gate must be removed. However, after the gate is removed defects will appear in the final product. Therefore, removal of gate has become an important factor affecting the quality of the product.
[0005] One conventional method of removing gate is cutting off the gate inside the mold. However, the product may be adhered to the mold in this method. In addition, the workers directly contact with the products during surface treatment so that the surfaces of the products may easily become scratched and polluted.
[0006] Another conventional method for removing gate is cutting off the gate outside the mold. The gate may be removed by means of hot cutting or cold cutting. If the products are thin and the gate is relatively thick compared to the product the product easily become damaged in hot cutting, and may easily form burrs during cold cutting.
[0007] What is needed, therefore, is a method for manufacturing plastic products which can overcome the above-described shortcomings.
SUMMARY OF THE INVENTION
[0008] In a preferred embodiment, a method for manufacturing plastic product includes the steps of: forming a work piece in an injection molding apparatus, the work piece including at least one original product, a butt end, and at least one gate, each gate connecting a corresponding original product with the butt end; precutting each gate in mold before the work piece is completely cooled; removing the work piece from the injection molding apparatus; separating each original product from the butt end.
[0009] Other advantages and novel features of preferred embodiments of the present method and its applications will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a schematic, cross-sectional view of a mold in accordance with a preferred method according to the present invention, showing a work piece formed in an injection molding apparatus;
[0011] FIG. 2 is an isometric, top plan view of the work piece of FIG. 1 , the work piece including four products, and a butt end; and
[0012] FIG. 3 is a cross-sectional view of the work piece in FIG. 2 along a line III-III.
DETAILED DESCRIPTION OF THE INVENTION
[0013] In a first preferred embodiment, a method for manufacturing protective covers applied to electronic devices is disclosed according to the present invention. The protective covers are used to protect lenses mounted on electronic devices. The protective covers are generally square and roughly 0.75 mm thick. Each protective cover has a circular transparent portion at a central area thereof and an opaque portion around the transparent portion.
[0014] Referring to FIG. 1 , a work piece 30 is formed in an injection molding apparatus (not labeled).
[0015] The material of the work piece 30 is polymethylmethacrylate (PMMA). The injection molding apparatus includes an upper mold 10 , a lower mold 20 , and a precutting mechanism (not labeled). The upper mold 10 has a main runner 11 , and four divaricate runners 12 extending from the main runner 11 . The lower mold 20 has four mold cavities 22 defined therein. The shape of each mold cavity 22 corresponds to the protective cover in design. Each divaricate runner 12 communicates with a corresponding mold cavity 22 . A plurality of ejector pins 24 are moveably positioned in the lower mold 20 . The ejector pins 24 are used to push products out from the lower mold 20 . The precutting mechanism includes four precutting pins 26 . The precutting pins 26 are moveably disposed in the lower mold 20 , and are positioned under the joining points of the corresponding cavities 22 and the divaricate runners 12 .
[0016] The molten material is injected into the mold cavities 22 via the main runner 11 and the divaricate runners 12 , a gate 32 is thus formed between a corresponding mold cavity 22 and a corresponding divaricate runner 12 . The precutting pins 26 move upward and press the gate 32 before the material in mold is not completely cooled, and the material of the gate 32 is thus partly move away and the gate 32 becomes thinner. When the material in mold is completely cooled, a work piece 30 is formed. The work piece 30 includes four original lenses 34 , four precut gates 32 , and a butt end 36 . The original lens 34 connects with the butt end 36 by means of the precut gates 32 .
[0017] The thickness of the precut gates 32 can be controlled by the precutting mechanism. The thickness of the precut gates 32 depends on the moving distance of the precutting pins 26 . In this preferred embodiment, the optimal leaving thickness of the gate 32 is 0.1 mm. In this case, on one hand, the gates 32 connect the original lens 34 with the butt end 36 so that the original lens 34 can be picked up by means of the butt end 36 thus avoiding the original lens 34 being scratched and polluted. On the other hand, the gate 32 becomes thinner is weakened as a result. Therefore the gate 32 can easily be broken without forming burr or gaps.
[0018] The work piece 30 is pushed out from the lower mold 20 by the ejector pins 24 . A manipulator picks up the work piece 30 and lays it down on a reused carrier. The carrier has lots of cavities for receiving the original lens 34 . The carrier is made of flexible material.
[0019] The carrier receiving the work piece 30 is transported to the printing room. The work piece 30 is picked up by hand or manipulator via the butt end 36 , and laid down on a holder. One surface of each original lens 34 is printed using transfer printing, forming a circular transparent portion in a central area of the original lens 34 and an opaque portion around the transparent portion. The work piece 30 is dried by ultraviolet radiation in a drying apparatus. The work piece 30 is put on the carrier again. Touching of the lens 34 during operation is avoided, and of pollution and damage to the lens 34 is reduced as a result. Accordingly, the quality rate of the product is increased.
[0020] The work pieces 30 received in the carriers are transported to the assembly room. The gate 32 can be broken off by hand, in this way each lens 34 is separated from the butt end 36 . The protective lens 34 can then be assembled with other parts and used in optical devices.
[0021] During the transportation of the work piece 30 , the carriers protect the lens 34 instead of plastic bags used in the conventional method. In this case, the process of packing the work piece 30 with plastic bags is omitted. Accordingly, the production efficiency is increased, and the cost of manufacturing is reduced.
[0022] In a second preferred embodiment according to the present invention, the method is used for manufacturing keys. The material of the keys is made of acrylonitrile-butadiene-styrene (ABS). The surface treatment on the keys may involve many different methods such as crazing, spray painting, plating, and physical vapor deposition (PVD).
[0023] In a third preferred embodiment according to the present invention, the method is used for manufacturing infrared windows. The infrared windows can be made of polycarbonate (PC). In this case, the surface treatment is omitted, in which the work pieces formed in the mold are directly transported to the assembly room.
[0024] It is to be further understood that even though numerous characteristics and advantages of the present embodiments have been set forth in the foregoing description, together with details of the structures and functions of the embodiments, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.
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A method for manufacturing plastic product includes the steps of: forming a work piece ( 30 ) in an injection molding apparatus, the work piece ( 30 ) including at least an original product ( 34 ), a butt end ( 36 ), and gate ( 32 ), the gate ( 32 ) connecting a corresponding original product ( 34 ) with the butt end ( 36 ); precutting the gate ( 32 ) in a mold before the work piece ( 30 ) has completely cooled; removing the work piece ( 30 ) from the injection molding apparatus; separating each original product ( 34 ).
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to a photonic crystal fiber, a light controller, a projector, and a method of manufacturing a photonic crystal fiber, specifically to an optical fiber with the so-called photonic crystal structure in which a multiplicity of voids are arranged in a light propagation medium in the state of being extended along the longitudinal direction of the optical fiber, a light controller and a projector which each include the optical fiber, and a method of manufacturing the photonic crystal fiber.
[0002] In an optical fiber in which propagation of light energy and amplification of light are performed, a connection part called ferrule is joined to the fiber end.
[0003] The joining of the ferrule is ordinarily conducted by use of an organic adhesive. In this case, however, there have been a problem as to heat resistance, problems such as secular change, and, hence, a problem as to reliability.
[0004] As a countermeasure against the above problems, there has been proposed a method in which a holed ferrule provided, for example, with a V-shaped groove in its side surface is used, an optical fiber is disposed in and along the groove, and the ferrule and the fiber are fused to each other at their circumferential surfaces using a glass having a low softening temperature (see, for example, Japanese Patent Laid-open No. Hei 6-109944 (FIG. 2, paragraph No. [0003]).
[0005] Meanwhile, in recent years, attendant on the remarkable progress of optical digital communication, optical communications in great capacity and over long distances on a scale of several tens of kilometers have been conducted vigorously.
[0006] In this case, there is need for optical fibers having a light transmission efficiency as high as possible and a high numerical aperture. As an optical fiber of this type, there has been developed a fiber with a photonic crystal structure, i.e., a photonic crystal fiber.
[0007] The photonic crystal fiber has a configuration in which fine voids with a diameter of several micrometers or below surround the periphery of the so-called core portion of a light propagation medium composed, for example, of quartz, whereby a large variation in refractive index distribution is provided in the diametral direction, to obtain a high transmission efficiency and a high numerical aperture of not less than 0.5, for example.
[0008] On the other hand, in the long-distance high-capacity optical communications mentioned above, optical fiber amplifiers for amplifying optical signals without conversion of the optical signals into electrical signals have come to be used widely.
[0009] In the optical fiber amplifiers, also, there has been proposed an optical fiber amplifier having the above-mentioned photonic crystal fiber configuration which promises a high light transmission efficiency and a high numerical aperture.
[0010] Besides, the demand for a high light transmission efficiency and a high numerical aperture has been increased not only in the optical communication field but also in the filed of projectors and the like for which a high light intensity is desired.
[0011] In the optical fiber for conducting the light energy propagation and light amplification, light with a high output of not less than several watts is inputted and outputted through an optical fiber end, so that special care is required in fixation of the optical fiber end, from the viewpoint of safety.
[0012] Therefore, it is inappropriate to use the above-mentioned holed ferrule designed for fusion onto a circumferential side surface of the fiber. Besides, also in the case of using a normal ferrule not provided with a hole such as a V-shaped groove in its side surface, when an organic adhesive is used, the secular change of the adhesive causes the ferrule to be positionally staggered by an amount of several to several tens of micrometers, resulting in that the high-output light to be introduced into the fiber end portion leaks from the core, namely, the light propagation medium. Generation of heat attendant on the leakage of light would lead to a safety problem such as a breakage of the device including the fiber.
[0013] In addition, in the photonic crystal fiber, the voids are opening at the fiber end face, so that moisture or contaminants in air may penetrate through the openings into the voids. The penetration of moisture or contaminants generates a variation in refractive index distribution in the diametral direction of the fiber, whereby it is made impossible to maintain the intrinsic light transmission efficiency, the performance is lowered, and propagation characteristics and numerical aperture are degraded or varied, thereby lowering the reliability.
[0014] In view of this, in the photonic crystal fiber, it is necessary to seal the opening ends at the void end portion.
[0015] The sealing is carried out, for example, by a technique in which the void end portion is collapsed by heating only the end portion to a temperature of not less than 1600° C., which is the melting point of the quartz glass constituting the propagation medium of the optical fiber, for example, a temperature of 2000° C. by arc discharge.
[0016] Where this technique is used, however, the terminal end of the optical fiber is deformed, which generates such inconveniences as, for example, a distortion in the intensity distribution of the light outputted from the fiber.
[0017] In addition, in the optical fiber amplifier configuration mentioned above, a double structure is adopted in which a core composed of a gain medium for propagating incident light, for example, signal light and for amplifying the input light by excitation of excitation light is provided in a propagation medium for propagating the excitation light. In this case, also, generation of a strain in the core structure leads to the generation of a distortion in the intensity distribution of the output light, resulting in, for example, a lowering in the light transmission efficiency at a joint portion between this optical fiber and other optical fiber.
SUMMARY OF THE INVENTION
[0018] It is an object of the present invention to solve the above-mentioned problems concerning the terminal end of an optical fiber having the photonic crystal structure.
[0019] According to the first aspect of the present invention, there is provided a photonic crystal fiber which includes a ferrule disposed at a terminal end portion of a photonic crystal fiber member including a multiplicity of voids arranged in a light propagation medium in the state of being extended along the longitudinal direction of the fiber, wherein
[0020] the terminal end of the photonic crystal fiber, inclusive of an end face of the terminal end portion, is fusion bond sealed with a glass fusing material lower than the light propagation medium in melting point and transmissive to the light introduced into the photonic crystal fiber member, and
[0021] the ferrule is attached to the photonic crystal fiber member by the glass fusion bonding, and opening ends of the voids opening at the end face of the terminal end portion of the photonic crystal fiber member are sealed by the glass fusion bonding.
[0022] According to the second aspect of the present invention, there is provided a method of manufacturing a photonic crystal fiber, which includes the steps of:
[0023] disposing a ferrule at a terminal end portion of a photonic crystal fiber member including a multiplicity of voids arranged in a light propagation medium of an optical fiber in the state of being extended along the longitudinal direction of the fiber, and
[0024] fusion bond sealing the terminal end portion of the photonic crystal fiber member, inclusive of an end face of the terminal end portion, with a glass fusing material lower than the light propagation medium in melting point and transmissive to the light introduced into the photonic crystal fiber member, wherein
[0025] the ferrule is attached to the photonic crystal fiber member by fusion of the glass fusing material, and opening ends of the voids opening at the end face of the terminal end portion of the photonic crystal fiber member are sealed by fusion of the glass fusing material.
[0026] According to the third aspect of the present invention, there is provided a light controller which includes:
[0027] a light source portion, and
[0028] a light modulation device including an arrangement of light diffraction elements composed of micro-ribbons and varying the quantity of diffracted light by displacements of the light diffraction elements, wherein
[0029] the light source portion includes a light oscillator, and a photonic crystal fiber,
[0030] the photonic crystal fiber includes a ferrule disposed at a terminal end portion of a photonic crystal fiber member including a multiplicity of voids arranged in a light propagation medium in the state of being extended along the longitudinal direction of the fiber,
[0031] a glass fusing. material lower than the light propagation medium in melting point and transmissive to the light introduced into the photonic crystal fiber member is fused to the terminal end portion of the photonic crystal fiber member inclusive of an end face of the terminal end portion, the ferrule is attached to the photonic crystal fiber member by fusion of the glass fusing material, and opening ends of the voids opening at the end face of the terminal end portion of the photonic crystal fiber member are sealed by fusion of the glass fusing material, and
[0032] light from the light oscillator is introduced into the photonic crystal fiber, light is radiated from the photonic crystal fiber to the light modulation device, and the quantity of diffracted light is controlled by displacements of the micro-ribbons of the modulation device.
[0033] According to the fourth aspect of the present invention, there is provided a projector which includes:
[0034] a light source portion, and
[0035] a light modulation device including an arrangement of light diffraction elements composed of micro-ribbons and varying the quantity of diffracted light by displacements of the light diffraction elements, wherein
[0036] the light source portion includes a light oscillator, and a photonic crystal fiber,
[0037] the photonic crystal fiber includes a ferrule disposed at a terminal end portion of a photonic crystal fiber member including a multiplicity of voids arranged in a light propagation medium in the state of being extended along the longitudinal direction of the fiber,
[0038] a glass fusing material lower than said light propagation medium in melting point and transmissive to the light introduced into the photonic crystal fiber member is fused to the terminal end portion of the photonic crystal fiber member inclusive of an end face of the terminal end portion, the ferrule is attached to the photonic crystal fiber member by fusion of the glass fusing material, and opening ends of the voids opening at the end face of the terminal end portion of the photonic crystal fiber member are sealed by fusion of the glass fusing material, and
[0039] light from the light oscillator is introduced into the photonic crystal fiber, light is radiated from the photonic crystal fiber to the light modulation device, and the quantity of diffracted light is controlled by displacements of the micro-ribbons of the modulation device, so as thereby to form a projected optical image.
[0040] In the photonic crystal fiber according to the present invention, the terminal end portion of the fiber member is sealed by glass fusion bonding, so that it is possible to obviate the secular change which would occur where an organic adhesive is used. Therefore, it is possible to effectively obviate a positional stagger of the ferrule.
[0041] In addition, since the glass fusion bonding is conducted by use of a glass which is lower than the light propagation medium in melting temperature, deformation and/or distortion of the core portion in the optical fiber member as well as the distortion of intensity distribution of output light, which would occur due to high-temperature heating in the case of using a quartz glass, can be obviated, and the output light having an appropriate light intensity distribution can be maintained.
[0042] Further, since the end face of the terminal end portion of the fiber is sealed, it is possible to obviate the problem intrinsic of the photonic crystal fiber, i.e., the problem that moisture and the like would penetrate into the inside of the voids through the opening ends of the voids. Therefore, the photonic crystal fiber can stably display its performance for a long time without spoiling the intrinsic characteristics thereof, i.e., a high light transmission efficiency and a high numerical aperture.
[0043] In addition, the photonic crystal fiber according to the present invention and a light amplification fiber using the same can maintain the high light transmission efficiency, the high numerical aperture, and hence the high light intensity possessed by the fiber member. Therefore, in the light controller and the projector according to the present invention which use this configuration, light control and projection can be performed efficiently and stably.
[0044] According to the method of manufacturing a photonic crystal fiber of the present invention, the purpose of sealing the voids at the end face of the terminal end portion of the photonic crystal fiber can be accomplished, simultaneously with the purpose in the case of using an organic adhesive according to the related art, i.e., the purpose of simply adhering the fiber member and the ferrule to each other.
[0045] Besides, the light controller and the projector according to the present invention are excellent in the above-mentioned characteristics, and can perform stable light propagation by the photonic crystal fiber, so that it is possible to achieve assured light control and projection.
BRIEF DESCRIPTION OF THE DRAWINGS
[0046] The above and other objects, features and advantages of the present invention will become apparent from the following description and appended claims, taken in conjunction with the accompanying drawings, in which:
[0047] FIG. 1 is a schematic vertical sectional view of an essential part of one embodiment of a photonic crystal fiber according to the present invention;
[0048] FIG. 2 is a schematic front view, as viewed from an end face of a terminal end portion of a photonic crystal fiber member, of one embodiment of the photonic crystal fiber according to the present invention;
[0049] FIG. 3 is a schematic front view, as viewed from the end face of the terminal end portion of the photonic crystal fiber member, of another embodiment of the photonic crystal fiber according to the present invention;
[0050] FIG. 4 is a schematic step diagram illustrating a part of one embodiment of a method of manufacturing a photonic crystal fiber according to the present invention;
[0051] FIG. 5 schematically shows the constitution of one example of an apparatus for evaluating the reliability of the photonic crystal fiber according to the present invention;
[0052] FIG. 6 schematically shows the constitution of one example of an apparatus for evaluating the light amplification performance of the photonic crystal fiber according to the present invention;
[0053] FIGS. 7A and 7B schematically show the constitutions of embodiments of a light controller using the photonic crystal fiber according to the present invention;
[0054] FIG. 8 schematically shows the constitution of one embodiment of a light modulation device used in the light controller according to the present invention;
[0055] FIG. 9 is a schematic perspective view of one example of a diffraction grating structure constituting the light modulation device used in the light controller according to the present invention;
[0056] FIG. 10 is a schematic illustration of the principle of generating primary diffracted light, in the diffraction grating structure constituting the light modulation device used in the light controller according to the present invention; and
[0057] FIG. 11 schematically shows the constitution of one embodiment of a projector including the light controller using the photonic crystal fiber according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0058] Now, embodiments of a photonic crystal fiber, a light controller, a projector, and a method of manufacturing a photonic crystal fiber according to the present invention will be described below. It should be understood that the present invention naturally is not limited to the embodiments.
[0059] First, an embodiment of the photonic crystal fiber according to the present invention will be described.
[0060] FIG. 1 is a schematic vertical sectional view of an essential part of a photonic crystal fiber 9 according to the present invention.
[0061] The photonic crystal fiber 9 includes a photonic crystal fiber member 1 , and a ferrule 2 attached to a terminal end portion 1 a of the fiber member 1 . The ferrule 2 is composed, for example, of a tubular body provided with a through-hole 2 h in its center.
[0062] The terminal end portion 1 a of the fiber member 1 is inserted into the through-hole 2 h of the ferrule 2 , and is so disposed that an end face 1 f of the terminal end portion 1 a is located in the through-hole 2 h on the inner side relative to an opening end 2 f of the through-hole 2 h.
[0063] The fiber member 1 and the ferrule 2 are fusion bonded to each other in such a manner that opening ends 5 f of voids 5 (shown in FIG. 2 ) at the terminal end portion 1 a of the fiber member 1 are sealed with a glass fusing material 3 , for example, a lead-based glass or a non-lead-based bismuth glass which is lower than a light propagation medium of the fiber member 1 and the ferrule 2 in melting point.
[heading-0064] First Embodiment of Photonic Crystal Fiber Member
[0065] In this embodiment, as shown in FIG. 2 , a multiplicity of voids 5 are arranged in a light propagation medium 4 composed of quartz with an outside diameter of 125 μm, for example, in the state of being extended along the longitudinal direction of the fiber, and are arranged regularly with predetermined positional relationships in the cross section thereof having a diameter of about 5 μm, for example, i.e. in a section orthogonal to the longitudinal direction of the fiber. In other words, as viewed from the side of the light propagation medium 4 , most of the propagation medium 4 is disposed with its periphery surrounded by the voids, so that a large refractive index distribution, or refractive index difference, is generated in the diametral direction of the fiber member 1 .
[0066] In addition, the fiber member 1 is coated with a protective layer 6 composed, for example, of an acrylic resin on the circumferential surface thereof.
[0067] Next, as a second embodiment, an embodiment of a photonic crystal fiber member including a gain medium at a part of a propagation medium and having a light amplifying effect on input light, for example, signal light will be described.
[heading-0068] Second Embodiment of Photonic Crystal Fiber Member
[0069] In this embodiment, as a schematic front view as viewed from the end face 1 f of the terminal end portion 1 f of a photonic crystal fiber member 1 including a gain medium is shown in FIG. 3 , a core portion of a gain medium 7 doped with a rare earth ion, for example, erbium (Er) ion or neodium (Nd) ion to have a light amplifying effect for exciting and emitting light with a predetermined wavelength by excitation light with a predetermined wavelength is arranged in a central portion of a light propagation medium 4 composed, for example, of quartz of the fiber member 1 in the state of being extended along the longitudinal direction of the fiber.
[0070] Propagation of light is performed while incident light, for example, signal light is amplified by the gain medium 7 .
[0071] The core portion of the gain medium 7 may be elliptic in sectional shape with a major diameter of about 8 μm and a minor diameter of about 3 μm, for example. The core portion of the gain medium 7 may be composed of a quartz glass to which, for example, neodium (Nd) ions for generating amplified light with a central wavelength of about 1064 nm by excitation light and aluminum (Al) ions or germanium (Ge) ions for regulation of refractive index have been added.
[0072] In addition, in the surrounding of the core portion, a multiplicity of voids 5 with a diameter of about 5 μm are arranged in the surrounding of the propagation medium of a non-gain medium composed only of the quartz glass.
[0073] Besides, in this embodiment also, the multiplicity of voids 5 arranged regularly with predetermined positional relationships in a section orthogonal to the longitudinal direction of the fiber so as to have a refractive index distribution, or refractive index difference, in the section are arranged in the state of being extended along the longitudinal direction of the fiber.
[0074] In addition, the fiber member 1 is coated with a protective layer 6 composed, for example, of an acrylic resin on the circumferential surface thereof.
[heading-0075] Embodiment of Method of Manufacturing Photonic Crystal Fiber
[0076] A ferrule 2 is attached to the terminal end portion 1 a of the above-mentioned photonic crystal fiber member 1 .
[0077] The photonic crystal fiber member 1 has an outside diameter of about 125 μm and a length of about 6 m, for example.
[0078] The ferrule 2 may be composed of a superhigh-density light-transmitting sintered alumina body having an inside diameter of about 127 μm, an outside diameter of about 1.3 mm, and a length of about 3 mm, for example.
[0079] The ferrule 2 is composed, for example, of quartz or superhigh-density alumina, and assumes the shape of a tubular body such as a hollow cylindrical body, a polygonal-section tubular body, etc. provided with a through-hole 2 h in its center.
[0080] As for example a schematic vertical sectional view is shown in FIG. 4 , the terminal end portion 1 a of the fiber member 1 is inserted into the through-hole 2 h of the ferrule 2 , and the assembly is mounted on and fixed to a heat-insulating body 8 serving as a base for performing a fusion bonding operation thereon. In this case, the end face 1 f of the terminal end portion 1 a of the fiber member 1 is prevented from projecting from the end face 2 f of the ferrule 2 .
[0081] Next, a glass fusing material 3 , for example, a lead-based glass or a non-lead-based bismuth glass having been drawn into a bar-like shape is placed on a central area of the end face 2 f of the ferrule 2 .
[0082] The drawn fusing glass 3 may have a diameter of about 220 μm, and, for example, about 30 mg of the drawn fusing glass 3 may be used. The fusing glass may have a softening temperature of about 560° C., for example, and the working temperature therefor may be about 620° C., for example.
[0083] In this condition, the ferrule 2 is heated, for example, to about 650° C. for 30 min by use of, for example, a small-type heater (not shown) so as to melt the glass fusing material 3 , and the molten glass fusing material 3 is permitted to flow into the ferrule 2 , thereby filling the gap between the through-hole 2 h and the fiber member 1 with the molten glass fusing material 3 to a depth of 2 mm, for example, from the end face 2 f of the ferrule 2 . Thus, the ferrule 2 is fusion bonded and fixed to the terminal end portion 1 a of the fiber member 1 , and all opening ends 5 f of all voids 5 in the fiber member 1 are sealed gas-tight.
[0084] In addition, the molten glass fusing material 3 is permitted to flow into the voids in the fiber member 1 to a depth of about 300 μm, for example, from the end face 1 f of the terminal end portion 1 a of the fiber member 1 .
[0085] The terminal end face 2 f of the ferrule 2 treated as above was subjected to optical polishing by use of a tip polisher for optical fiber.
[0086] The photonic crystal fiber of the present invention according to first embodiment, produced as above, was subjected to evaluation of reliability as an optical fiber.
[heading-0087] Evaluation of Reliability
[0088] The evaluation method will be described. FIG. 5 schematically shows the constitution of an evaluation apparatus used here. As shown in the figure, the evaluation apparatus includes a photonic crystal fiber 9 according to the first embodiment of the present invention, as a specimen to be evaluated, an excitation-light light source 10 composed, for example, of a semiconductor laser, a light transmission cable 11 , a collimator lens 12 , a condenser lens 13 , a winding coil 14 on which the photonic crystal fiber 9 of the present invention is wound, and a light output meter 15 .
[0089] Laser light with a central wavelength of about 807 nm and an output of about 18 W. for example, from the excitation-light light source 10 is inputted into the light transmission cable 11 , then passed through the collimator lens 12 and the condenser lens 13 , and inputted into the photonic crystal fiber 9 of the present invention through the terminal end portion thereof.
[0090] In this reliability evaluation, the excitation light incident on the terminal end portion of the photonic crystal fiber 9 of the present invention from the condenser lens 13 is inputted, with its spot diameter regulated to about 50 μm, for example, so that leakage of light is generated when the excitation light is incident on the photonic crystal fiber 9 of the present invention which has a diameter of about 40 μm, for example.
[0091] Under this condition, the light output from the photonic crystal fiber 9 of the present invention was measured by the light output meter 15 , to be about 14 W, which indicates a leakage of output of about 3 W taking into account the portion lost by reflection.
[0092] The system was operated continuously for 2 hr in this configuration, upon which the photonic crystal fiber 9 of the present invention showed no particular change, and the value of the outgoing light output showed no large variation.
[0093] On the other hand, when a specimen produced by attaching an optical fiber to a ferrule by use of a conventional adhesive was subjected to the same evaluation as above, the adhered portion was burned about 5 min after the start of operation of the excitation-light light source 10 , and the outgoing light output from the conventional optical fiber was lowered to 0.5 W.
[0094] The above results clearly show that the use of the photonic crystal fiber 9 according to the present invention makes it possible to enhance reliability and to enhance resistance to leakage of light at the incidence of high-output light on the optical fiber end, and is suitable for transmission of optical energy.
[0095] Next, the photonic crystal fiber of the present invention according to second embodiment was evaluated as to light amplification performance.
[heading-0096] Evaluation of Light Amplification Performance
[0097] The evaluation method will be described. FIG. 6 schematically shows the constitution of an evaluation apparatus used here. The evaluation apparatus includes a photonic crystal fiber 9 of the present invention, an input light source, i.e., a signal light source 16 , a mirror 17 , a dichroic mirror 18 , a condenser lens 19 , a collimator lens 20 , a dichroic mirror 21 , a mirror 22 , a condenser lens 23 , an image pickup device 24 , and a beam analyzer 25 . In addition, the apparatus includes a pumping-light light source, i.e., an excitation-light light source 26 , a cable 27 for transmitting the pumping light from the pumping-light light source, and a collimator lens 28 . Further, the apparatus includes a condenser lens 29 and a mirror 30 on the opposite side of the condenser lens 19 with respect to the dichroic mirror 18 .
[0098] In the above configuration, light amplification is evaluated.
[0099] First, signal light with a central wavelength of about 1064 nm, a pulse width of 5 nanoseconds with an interval of 2 MHz, and a maximum output of 0.2 W, for example, outputted from the signal light source 16 is reflected respectively by the mirror 17 and the dichroic mirror 18 , and is condensed by the condenser lens 19 , to be incident on a terminal end portion on one side of the light-amplifying photonic crystal fiber 9 of the present invention.
[0100] On the other hand, pumping light with a central wavelength of 807 nm, for example, outputted from the pumping-light light source 26 is transmitted through the pumping-light guide cable 27 , the collimator lens 28 and the condenser lens 20 , to be incident on the photonic crystal fiber 9 .
[0101] In this instance, in the photonic crystal fiber 9 of the present invention, the above-mentioned gain medium 7 is excited, whereby excitation is caused to amplify the light with the wavelength of about 1064 nm, for example. The amplified light is transmitted through the collimator lens 20 , the dichroic mirror 21 , the mirror 22 , and the condenser lens 23 , to be introduced into the image pickup device 24 , and the resulting image pickup light is analyzed by the beam analyzer 25 .
[0102] In this case, a part of the pumping light incident on the photonic crystal fiber 9 of the present invention is collimated by the condenser lens 19 , is transmitted through the dichroic mirror 18 , is condensed by the condenser lens 29 , and is reflected by the mirror 30 , to be again incident on the photonic crystal fiber 9 , thereby exciting the gain medium 7 .
[0103] In this configuration, the intensity distribution of the light having undergone the light amplification by the photonic crystal fiber 9 of the present invention was observed on the beam analyzer 25 , upon which an intensity distribution conforming to Gaussian distribution could be obtained.
[0104] On the other hand, when a photonic crystal fiber produced by sealing the voids through melting by arc discharge based on the above-mentioned conventional method was used, the intensity distribution of amplified light was asymmetric.
[0105] Next, an embodiment of a light controller having the photonic crystal fiber structure according to the present invention will be described.
[heading-0106] Embodiment of Light Controller
[0107] In this embodiment, as a schematic illustration of the constitution of a light controller is shown in FIG. 7A , the light controller includes a light source portion 32 and a light modulation device 33 .
[0108] The light source portion 32 includes an input light source 34 , a light-amplifying photonic crystal fiber 9 , and an excitation-light light source (pumping-light light source) 35 .
[0109] In this configuration, input light from the light source portion 32 is introduced into the photonic crystal fiber 9 ; on the other hand, excitation light from the excitation-light light source 35 composed, for example, of a semiconductor laser is introduced into the optical fiber 9 , for amplifying the input light, and the amplified light is introduced into the light modulation device 33 .
[0110] In another embodiment, as a schematic illustration of the constitution of a light controller is shown in FIG. 7B , a waveform conversion device (SHG: Secondary Harmonic Generator) 36 composed of a non-linear optical device is provided. In FIG. 7B , the portions corresponding to those in FIG. 7A are denoted by the same symbols as used above, and description thereof is omitted.
[0111] In this case, amplified light from the above-mentioned photonic crystal fiber 9 is subjected to waveform conversion by the waveform conversion device 36 . For example, input light with a central wavelength of about 1064 nm from the input light source 34 is inputted into the photonic crystal fiber 9 , is excited by excitation light with a central wavelength of about 807 nm, for example, coming from the excitation-light light source, and the light with the central wavelength of about 1064 nm, for example, is inputted from the fiber 9 into the wavelength conversion device 36 , whereby green light with a central wavelength of about 532 nm as secondary harmonic wave is obtained from the light source portion 32 .
[0112] FIG. 8 is a schematic plan view of the light modulation device 33 . As shown, the light modulation device 33 , for example, the so-called GLV (Grating Light Valve) included of an arrangement of light diffraction elements composed of micro-ribbons has a structure in which a multiplicity of pixels 37 each included of an arrangement of the diffraction gratings composed of the micro-ribbons are arrayed in a one-dimensional manner.
[0113] FIG. 9 is a schematic perspective view of the internal structure of the pixel 36 . As shown, the pixel 36 has an internal structure in which, for example, six laser light-reflective micro-ribbons 39 each supported at both ends thereof are arranged in parallel to each other on a substrate 38 , to constitute a diffraction grating.
[0114] On the other hand, under and across the array of the micro-ribbons 39 , a common counter electrode 40 is formed on the substrate 38 oppositely to all the micro-ribbons 39 , with a required spacing therebetween.
[0115] When a required voltage is impressed between, for example, every other one of the micro-ribbons 39 and the counter electrode 40 , the central portions of the relevant micro-ribbons 39 are shifted to and held at a predetermined distance from the substrate 38 ; as shown in a schematic sectional view in FIG. 10 , when incident light Li, or the light from the light source portion 32 in FIG. 7 , is inputted to the micro-ribbons 39 in each pixel, primary diffracted light beams Lr (−1) and Lr (+1) are generated.
[0116] In this manner, the light from the light source portion 32 is modulated by the light modulation device 33 into the presence or absence of or intensity (gradation) of ±1 primary diffracted light beams.
[0117] Next, an embodiment of a projector including the photonic crystal fiber according to the present invention will be described.
[heading-0118] Embodiment of Projector
[0119] In this embodiment, as a schematic illustration of the constitution of a projector is shown in FIG. 11 , the projector includes light source portions 32 R, 32 G, 32 B for obtaining red, green and blue light beams, and light modulation devices 33 R, 33 G, 33 B composed, for example, GLVs provided correspondingly to the light source portions for obtaining red, green and blue one-dimensional projection optical images, respectively. The one-dimensional optical images are synthesized by dichroic mirrors 43 and 44 , and a two-dimensional image is projected on a screen 47 by a scanner 46 . The light source portions 32 R and 32 B each have the configuration shown in FIG. 7A , while the light source portion 32 G has the configuration shown in FIG. 7B . The projector further includes a reflector 41 , a condenser lens 42 , and a projection lens 45 .
[0120] The photonic crystal fiber, the light controller, the projector, and the method of manufacturing the photonic crystal fiber according to the present invention are not limited to the above-described embodiments, and various changes or modifications are possible within the scope of the present invention.
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A photonic crystal fiber has a configuration in which a multiplicity of voids are arranged along the longitudinal direction of the fiber and with a regular sectional structure, a terminal end portion of the fiber is fusion bond sealed with a fusing material composed of a glass lower than a light propagation medium of the fiber in softening temperature, and the terminal end portion is connected to a ferrule with the fusing material. With this configuration, it is possible to obviate the lowerings in optical characteristics such as a large refractive index difference between the light propagation medium and the voids, a high light transmission efficiency, a high numerical aperture, etc., and to obviate such problems as the penetration of foreign matter into the inside of the voids, a burning failure arising from a positional staggering of the ferrule, etc.
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BACKGROUND
[0001] Web pages are typically formatted in a standard landscape or portrait fashion. Landscape formatted web pages provide a user with a monitor displayed content that is wider than it is high. Portrait formatted web pages provide a user with a monitor displayed content that is higher than it is wide. Most web pages are formatted in a landscape fashion to accommodate the demands of a landscape dimensioned screen.
[0002] Printers typically have the ability to print in a landscape or portrait formatted fashion. However, most printers have their default format set to print in a portrait mode because this is the typical formatting requirement for word processing software applications and other similar text based software applications.
[0003] To print a web page, a user typically will follow a standard procedure for printing files that does not include the selection of an appropriate formatting, i.e. either landscape or portrait. Consequently, the default printing format will be a portrait formatted print job. Because most web pages are formatted in a landscape fashion, the printed web page will normally be printed in a portrait formatted fashion and a right portion of the web page will not be printed.
[0004] One way to insure all the content of a landscape formatted web page is printed involves the use of wrap around text, whereby the content of the landscape formatted web page outside of the portrait formatted margin is wrapped around to the next line within the portrait formatted margins. Some web sites are configured to provide this wrap around feature, however many do not wrap around the web content and the portrait formatted printer output excludes the right portion of the landscape formatted web page.
BRIEF DESCRIPTION
[0005] A computer program product comprising a computer-usable data carrier storing instruction that, when executed by a computer, causes the computer to perform a method comprising capturing the content of a web page; determining if a portrait formatted representation of the said web page and a landscape formatted representation of the said web page, include equivalent content; and outputting the portrait formatted representation of the web page if the said portrait formatted representation has the equivalent content of the said landscape formatted representation, otherwise outputting a landscape formatted representation of the said web page.
[0006] A printing method comprising capturing the content of a web page; determining if a portrait formatted representation of the said web page and a landscape formatted representation of the said web page, include equivalent content; and outputting the portrait formatted representation of the web page if the said portrait formatted representation has the equivalent content of the said landscape formatted representation, otherwise outputting a landscape formatted representation of the said web page.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 illustrates a flow chart according to one exemplary embodiment;
[0008] FIG. 2 illustrates a landscape formatted web page;
[0009] FIG. 3 illustrates a portrait formatted web page;
[0010] FIG. 4 illustrates a landscape and portrait area diagram;
[0011] FIG. 5 illustrates a flow chart according to another exemplary embodiment;
[0012] FIG. 6 illustrates a flow chart according to another exemplary embodiment;
[0013] FIG. 7 illustrates a flow chart according to another exemplary embodiment; and
[0014] FIG. 8 illustrates a flow chart according to another exemplary embodiment;
DETAILED DESCRIPTION
[0015] Provided below is a detailed description of various exemplary embodiments of this disclosure. These embodiments provide a printing apparatus and method for printing a web page that includes printing the web page with the appropriate printed page format.
[0016] With reference to FIG. 1 , illustrated is a flow chart 2 representing a printing apparatus and method according to one exemplary embodiment of this disclosure. This printing method can be implemented in various ways as is known to those of skill in the art. Specifically, the flow chart 2 is implemented with a computer program product, the computer program product including a computer-usable data carrier that stores computer instructions to be executed by a computer. The computer program product can be implemented via software or firmware installed on a computer or a printing device.
[0017] With further reference to FIG. 1 , the printing method and computer program product is now described. Initially, the computer program product captures 4 the content of a web page to be printed. Next, a data file is created 6 including the content of the web page outside the margins of a portrait formatted web page. At this point the computer program product determines 8 if the data file including the content of the web page outside the margins of a portrait formatted web page, includes web page content. If the data file includes web page content, the computer program outputs 12 a landscape formatted data file. If the data file does not include web page content, indicating the web page is portrait formatted, the computer program outputs 10 a portrait formatted data file.
[0018] Subsequent to generating the output data file discussed in the preceding paragraph, the computer program outputs the data file to a printing device which produces a portrait or landscape formatted printed output. In effect, this printing method and apparatus provides a web page printed output which more accurately reproduces the original web page formatting. More specifically, if the web page format is portrait, the printing method and apparatus produces an output data file representative of the web page portrait formatted. If the web page portrait formatted is landscape, the printing method and apparatus produces an output data file representative of the web page landscape formatted.
[0019] To better illustrate the printing method and apparatus described with reference to FIG. 1 , further discussion is now provided with reference to FIG. 2 , FIG. 3 and FIG. 4 .
[0020] FIG. 2 illustrates a landscape formatted web page 20 as it would appear on a computer monitor which is operatively connected to a computer operatively connected to an internet server. The internet server provides a user, i.e. computer, with access to the web page 20 illustrated. As illustrated in FIG. 2 , the landscape formatted web page 20 is wider than it is tall, which is representative of a landscape formatted page. With reference to FIG. 2 , reference items for purposes of discussion include a “WebBoard” heading 34 , art work 26 , vertical line 28 , drop down box 40 , bolded company 32 , graphical illustration 24 , vertical line 36 , and vertical line 38 . In addition, a right area 22 of the web page is indicated.
[0021] With reference to FIG. 3 , illustrated is a portrait formatted output of a web page 50 which includes content as illustrated in FIG. 2 . As illustrated in FIG. 3 , the portrait formatted web page 50 output is taller than it is wide, which is representative of a portrait formatted page. With further reference to FIG. 3 , reference items for purposes of discussion include a “WebBoard” heading 34 , art work 26 , vertical bar 56 and vertical bar 58 .
[0022] FIG. 4 illustrates the areas covered by a landscape formatted web page for printing and a portrait formatted web page for printing. Specifically, a portrait formatted page layout includes Area 1 62 and Area 3 66 , but not Area 2 64 . A landscape formatted page layout includes Area 1 62 and Area 2 64 , but not Area 3 66 . The overlay 60 illustrated in FIG. 4 depicts a landscape formatted page laid directly on top of a portrait formatted page.
[0023] As briefly explained in the Background section of this disclosure, a problem associated with printing a web page as illustrated in FIG. 2 , i.e. a landscape formatted web page, is computers and their associated drivers are generally configured to print a portrait formatted page unless the user specifically configures the software to print in a format different than the default format, i.e. portrait format. Consequently, a landscape formatted web page as illustrated in FIG. 2 , will print as the portrait formatted output illustrated in FIG. 3 . By comparing FIG. 2 and FIG. 3 , it should be noted that the drop down menu 40 , the company name, vertical bar 30 , and graphical illustration 24 are not included as part of the portrait formatted web page 50 of FIG. 3 . In effect, Area 2 64 of the overlay 60 illustrated in FIG. 4 is omitted from the portrait formatted web page 50 .
[0024] To provide a landscape formatted print output for a landscape formatted web page, and a portrait formatted print output for a web page portrait formatted, the printing method and apparatus previously described with reference to FIG. 1 is provided. This printing method and apparatus operates as follows with reference to FIGS. 1 , 2 , 3 and 4 .
[0025] Initially, the computer program product captures the content of a web page 4 to be printed. This includes Area 1 62 and Area 2 64 as illustrated in FIG. 4 . Next, a data file is created 6 including the content of the web page outside the margins of a portrait formatted web page. This content is defined by Area 2 64 as illustrated in FIG. 4 . Next, the computer program determines 8 if the data file representing Area 2 64 includes web page content. If Area 2 64 includes web page content, the computer program determines the web page is landscape formatted and outputs 12 a landscape formatted data file for printing. If the computer program determines the data file representing Area 2 64 does not include web page content, the computer program outputs 10 a portrait formatted data file for printing.
[0026] With reference to FIG. 5 , illustrated is a flow chart 70 representing a printing method and apparatus according to another embodiment of this disclosure. The general principle of operation is similar to the embodiment illustrated and described with reference to FIG. 1 .
[0027] The computer program initially captures 72 the content of a web page for printing. Next, the computer program generates 74 a data file representative of the captured web page content portrait formatted, and the computer program generates 76 a data file representative of the captured web page content landscape formatted. Next, the portrait formatted data file and landscape formatted data file are compared 78 to determine 80 if the files have equivalent content. If the portrait and landscape formatted data files have equivalent content, the computer program outputs 82 a portrait data file for printing. If the portrait and landscape formatted data files do not have equivalent content, the computer program outputs 84 a landscape data file for printing.
[0028] With reference to FIG. 6 , illustrated is a flow chart 90 representative of another exemplary embodiment of a printing apparatus and method according to this disclosure.
[0029] Initially, the computer program captures 92 the content of a web page for printing. Next, the computer program creates 94 a first data file including the content of the web page outside the margins of a portrait formatted web page. Next, the computer program determines 96 if the first data file includes web page content. If no web page content is included, the computer program outputs 98 a portrait formatted data file for printing. If the first data includes web page content, the computer program creates 100 a second data file of the web page portrait formatted.
[0030] The web content of a second data file is then compared 102 with the web content of the first data file. If the second data file does not include the web content of the first data file, the computer program outputs 110 a landscape formatted data file. It should be noted that comparing the portrait formatted web page content, i.e. second data file, with the content of the web page outside the margins of a portrait formatted web page, i.e. first data file, provides a basis for determining if web content is omitted form the portrait formatted web page. If the computer program determines the second data file includes the web content of the first data file, then the computer program creates 104 a third data file representative of the web page landscape formatted.
[0031] Next, the computer compares 106 the second data file with the third data file to determine if the portrait formatted web page content, i.e. second data file, includes the content of the landscape formatted web page, i.e. third data file. If the second data file does not include the web content of the third data file, the computer program outputs 110 a landscape formatted data file for printing. If the second data file does include the web content of the third data file, the computer program outputs 108 a portrait formatted data file for printing.
[0032] With reference to FIG. 7 , illustrated is a flow chart 120 representative of another exemplary embodiment of this disclosure.
[0033] Initially, the computer program captures 122 the content of a web page to be printed. Next, the computer program determines 124 if there is an image within Area 2 of the captured web content. If there is no image within Area 2 of the captured web content, the computer program outputs 126 a portrait formatted data file. If there is image within Area 2 of the captured web content, the computer program goes to an image type comparison 128 step.
[0034] The computer program determines 128 the image types included within Area 2 of the landscape formatted web page. Image types could include half tone, line graphics, etc. The computer program also determines 128 if Area 1 of a portrait formatted web page includes the image types of Area 2 of the landscape formatted web page. If Area 2 of the landscape formatted web page includes image types not within Area 1 of the portrait formatted web page, the computer program outputs 130 a landscape formatted data file. Alternatively, if Area 1 of the portrait formatted web page includes the image types within Area 2 of the landscape formatted web page, the compute program counts 132 the number of occurrences of the image types within each respective area.
[0035] If the number of occurrences of each image type within the respective areas are equal, the computer program outputs 134 a portrait formatted data file. Alternatively, if the number of occurrences of each image type within the respective areas are not equal, the computer program outputs 130 a landscape formatted data file.
[0036] With reference to FIG. 8 , illustrated is a flow chart representative of another exemplary embodiment of a printing apparatus and method according to this disclosure. This exemplary embodiment operates identically to the exemplary embodiment described with reference to FIG. 7 , except the image features, not the image types, within Area 2 64 of the landscaped formatted web page and Area 1 62 of the portrait formatted web page are compared. Image features include blocks of a specific color, etc.
[0037] Initially, the computer program captures 142 the content of a web page to be printed. Next, the computer program determines 144 if there is an image within Area 2 of the captured web content. If there is no image within Area 2 of the captured web content, the computer program outputs 146 a portrait formatted data file. If there is image within Area 2 of the captured web content, the computer program goes to an image feature comparison 148 step.
[0038] The computer program determines 148 the image features included within Area 2 of the landscape formatted web page. The computer program also determines 148 if Area 1 of a portrait formatted web page includes the image features of Area 2 of the landscape formatted web page. If Area 2 of the landscape formatted web page includes image features not within Area 1 of the portrait formatted web page, the computer program outputs 154 a landscape formatted data file. Alternatively, if Area 1 of the portrait formatted web page includes the image features within Area 2 of the landscape formatted web page, the compute program counts 150 the number of occurrences of the image features within each respective area.
[0039] If the number of occurrences of each image feature within the respective areas are equal, the computer program outputs 152 a portrait formatted data file. Alternatively, if the number of occurrences of each image feature within the respective areas are not equal, the computer program outputs 154 a landscape formatted data file.
[0040] Other techniques for comparing the content of a portrait formatted data file and landscape formatted data file, representative of a captured web page image, include vertical line comparison, pixel value summation comparison and accessing a knowledge base.
[0041] A vertical line comparison printing apparatus and method determines if the number of web content dividing vertical lines within the portrait formatted data file is equivalent to the number of content dividing vertical lines within the landscape formatted data.
[0042] A pixel value summation comparison printing apparatus and method determines if the sum of the pixel values within the portrait formatted data file is approximately equal to the sum of the pixel values within the landscape formatted data file.
[0043] A knowledge base printing apparatus and method accesses a knowledge base to determine if the portrait formatted data file is equivalent to the landscape formatted data file.
[0044] It will be appreciated that various of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Also that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.
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A printing apparatus and method for capturing and formatting the content of a web page. The apparatus and method determining if a portrait formatted representation of the web page and a landscape formatted representation of the web page, include equivalent content, and outputting the portrait formatted representation of the web page if the portrait formatted representation has the equivalent content of the landscape formatted representation. Otherwise outputting a landscape formatted representation of the said web page.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a tool for weighing ice baskets, or ice condensers, as are employed as a safety element with certain types of nuclear reactors, and, more particularly, to a compact such ice basket weighing tool for use at the top of the ice basket, with minimal disturbance to the existing framework and supports, for lifting the basket and determining its weight.
2. State of the Prior Art
Ice baskets, or ice condensers, of the type with which the compact ice basket weighing tool of the invention is to be employed, are provided with various types of nuclear reactors for condensing the steam from the primary water of a reactor in the event of an accidental loss of coolant. In a typical installation, there are provided approximately two thousand ice baskets, each of which is approximately one foot in diameter and 48 feet in height, and initially is filled with approximately 1,500 pounds of ice. The sidewalls of the ice basket are substantially cylindrical in configuration and are perforated, to permit rapid exposure of the steam to the ice and thus achieve corresponding, rapid condensation. The ice baskets are of substantial size, typically some 48 feet in height and approximately one foot in diameter, and are closely spaced within existing framework and supports which greatly restrict access thereto. To be effective, the ice baskets must contain a sufficient volume and weight of ice, typically a minimum of 1,200 pounds of ice per basket, to achieve the required cooling effect. Due to sublimation of ice, however, the initial charge of ice within each basket is depleted over time.
It thus is necessary to determine the amount of ice actually resident within each of the baskets, and to do so with a minimum of disturbance to the existing framework and supports associated with the assemblage of ice baskets and preferably with a minimum possible amount of time and effort on the part of service personnel performing this task.
SUMMARY OF THE INVENTION
In accordance with the invention, there is provided both apparatus and a related method for determining the amount of ice in an ice containment structure, or ice basket, employed with nuclear power plants. Particularly, a weighing tool is provided which is ideally suited for being inserted within the upper end of the ice basket, despite the presence of confining structures limiting access thereto. Particularly, a lattice frame defines compartments in which respective ice baskets are received, the frame extending above the top ends of the ice baskets and providing lateral support therefore.
The weighing tool comprises a cylinder housing, or body, which receives a piston in sealed, sliding relationship therewithin, defining thereby upper and lower sealed chambers within the body, a piston rod being secured at its lower end to the piston and having an upper, free end extending above the body. Support frames extending laterally from the housing define channels therewithin for receiving moveable support lugs in sliding relationship, the lugs being moveable to a retracted position to facilitate positioning the tool within the upper, open end of the ice basket and an extended position in which the lugs are received through holes conventionally provided in the cylindrical sidewalls of the ice basket. Preferably, the lugs are received through holes in the cylindrical sidewall of the ice basket which are immediately adjacent a conventional support ring attached within the ice basket, the support ring being the load bearing element on which the lugs act in lifting the ice basket.
The tool, as initially inserted with the lugs disposed in the holes in the cylindrical sidewalls in their extended positions, then is held in position while a support bar having a central aperture therein is positioned on the lattice support frame so as to span the compartment surrounding the given ice basket, the upper free end of the piston rod being received through the central aperture in the support bar. The upper end of the piston rod preferably is threaded such that a nut may be manually screwed thereon to tightly engage the upper end of the piston rod with the support bar, thereby assuring that the piston is in abutting relationship with an upper end closure of the cylinder body and the lugs are engaging the support ring of the ice basket. Hydraulic fluid under pressure then is introduced into the upper chamber of the housing, driving the housing upwardly relatively to the stationary piston, and lifting the ice basket from its base. The pressure of the applied fluid, necessary to lift the ice basket, relative to the area of the piston, affords, through a known calculation, the weight of the ice basket. Additionally, or alternatively, a transducer may be interposed between the support bar and the nut which secures the upper end of the piston rod to the support bar, which provides an output indicating the weight of the ice basket, when raised. Since the weight of the empty ice basket is known, a simple subtraction calculation affords the weight of the ice contained therein.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified elevational view, partly in cross-section, of an ice basket, or ice condenser, illustrating its basic configuration and related supporting structure;
FIG. 2 is a cross-sectional view, partly in cross-section, of the compact ice basket weighing tool of the present invention, as assembled within the top portion of an ice basket in preparation for a weighing operation; and
FIG. 3 is an elevational view, partly exploded and partly in cross-section, of portions of the ice basket weighing tool in accordance with the present invention, as illustrated in FIG. 2, for purposes of clarification.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a simplified elevational view, partly in cross-section, of an ice basket 10, also termed an ice condenser, of the type with which the ice basket weighing tool of the present invention may be employed. The ice basket 10 is a generally cylindrical structure, approximately one foot in diameter and approximately 48 feet in height. The cylindrical sidewall 11 of the ice basket 10 includes a number of apertures 12 illustratively disposed in aligned rows and columns about the circumference of the cylindrical sidewall 11. Typically, the ice basket 10 is open at its upper end and is closed by a circular metal wire mesh plate 14 at its lower end. A mounting plate 16 is secured to the bottom of the basket 10, to which is affixed a pair of depending brackets 18 (only one of which is shown in FIG. 1). Each bracket 18 includes an elongated slot 19 through which a restraining pin 20 is received, the latter being secured within a vertical frame element 22 which is rigidly mounted on an underlying support 24. A series of lattice frames 23, typically seven in number and spaced at six foot vertical intervals, defines a compartment 25 which surrounds and confines the corresponding ice basket 10, closely spaced from the sidewall 11 thereof. The lattice frame 23 may take any of various forms, its principal purpose being to provide lateral support for the ice basket 10, given its somewhat loose and pivotal mounting as above described. Thus, the lattice frame 23 is shown to include horizontal straps 23' and 23" which extend in criss-cross fashion at each interval or level (i.e., straps 23' and 23" would cross in X-shaped relationship) so as to engage the exterior side walls of the basket 10 and maintain same in a generally vertical orientation. Thus, the lattice frame 23 defines a vertically extending grid of plural independent compartments for receiving respectively corresponding ice baskets 10 in closely spaced relationship therewithin. Thus, it will be understood that additional ice baskets 10 (not shown) would be disposed on the opposite sides of the sections of the lattice frame 23 illustrated in FIG. 2. In some installations, there additionally exists an overhead structure disposed closely above the top of the ice basket 10 and which may comprise a central support frame 26 which spans across and above the ice baskets 10 and cover plates or access doors 27 and 28 which are connected to the frame 26 by hinges 29 and 30, respectively. Although illustrated in a simplified manner in FIG. 1, the support frame 26 may comprise plural I-beams extending in generally parallel relationship, successive pairs of hinged access doors being supported at their hinged connections on corresponding, alternate ones of the I-beams and at the respective free ends thereof on the corresponding, adjacent I-beams, in a repeating pattern, so as to cover all of the ice baskets 10. As will be understood, the hinged access doors 27 and 28 may be tilted upwardly and/or removed, as is appropriate, to gain access to the top of the ice basket 10.
The elevational view of FIG. 2, shown partly in cross-section, illustrates the ice basket weighing tool 50 of the invention as received within an ice basket 10 from the open, upper end thereof, positioned to initiate a weighing operation. As will now be explained, the design of the weighing tool 50 of the invention takes into account the restricted access limitations imposed by the overhead structure 26, and is specially adapted for cooperation with the configuration of the typical ice basket 10. Particularly, on the interior of the cylindrical walls 11 of the ice basket 10, there are provided a plurality of support rings 32 at vertically displaced locations throughout the ice basket 10 (only one of which is shown in FIG. 2). Each ring 32 has a rib-like cross-section and is secured to the cylindrical sidewall 11 of the ice basket 10 by screws or other suitable techniques. FIG. 2 as well illustrates the overhead structure 26, the hinged cover plates 27 and 28 being removed for ease of illustration.
From FIG. 2, it will be appreciated that where an overhead structure 26 is present, only very limited access space is available for reaching the interior of the ice basket 10. The ice basket weighing tool 50 thus must be capable of being inserted through the limited opening between the overhead structure 26 and the lattice frame 23 for insertion into the interior of the ice basket 10. This imposes the requirement that the tool 50 be relatively compact in size while also being of sufficient structural integrity for performing its required function of weighing the ice basket 10 and that it be easily operable for this purpose. As will be appreciated from the following description, the ice basket weighing tool 50 of the invention is of a highly effective design which meets and satisfies these stringent requirements.
With concurrent reference to FIG. 2 and the exploded, perspective view of FIG. 3, the compact ice basket weighing tool 50 of the invention comprises a cylinder body 52 having a cylindrical sidewall 53, a bottom enclosure 54 and a top enclosure 56. In the configuration shown in FIG. 2, each of the bottom enclosure 54 and the top enclosure 56 may be of generally square configuration such that bolts, as shown at 57 and 58, may be received through suitable holes (not shown) in the corners of the bottom enclosure 54 and engage corresponding, threaded holes (not shown) in the corresponding corners of the top enclosure 56, as shown at 59. Each of the enclosures 54 and 56 is machined to define a circular ledge thereabout for receiving the corresponding ends of the cylindrical sidewall 53, O-ring 62 sealing the lower end thereof to the bottom enclosure 54 and weld bead 64 joining the top end thereof to the top enclosure 56. The perspective, exploded view of FIG. 3 illustrates an alternative but functionally equivalent structure in which the bottom enclosure 54' includes an annular groove 60 in its upper surface for receiving the lower end of the cylindrical sidewall 53 of the body 52', the assembled elements conveniently being secured and sealed together by welding. A generally square mounting block 66 having a central aperture therethrough is received over and welded to the cylindrical sidewall 53' and is machined to include threaded holes (not shown) in each corner for receiving a corresponding bolt 58' for securing the bottom plate 54' thereto. In this embodiment, the top enclsoure 56' is of circular configuration and is secured to the cylindrical sidewall 53' by a weld bead 64'.
In both of the equivalent embodiments of FIGS. 2 and 3, a piston 70 includes a central threaded aperture 72 for receiving the threaded lower end 74 of a piston rod 76, the latter having an upper threaded end 78. An annular groove 71 is formed in the piston 70 for receiving an O-ring 73 for sealing the piston to the interior of the cylindrical sidewall 53 while permitting reciprocating, axial sliding movement of the body 52 relative to the piston 70. Likewise, an annular groove 75 is formed in the central aperture in the piston 70 for receiving an O-ring 77 for sealing the piston rod 76 to the piston 70. There is thus defined a sealed lower chamber 80 between the lower surface of the piston 70 and the bottom enclosure 54, and a sealed upper chamber 82 between the upper surface of the piston 70 and the top enclosure 56 of the cylinder body 52. The piston rod 76 further includes a central aperture or bore 79 extending throughout its length for venting the lower chamber 80. For this purpose, the piston rod 76 includes an interiorally threaded hole 81 at its upper end within which is received a porous plug 84 (shown in FIG. 2 only). The top enclosure 56 furthermore includes an annular groove 91 for receiving an O-ring 92 for sealing the piston rod 76 thereto. Hydraulic fluid for operating the assemblage of piston 70 and body 52 is introduced from a hydraulic line 93 connected at a remote end to a suitable source of hydraulic fluid (not shown) and through a quick disconnect coupling 94, inlet fitting 96 and an inlet passageway 90 to the upper chamber 82.
Affixed to the body 52 is a pair of radially extending support frames 100 and 102 which are identical in construction and respectively carry retractable support lugs 101 and 103. Since these structures are identical, detailed reference will be had only to the frame 102 and lug 103, best seen in FIG. 3. The frame 102 defines therein a channel 104 of generally rectangular cross-section for receiving therewithin the mating rectangular portion of the lug 103. Hole 106 formed in the lug 103 is disposed to be in alignment with slot 108 in the upper wall 104b; the lower wall 104a of the channel 104 furthermore includes a pair of inward and outward, i.e., radially displaced, holes 110 and 112 (FIG. 2), with which the hole 106 of the lug 103 may be selectively aligned. In either aligned position, a locking pin support ring 114 having a threaded shank 115 is inserted through the slot 108, the hole 106, and the selected one of the holes 110 and 112, and thereafter a locking pin 116 is threaded onto the shank 115. In use, the locking pin support ring 114 simply is raised, withdrawing the locking pin 116 into the aligned hole 106 of the lug 103 and thus permitting the lug 103 to be moved from its extended position illustrated in FIG. 2 to a retracted position in which the locking pin support ring 114 is aligned with the radially inward hole 110; the pin 116 then is lowered into hole 110 to lock the lug 103 in its retracted position.
With reference to the structure as shown in assembled fashion in FIG. 2, the aforedescribed elements of the tool 50 of the invention are inserted into the top of the ice basket 10, with the lugs 101 and 103 locked in the retracted position. When necessary, any ice within the top portion of the basket is removed to accommodate positioning the tool 50 therewithin; due to the small height of the tool 50, it can be appreciated that only a minimal amount of ice would have to be removed to accommodate same. Once the tool 50 is positioned within the upper portion of the ice basket 10, generally in the position indicated, the lugs 101 and 103 are moved to the extended position with the outer ends thereof projecting through associated, aligned openings 12 in the sidewall 11 of the ice basket 10, as shown. While different configurations of course are possible, it has been found convenient to configure the outer ends or extremities of the lugs 101 and 103, as seen for lug 103, to include bifurcated end projections 103a and 103b which are received in correspondings ones of an adjacent pair of the openings 12 in the sidewall 11 of the ice basket 10. Moreover, as seen from FIG. 2, the lugs 101 and 103 include lips 101c and 103c adjacent the outer ends thereof for engaging the lower edge of the support ring 32, as seen in FIG. 2.
A support bar 120 then is positioned on the upper ends of the lattice frame 23, so as to span the corresponding compartment therein containing the illustrated ice basket 10, with the upper threaded end 78 of the piston rod 76 inserted through the accommodating, central hole 121 in the support bar 120. A load cell, or transducer, 122 is received over the upper end of the piston rod 76 and a support ring 124 then is threaded onto the upper, threaded end of the piston rod 76 for securing the structure together. The ring 124 is tightened by hand, raising the tool 50 so that the lugs 101 and 103 are engaging the support ring 32 and the piston 70 is in contact with the top enclosure 56.
It will be appreciated that in those ice basket installations which do not have a confining overhead structure, as illustrated by the frame 26 in FIG. 2, that the tool 50 simply can be maintained in assembled condition and moved to successive ice baskets 10, simply by movement of lugs 101 and 103 between retracted and extended positions, without requiring the assembly steps just described.
In use, it will be appreciated that it is necessary to remove any ice situated within the upper reaches of the ice basket 10, typically to a depth of 8" to 10", so as to permit insertion of the tool 50 into the upper, open end of the ice basket 10 for positioning same therewithin in the manner indicated in FIG. 2. Thereafter, hydraulic fluid under controlled, increasing pressure is applied through the line 90 into the upper chamber 82. A hydraulic hand pump (not shown) may be used for this purpose. Since the piston 70 remains stationary due to the rigid connection of the piston rod 76 and the support bar 120, the cylinder body 52 is driven upwardly by the hydraulic force of the applied fluid. From FIG. 1, it will be appreciated that the height to which the ice basket 10 is raised is restricted by the length of the slots 19 in the support brackets 18. Since the top of the slot 19 normally is in contact with the pin 20, any upward movement of the ice basket 10 will be readily detected, and will provide a sufficient indication that the ice basket 10 has been lifted.
The area on which the pressure acts, for a given level of applied pressure, permits easy computation of the total basket weight. Moreover, the load cell 122, through an appropriate meter, may indicate the weight directly. Since the actual weight of the empty ice basket is known in advance, the weight of the ice in the ice basket may readily be calculated from the total basket weight, as measured.
Once the weight determination has been made, the hand pump or other source of supplied hydraulic fluid may be vented, as with a conventional hydraulic jack, and the ice basket 10 will settle slowly to its rest postiion as shown in FIG. 1. By venting the lower chamber 80 through the axial hole 79 in the piston 76, an operator will be able to tell immediately if any leakage of the hydraulic fluid into the lower chamber 80 has occurred.
In accordance with the foregoing, it will be appreciated that, in accordance with the invention, a simple, yet rugged and compact structure has been afforded as an ice basket weighing tool permitting efficient and effective weighing of ice baskets, for determining the weight of the ice contained therein. It will be appreciated to those of skill in the art that numerous modifications and adaptations of the compact ice basket weighing tool of the invention may be made, and thus it is intended by the appended claims to cover all such modifications and adaptations which fall within the true spirit and scope of the invention.
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A weighing tool and method for determining the weight of ice contained within each of a plurality of ice baskets received within corresponding compartments of a lattice frame, as employed with nuclear power generators. A cylinder body includes lug support frames and corresponding lugs movable to retracted positions for inserting the weighing tool within the upper end of an ice basket, and to extended positions for being engaging in the ice basket and securing the tool thereto. A piston movable in sliding relationship within the body and defining upper and lower compartment therein is secured through a piston rod to a support bar which rests on the lattice frame and spans the compartment. Hydraulic fluid under controlled, increasing pressure is introduced into the upper compartment, driving the cylinder body upwardly relatively to the stationary piston so as to raise the ice basket. The pressure necessary to lift the ice basket provides a measure of the total weight of the ice basket. Alternatively or additionally, a load cell subjected to the weight of the raised ice basket provides an output indication of the weight. Since the weight of the empty ice basket is known, a simple subtraction yields the weight of ice resident within the ice basket.
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The present invention relates to generally to telephone systems, and in particular, to telephone billing systems for central office switches that provide advanced intelligent network (AIN) operations and services.
BACKGROUND OF THE INVENTION
Over the past few years, the number of new services and features offered over telephone networks has grown. These enhanced telephone networks are knows as "Advanced Intelligent Networks" (AINs). Telephone control networks conforming to AIN architecture contain intelligent subsystems for controlling switched traffic and user services such as conference calls, call waiting, call forwarding, voice announcements, voice response, keyboard response, etc. These intelligent subsystems, called "intelligent peripherals" (IP), are configured for specific regional calling services.
Multi-processor systems used as an AIN system are disclosed in patent application Ser. No. 08/792,018 by Deborah L. Acker and Thomas E. Creamer, which is assigned to International Business Machines (IBM) and the disclosure of which is incorporated herein by reference.
For a conference call, the host caller instructs the intelligent peripheral to connect each conference participant. A telephone switch then establishes a separate leg of the conference by calling each participant and connecting together the telephone line for each leg. A given leg may be a local or a long distance call. Billing is based on a per minute rate for each leg of the call and the rate typically is higher than a rate for a two party call along the same leg. Thus, different rates usually apply to each leg of the conference call. It is apparent that the charges accumulate at a rapid rate when there are a number of parties connected by legs to which long distance toll charges apply. Therefore, it is desirable for one or more conference participants to be able to monitor the accumulated charges for a conference call on a real-time basis while the call is taking place. However, real-time monitoring of conference call charges is further complicated by participants joining and dropping from the call at different times.
It may be desirable to place a monetary limit on the total charges for the conference call so that the call does not exceed a budgeted amount. By limiting the call duration in this manner, forces the participants to adhere to an agenda for the call and not be verbose.
It is customary that telephone and other types of network services are billed on a periodic, e.g. monthly, basis. A bill for a given call is not issued until the end of the billing cycle in which the call occurred and then the customer has several weeks to make payment. It is advantageous to bill and receive payment for service as soon after delivery as possible. Thus it is desirable, immediately after the completion of the call, to automatically submit a bill for a particular service to a credit or debit account maintained by a third party service provider, such as a bank credit card operation.
SUMMARY OF THE INVENTION
The general object of the present invention is to provide real-time billing of advanced intelligent network services.
Another object is to enable the suer of the advanced network services to monitor the service charges which are accumulating during service use.
A further object of the present invention is to enable the user at the commencement of service to place a monetary limit on the total charge for that particular usage and to have that usage terminate automatically when that limit is reached.
Yet another object is to provide billing of enhanced network service automatically to a credit or debit account following each use.
These and other objectives are satisfied by a method of monitoring charges for a service provided by an advanced intelligent communication network wherein the method detects occurrences of billing events which take place during use of the service. When a billing even occurs, a charge fee associated with the event is added to a cumulative charge total for the service. The cumulative charge total is occasionally transmitted via the Internet to a device located with a person using the service. For example the transmission occurs whenever the cumulative charge total changes. The device displays the cumulative charge total received from the Internet to the person while the service is being used.
In this manner the running costs of the service are continuously being tracked and displayed to the person during usage of the service. This enables a suer to know at any give point in time how much the current use of the service has cost.
The preferred embodiment of this method allows the user to define a maximum cost limit for a particular use of the service. When the cumulative charge total reaches that maximum cost limit, the use of the service automatically terminates.
For example this method has particular application to telephone conference call services. Here a running subtotal of the charges for each telephone line connected to the conference is maintain even where different usage rates apply to each telephone line and where telephone liens are connected to and disconnected from the conference at different points in time. The per line subtotals also are sent and displayed to the conference participant.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a functional block diagram of a telephone network which conforms to the AIN architecture; and
FIG. 2 is a flow chart of the process implemented on the network for real-time billing of extended telephone services, according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
With initial reference to FIG. 1 a public switched telephone network (PSTN) 10 conforms to the architecture for an advanced intelligent network (AIN). Further information about AIN architecture can be obtained by referring to one or more of the following published documents, whose teachings are incorporated herein by reference:
Bellcore, GR-2802-CORE, Advanced Intelligent Network (AIN) 0.X Issue 1, Generic Requirements, Issue 2, December 1993. Bellcore, GR-1129-CORE, Advanced Intelligent Network (AIN) 0.2 Switch Intelligent Peripheral Interface (IPI) Generic Requirements, ILC 1E, November 1994.
A plurality of telephones 12 are connected to local lines of the PSTN. It is understood that some of these connections may involve long distance connections within the PSTN.
Also connected to the PSTN 10 is an intelligent peripheral 14 which provides switched connections for telephone calls passing through a regional node of the PSTN (e.g. between local and trunk lines traversing the node), and which controls service applications associated with the respective calls. These service applications include enhanced voice services, such as multiple party conferencing, voice announcements, speech recognition, call waiting, and call forwarding, for example.
The hardware of the intelligent peripheral 14 may be based upon an IBM intelligent peripheral system which elements include a "switch fabric" complex 18, a call processor 20, a billing server 22 and voice peripheral processor 24. Critical components such as the voice peripheral processor 24 and call processor 20 are configured redundantly to ensure continuous availability in case of any component failure. Voice and data connections among those components of the intelligent peripheral 14 are provided by a local area network, commonly referred to as an asynchronous transfer mode (ATM) switch 16.
The intelligent peripheral 14 is coupled to the PSTN 10 by the "switching fabric" complex 18, which is a conventional telephone switch that interconnects lines of the PSTN 10 to establish a two-party telephone call or a conference call involving the interconnection of a greater number of PSTN lines. The call processor 20 implements a call model which defines the procedure when a call comes into the switching fabric 18. With respect to the present invention, the switching fabric 18 provides the physical connection of the PSTN lines to form the conference call. The billing server 22 utilizes a set of custom application programming interfaces (APIs). When billing is initiated for a particular service, the billing server 22 receives the identification of the service provided, the telephone numbers involved in the service and the originating line number. The APIs sequence consists of opening the billing process, populating the billing elements with the appropriate billing information, such as the date of the transaction, connect time of the transaction, disconnect time of the transaction, originating telephone number, the terminating telephone number or numbers, type of service, billing type, billing rates, and cumulative charge amount. The billing server 22 provides the appropriate billing data on a per transaction per subscriber basis. The billing can be designed on a time duration of usage or a per usage basis. Once the API closes the billing process for a given service transaction, the raw billing data is composed into an acceptable format and sent to the billing computer system 28 for the network serve provider.
Another component of the intelligent peripheral 14 is the voice peripheral processor 24 which provides digitally stored audio messages or digitally synthesized voice messages which provide information to the caller regarding the status. For example, these messages state that the caller has reached a non-working number, or prompts the user to enter commands via a telephone's keypad to select service functions.
For the present invention, the standard intelligent peripheral 14 has been enhanced with the addition of a conventional web server 26 to interface the intelligent peripheral to the Internet 30. This allows personal computers 32 and 33 connected to the Internet to access the intelligent peripheral 14 to set up different enhanced voice service. With respect to the present invention, a customer can setup a conference call via the Internet and during the call receive real-time billing information on a personal computer 32.
The software for implementing the present billing technique is stored within the components of the intelligent peripheral 14. The present billing technique is best understood in the context of an automated conference call, one that is established and managed without requiring intervention by a human operator. Nevertheless, one skilled in the art will understand and appreciate that the present billing techniques can be applied to other forms of enhanced voice service and even other types of communication networks than just telephone systems.
A conference call commences at step 40 on FIG. 2 by a host of the conference call, hereinafter referred to as the "host caller", accessing the intelligent peripheral 14 to set up the conference call. This pre-registration of the conference call may take place either at the beginning of the call or some greater time prior to the call, for example at a point when all of the participants have agreed to be available at a given time. The host caller can perform the pre-registration either by accessing the intelligent peripheral 14 by one of the telephones 12 or from a personal computer 32 via the Internet 30. In the case of accessing the intelligent peripheral via a telephone 12, the host caller dials an "800" telephone number assigned for this purpose. The incoming telephone call initiates a procedure in which the voice peripheral processor 24 issues step by step voice prompts to the host caller requesting information regarding the time of the call and telephone numbers for each of the call participants. The host caller enters the requested information via the telephone keypad. Similar access of the intelligent peripheral 14 via the Internet and the IP web server 26 causes the web server to send the host caller's personal computer 32 a series of display screens on which the host caller enters the necessary information for establishing a conference call. Other types of enhanced voice services may be initiated in the same manner, either via a telephone or the Internet connection. The information that the host caller provides to the intelligent peripheral 14 is stored in the call processor 20 until it is time to commence the conference call.
The conference call may be commenced automatically by the intelligent peripheral 14 or upon the host caller accessing the intelligent peripheral again. If during pre-registration, automatic commencement was indicated, the intelligent peripheral, and specifically the call processor 20 will initiate the conference call at the designated data and time. In this instance, the call processor 20 will call each of the participants via the switching fabric 18 and as each telephone call is answered, the voice peripheral processor 24 transmits an audio message informing the participant that this is the conference call. Then the switching fabric 18 connects the respective PSTN lines together in the conventional conference call format at step 44.
Alternatively, at step 42 the host caller may contact the intelligent peripheral either via one of the telephones 12, by dialing the appropriate "800" telephone number, or via access through the Internet 30 to the IP web server 26. In this situation, the intelligent peripheral requests the host caller by to enter a passcode that was assigned to the call during the pre-registration process. This passcode is forwarded to voice peripheral processor 24 which retrieves the pre-registration information from memory and uses that information to establish the conference call.
It is also understood that a peripheral also may join the conference call via an audio connection through the Internet 30. In this case, the person accesses the intelligent peripheral 14 via a personal computer 32 connected through the Internet 30 to the IP web server 26. The person then selects the hyperlink displayed on the web server's home page for joining a conference call and the personal computer 32 accessing the web server 26 then will receive a query to enter the pass code for the call to be joined. Thereafter, a voice path is established by the ATM switch 16 between the switching fabric 18 which handles the telephone calls of the conference and the web server 26. A peripheral connected via the Internet 30 is treated in the same manner as a call peripheral via the telephone and the PSTN 10. Such an Internet connection will have a specified billing rate per interval of connect time ($0.50 US per minute).
In order to monitor the status of the conference call in real-time, the host caller or anyone else can access the intelligent peripheral 14 via the Internet and web server 26. Upon selecting hyperlink for call monitoring on the web server's home page, the accessing personal computer 32 or 33 will receive a query to enter the pass code for the call to be monitored. In response to receiving a valid pass code, the intelligent peripheral 14 begins sending the conference call status information to that personal computer 32 or 33 for the web browser to display.
As the telephone lines forming the conference legs are connected, the status (connected or disconnected) of each leg of the conference call is sent by the voice peripheral processor 24 through the ATM switch 16 to the web server 26 where the call status is formatted into display data and sent over the Internet to the host caller's computer 32. This enables the host caller to monitor the call status and know when each participant has joined the conference.
When all of the participants who have answered the calls from the call processor 20 have been interconnected by the switching fabric 18, the conference call processing program advances to step 46. It is understood that when one or more of the designated participants does not answer the initiating telephone call, the conference application will periodically place the call again in an attempt to reach that participant and connect him or her into the conference. At step 46, the voice peripheral processor 24 monitors the conference call to determine whether any of the participants has dropped out of the conference, i.e. hung up the phone.
As a billing increment of time elapses (e.g. every X seconds, where X is a positive number) for each leg of the conference call, the charge amount for that leg is increased by the per increment toll charge thereby producing a running subtotal for each leg of the conference call. In addition, the running subtotals for each leg are summed to produce a cumulative total for the entire conference call. It should be understood that because each leg was connected at slightly different times the billing periods will be different.
Each time one of the running subtotals for a conference leg is increased, the new charge amounts are sent from voice peripheral processor 24 through the ATM switch 16 to the web server 26. The Web server 26 places the new charge information into a data packet which is transmitted via the Internet 30 at step 48 to the host caller's computer 32 where the amounts are displayed. This provides real-time cost data to the host caller which indicates the running subtotal for each leg of the conference call and the total amount for the call.
When a participant drops out of the conference call, the disconnect status is indicated to the host caller via the Internet connection. The running subtotal charge for that leg of the conference stop being incremented, but the final subtotal amount continues to be added into the cumulative total for the conference.
After sending updated data on the status and charges of the conference call, the voice peripheral processor 24 determines at step 50 whether the cumulative total has exceeded a dollar limit for the conference call which was established during the pre-registration (at step 40). This dollar limit function may or may not be implemented by the host caller. Until the call limit is exceeded, the real-time billing procedure advances to step 52 where a determination is made whether the cell is finished. If not, the process returns to step 46 so that the call processor can continue to monitor the conference.
When the cumulative charge of the call is found at step 50 to exceed the established call limit, the process branches to step 54 where the voice peripheral processor 24 instructs call processor 20 to terminate all of the conference call connections in the switching fabric 18. In practice, the voice peripheral processor 24 may be configured to detect when the cumulative charge for the call is approaching the call limit, i.e. the cumulative charge reaching a pre-defined dollar amount below the call limit. At that time the voice peripheral processor 24 sends an audio message via the switching fabric 18 to the conference participants alerting them at the call is approaching the dollar limit. A further enhancement of the present technique allows the host caller at this time to increase the dollar a limit via the personal computer Internet connection, thereby allowing the call to continue beyond the previously defined termination point.
Eventually when either all of the participants have hung up or termination occurs at step 54, completion of the conference call is detected at step 52 and the billing procedure advances to step 56. At this time the voice peripheral processor 24 sends the final cumulative charge to the billing server 22 along with other information regarding the conference call connection as outlined above. This data enables the billing server 22 to prepare and send a data packet to the billing computer system 28 of the network service provider so that the conference call charge will appear on the next statement of the host caller. At the same time, the cumulative cost information is sent to the web server 26 which then at step 58 sends the final call information via the Internet to the host caller's web browser on computer 32 and to the web browsers on any other personal computers connected to the Internet that were designated in the pre-registration information. The billing process then terminates.
As an alternative to the billing server 22 forwarding information about the conference call to the network provider's billing computer system 28, the intelligent peripheral 14 may send a transactional message via the web server 26 and the Internet 30 to a credit card account, debit account or an electronic commerce system maintained by a third party. Such third-party billing provides faster payment to the network provider than relying upon the provider's normal billing cycle and customer payment periods.
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The present method provides a technique for real-time monitoring of charges for using a communication network service, thereby enabling a user to continuously know the charges incurred during each usage. The user also is able to define a charge limit prior to using the service and the usage terminates automatically when the accumulated charge reaches that limit. The present method is particularly adapted to monitoring charges associated with a telephone conference call.
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This is a continuation of application Ser. No. 07/493,113, filed on Mar. 15, 1990, which was abandoned upon the filing hereof.
BACKGROUND OF THE INVENTION
This invention relates to a method of target aimpoint location, specifically, but not exclusively, to skeleton aimpoint location as may be implemented on parallel processing devices.
We have proposed a target tracking system in which digitized image of a target and its background are formed and then the image is processed to form a skeletal image of the target. The terms skeleton and skeletal image used herein mean an image comprising one or more linear elements forming a kind of "stick figure" representation of the original image. In the embodiment to be described, this "stick figure" representation comprises horizontal and vertical linear elements, one pixel across. These elements corresponding to features such as a central area and lobes of the target image. At least approximately, the linear elements are centered symmetrically between boundaries of the target at the two sides of the element. In this embodiment, the skeleton incorporates substantially all the information contained in the original image, i.e. the original image could be reproduced from the skeleton. This follows from an algorithm used to form the skeleton.
It may be desirable to assign a specific pixel within the target image, namely the center-of-gravity or centroid of the image, as an aimpoint for a weapon being guided onto the target.
SUMMARY OF THE INVENTION
One object of the present invention is to provide a quick and simple process for determining the aimpoint of a target using a parallel processing device.
According to one aspect of the present invention there is a method of determining a target aimpoint in a missile guidance tracking system, comprising the steps of:
forming an image of a viewed scene;
determining the presence of a target within the scene and forming a digitized binary image of the scene, the target being distinguished from the background of the scene;
contouring the binary image to form a contoured image of the target and forming a separate skeleton image of the target using a recursive process, the skeleton being substantially one element thick;
contouring the skeleton image to form a contoured skeleton; and,
using a parallel processor to determine a centroid from the contour values and position of the skeleton elements and to determine the element closest to said centroid.
BRIEF DESCRIPTION OF THE DRAWING
Reference will now be made, by way of example, to the accompanying drawings, in which:
FIG. 1 illustrates a binary image of a target;
FIG. 2 shows how the FIG. 1 image is contoured;
FIG. 3 illustrates a completed contoured image corresponding to FIG. 1;
FIG. 4 shows an image equivalent to FIG. 3 but which satisfies the skeleton image conditions;
FIG. 5 illustrates the skeleton image of the FIG. 1 target;
FIGS. 6A and 6B show part of another skeleton image in which contour values have been assigned to the pixels of the skeleton; and
FIG. 7 shows a block diagram which illustrates the operation of the aimpoint location process.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In order to determine the aimpoint for a given target, a skeleton image has to be obtained from an image of a viewed scene containing the target. As shown in FIG. 7, step 100, a binary image is formed of the target by any convenient method known to those skilled in the art. This binary image is shown in FIG. 1 and comprises, an array of pixels each having a value of either `0` (corresponding to the background) or `1` (corresponding to the target).
The binary image of FIG. 1 is contoured, step 101, to provide a weighting for each pixel of the target area. In order to do this, the array is scanned, raster fashion, until the first `1` is located. This `1` is the starting point for the first contour, the boundary contour. Moving in a clockwise direction, all pixels on the boundary are assigned the contour value of `2`, see FIG. 2. The array is scanned again as before until the first `1` is located, then as before all the pixels having a value of `1` inside the boundary contour (having a value `2`) are assigned the value `4` when moving in a clockwise direction. This process is repeated, each of the inner contours being assigned a value two greater than its adjacent outer contour, until no more pixels having a value of `1` are located. The completed contoured image is illustrated in FIG. 3.
At the same time as the contoured image is being produced, another `image` of the binary array is formed. Similar processing is used for the contoured image but certain `test` conditions have to be satisfied at each pixel. As before, the first `1` is located by scanning the binary array raster fashion. Once this `1` is located a 3×3 operator is applied to it, step 102, the operator being:
______________________________________A B AB C BA B A______________________________________
The pixel C is the one to which the `test` conditions are applied, and in this case is the first `1`. The other pixels of the operator respectively take the values of the eight neighbouring pixels unless any of those pixels does not have the value `1`. For each pixel which does not have the value `1`, the relevant pixel of the operator is given the value `0`.
For example, for the first `1`, we get:
______________________________________0 0 00 1 11 1 1______________________________________
The `test` conditions are then applied:
→(i) more than two of the light possible (A+B) adjacent pixel pairs must be equal to 1 i.e. A+B=1 for at least three pairs of adjacent pixels;
→(ii) the sum of all A's and B's must be less than three.
If one or both these conditions are satisfied the pixel located at C remains unaltered. If neither condition is satisfied, then the value of the pixel at position C is given an increased value in the same way that values were assigned to the pixels when the contoured image was formed as described above. In the example above neither condition is satisfied. Therefore, that pixel takes a contour value of `2`. If later on in the contouring process, another pixel having the value of `1` is taken:
______________________________________4 4 26 1 41 1 4______________________________________
All the values of A and B are not `1` so the operator elements corresponding to the non-`1` image elements are made zero:
______________________________________0 0 00 1 01 1 0______________________________________
In this case, condition (ii) is satisfied and therefore the pixel C (in the center) remains unaltered i.e. keeps its value of `1`. Once this process is completed for each pixel the array as shown in FIG. 4 is obtained i.e. a contoured image except where the `test` conditions are satisfied. From this array, in step 103 the skeleton image is formed where all the pixels not having a value of `1` are assigned the value of `0`, this array is shown in FIG. 5.
The array of FIG. 5 may be contoured by any appropriate method to produce an array similar to that of FIG. 6. For example, in step 104 the skeleton pixels may simply be assigned the contour values already determined for the corresponding pixels of the previously formed contour image, i.e. the skeleton pixels of FIG. 5 take the value of the correspondingly located pixels of FIG. 3, thus the information from the contoured image (FIG. 3) is also used to produce a contoured skeleton (FIG. 5).
Referring to FIG. 6, in order to determine a suitable aimpoint, step 105, location or actual centroid of the target, an xy axes system is centered on one of the pixels, preferably the one with the highest skeletal contour value, i.e. the skeletal centroid. The co-ordinates x,y of the actual centroid are then determined from:
x=ΣΣ×C(x,y)/ΣΣC(x,y)
and
y=ΣΣyC(x,y)/ΣΣC(x,y)
where x and y are values on the axes system and C(x,y) are the contour values found at the skeletal pixel locations. From x and y the distance D of the actual centroid (denoted *) from the skeletal centroid may be determined thus:
D=√(x.sup.2 +y.sup.2)
Considering the skeleton of FIG. 6. The centroid C is marked and has a contour value of 14. The x,y axis is centered on this point. ΣΣC(x,y), ΣΣxC(x,y) and ΣΣyC(x,y) are determined as shown. ##EQU1## The distance D from the actual centroid to the skeletal centroid is also determined:
D=√(x.sup.2 +y.sup.2)
D=√(0.1778.sup.2 +0.1555.sup.2)
D=√(0.0316+0.0242)
D=0.236
If necessary this distance D may be determined for each skeletal pixel so that the pixel closest to the centroid can be determined and this pixel be used as an indication of aimpoint location.
Referring to FIG. 7, a block diagram is shown which illustrates the above-described steps to determine the aimpoint location.
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This invention relates to a method for analyzing a viewed scene containing a target. The scene is digitized forming a binary image in which the target is distinguished from the background. The image is then processed to form a contoured representation of the target, and a target skeleton. Finally a contoured skeleton is produced and the target aimpoint is determined.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is the National Stage of PCT/AT2009/000216 filed on May 25, 2009, which claims priority under 35 U.S.C. §119 of Austrian Application No. A 1034/2008 filed on Jun. 30, 2008, the disclosure of which is incorporated by reference. The international application under PCT article 21(2) was not published in English.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a contact tube for a welding torch, having a longitudinal axis, along which a continuous opening is provided for guiding a welding wire from an inlet area to an outlet area and from an outlet opening in the direction of a workpiece, at least one slot being provided in the outlet area for contacting the welding wire.
All supplementary materials for greatly varying welding methods are included under the term welding wire.
2. Description of the Related Art
Manifold contact tubes for welding torches are known from the prior art, which are provided with at least one slot in the area of the outlet opening for the welding wire. In this way, the contact tube becomes flexible in the area of the at least one slot, so that the diameter of the outlet opening can be reduced. A contact force can thus be exerted for contacting the welding wire. Various methods are known for achieving this contact force.
For example, a contact tube for a welding torch, which is provided with two slots, is known from EP 1 266 714 A1. The opening for conveying the welding wire is constricted with the aid of a ring, which is pushed over the contact tube in the area of the slots. It is disadvantageous in this case that no readjustment of the contact force is possible, and the outlet opening is expanded again by the resulting abrasion of the welding wire in the contact tube and the set contact force thus can no longer be maintained.
A contact tube for a welding torch is also known from U.S. Pat. No. 6,710,300 B2, by which the contacting of a welding wire is to be improved. This is performed in particular by exerting a contact force on the welding wire, in that a part of the contact tube which is provided with two slots is pressed using a spring against a fixed body. It is disadvantageous in this case that the mobility is restricted by the resistance on the fixed body, so that the contact force on the welding wire can only be set to a limited extent and increased abrasion of the welding wire is caused. Furthermore, the replacement of the contact tube is connected with an increased time expenditure, since additional connections of elements to the contact tube must be detached.
JP 2004001088 A and WO 2008/018594 A1 describe contact tubes for welding torches, which have, in addition to the slot which runs in the longitudinal direction, vertically situated slots in the outlet area of the welding wire, by which an adaptation of the contact tube to the welding wire can be improved.
SUMMARY OF THE INVENTION
The object of the present invention comprises providing the most consistent and permanent contacting of the welding wire possible over the service life of a contact tube of a welding torch. Disadvantages of known contact tubes are to be prevented or at least reduced.
This object is achieved in that at least one further slot is provided in the inlet area, the slot in the inlet area and the slot in the outlet area being situated aligned, and a web which is used as a pivot point being formed between the slot in the outlet area and the at least one slot in the inlet area. Through the aligned configuration of the slot in the inlet area and the slot in the outlet area, mirror-inverted movement of the parts of the contact tube on both sides of the slots is made possible. It is advantageous in this case that the contact force required for the contacting is automatically readjusted, in that a fixed pre-tension is set in the inlet area of the contact tube. The welding wire can thus be permanently contacted during a welding process, whereby the welding quality is increased. The outlet area is flexible and/or movable due to the slot, whereby the contact tube can be used for various welding wire diameters, within a specific range. The contact force can thus be adapted optimally to the material and the diameter of the respective welding wire. Furthermore, this has the advantage that the conveyance force for the welding wire can be kept minimal and simultaneously an optimum current transfer to the welding wire is ensured. The abrasion of the welding wire and also the abrasion of the opening in the contact tube are thus minimal and/or are compensated for by this flexible closure part, so that permanent contacting of the welding wire is provided. Furthermore, the contact tube can be replaced rapidly and easily.
The slot in the outlet area is advantageously situated running along the longitudinal axis up to in front of the outlet opening of the contact tube and subsequently diagonally to the longitudinal axis, so that two jaws which differ in their shape are formed on both sides of the slot. Through such guiding of the slot in the outlet area of the contact tube, protection from contaminants, such as welding spatters, is provided, since the slot does not represent a direct engagement surface.
One jaw is advantageously implemented as essentially L-shaped and encloses the outlet opening for the welding wire.
According to a further feature of the invention, a contact area, which is adaptable to the diameter of the welding wire, is provided for contacting a welding wire in the outlet area of the contact tube, and the opening of the contact tube is implemented up to the contact area in such a manner that the welding wire can be guided essentially free running from the inlet area up to the contact area in the outlet area. Secure or permanent contacting of the welding wire is thus achieved, since the contact area essentially does not change and a constant electric arc is thus also ensured.
According to a further design of the contact tube, a ring-shaped expansion, having an external diameter greater than the remaining external diameter of the contact tube, is provided in the inlet area, and a stop surface is implemented on the side of the expansion oriented toward the outlet opening. This stop surface offers a hold for a fastener, via which the contact tube can be connected to the welding torch.
The inner surface of the ring-shaped expansion is preferably implemented as tapering conically toward the opening of the contact tube to receive a corresponding conical adapter part for fastening on the welding torch. By receiving a corresponding conical adapter part in this conical inner surface of the ring-shaped expansion, the contact tube can be spread apart in the inlet area and moved toward one another in the outlet area as a result. This is made possible by the mobility of the contact tube by the configuration of the slots according to the invention in the inlet area and outlet area. Through the mobility of the contact tube, better regulation and transmission of the contact force to the welding wire is also caused.
It is also advantageous if the inner surface of the ring-shaped expansion is implemented as curved. The contact between the corresponding conical adapter part and the contact tube is thus improved, from which better current transfer and better heat dissipation also result.
A union nut is advantageously provided for fastening the adapter part, so that the inlet area is spread apart by the conical adapter part and the jaws are moved toward one another in the outlet area as a result.
The union nut can be implemented so that it is situated as a protective envelope over the outlet area of the contact tube.
When the outlet area of the contact tube is implemented as conically tapering toward the outlet opening, a reduction of the area for the adhesion of welding spatters can be achieved. The union nut is also optionally implemented as conical in this area.
According to one embodiment, the adapter part has a hole for the welding wire, a cone on the side for use on the conical inner surface, and an external thread on the side diametrically opposing the cone for connection to the welding torch. Through an adapter part implemented in this manner, the contact tube can be used for arbitrary welding torches, since the adapter part is usable as an adapter.
An external thread for connection to a corresponding internal thread of the union nut is preferably situated on the side of the cone of the adapter part.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is explained in greater detail on the basis of the appended schematic drawings.
In the figures:
FIG. 1 shows a schematic view of a welder;
FIG. 2 shows a welding torch in a schematic exploded view;
FIG. 3 shows a sectional view of a first embodiment of a contact tube according to the invention;
FIG. 4 shows a perspective view of the contact tube according to FIG. 3 ;
FIG. 5 shows a sectional view of a union nut for fastening the contact tube on a welding torch;
FIG. 6 shows a perspective view of the union nut according to FIG. 5 ;
FIG. 7 shows a sectional view of an adapter part for fastening the contact tube on the welding torch;
FIG. 8 shows a perspective view of the adapter part according to FIG. 7 ;
FIG. 9 shows a sectional view of the contact tube, which is situated using the union nut and the adapter part on a torch body of a welding torch, before it is fixed;
FIG. 10 shows the configuration according to FIG. 9 after corresponding fixing on the torch body;
FIG. 11 shows the configuration according to FIG. 10 having a welding wire conveyed in the contact tube;
FIG. 12 shows a sectional view of a variant of the contact tubes on a tandem welding torch;
FIG. 13 shows a sectional view of a further embodiment of a contact tube; and
FIG. 14 shows a perspective view of the contact tube according to FIG. 13 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
For introductory purposes, it is noted that identical parts of the variants and embodiments are provided with identical reference numerals.
FIG. 1 shows a welder 1 or a welding system for greatly varying processes or methods, such as MIG/MAG welding or WIG/TIG welding or electrode welding methods, double wire/tandem welding methods, plasma or soldering methods, etc.
The welder 1 comprises a power source 2 having a power unit 3 , a control device 4 , and a switching element 5 , which is assigned to the power unit 3 and/or the control device 4 . The switching element 5 and/or the control device 4 is connected to a control valve 6 , which is situated in a supply line 7 for a gas 8 , in particular a protective gas such as CO 2 , helium, argon, or the like, between a gas reservoir 9 and a welding torch 10 .
In addition, a wire feed device 11 , which is typical for MIG/MAG welding, can be activated via the control device 4 , an auxiliary material or a welding wire 13 being supplied from a storage drum 14 or a wire roll in the area of the welding torch 10 via a supply line 12 . Of course, it is also possible that the wire feed device 11 , as is known from the prior art, is integrated in the welder 1 , in particular in the main housing, and is not implemented as an auxiliary device as shown in FIG. 1 .
It is also possible that the wire feed device 11 supplies the welding wire 13 to the processing point outside the welding torch 10 , for this purpose, a non-fusing electrode preferably being situated for this purpose in the welding torch 10 , as is typical in WIG/TIG welding.
The current for establishing an electric arc 15 , in particular a working electric arc, between the non-fusing electrode (not shown) and a workpiece 16 is supplied via a welding line 17 from the power unit 3 of the power source 2 to the welding torch 10 , in particular the electrode, the workpiece 16 to be welded, which is also formed from multiple parts, also being connected via a further welding line 18 to the welder 1 , in particular to the power source 2 , and thus a circuit being able to be established for a process via the electric arc 15 and/or the produced plasma jet.
To cool the welding torch 10 , the welding torch 10 can be connected via a cooling loop 19 , with a flow monitor 20 interposed, to a liquid container, in particular a water container 21 , whereby when the welding torch 10 is put into operation, the cooling loop 19 , in particular a liquid pump which is used for liquid situated in the water container 21 , being started and thus the welding torch 10 being able to be cooled.
Furthermore, the welder 1 has an input and/or output device 22 , via which greatly varying welding parameters, modes of operation, or welding programs of the welder 1 may be set and/or retrieved. The welding parameters, modes of operation, or welding programs which are set via the input and/or output device 22 are relayed to the control device 4 and subsequently the individual components of the welding system or the welder 1 are activated thereby and/or corresponding target values are specified for the regulation or control.
Furthermore, in the illustrated exemplary embodiment, the welding torch 10 is connected via a hose package 23 to the welder 1 or the welding system. The individual lines from the welder 1 to the welding torch 10 are situated in the hose package 23 . The hose package 23 is connected via a coupling device 24 to the welding torch 10 , while in contrast the individual lines in the hose package 23 are connected to the individual contacts of the welder 1 via terminal sockets or plug connections. In order that an appropriate tension relief of the hose package 23 is ensured, the hose package 23 is connected via a tension relief device 25 to a housing 26 , in particular to the main housing of the welder 1 . Of course, it is also possible that the coupling device 24 can also be used for the connection to the welder 1 .
Fundamentally, it is to be noted that all of the above-mentioned components do not have to be employed or used for the various welding methods or welders 1 , such as WIG devices or MIG/MAG devices or plasma devices. For this purpose, for example, it is possible that the welding torch 10 can be implemented as an air-cooled welding torch 10 .
A greatly simplified construction of a welding torch 10 , which is implemented as a MIG torch, is shown in FIG. 2 . This exploded view shows the essential components of the welding torch 10 , namely the hose package 23 , the coupling device 24 , a tube elbow 27 , a torch body 28 as the current-conducting part, on which finally a contact tube 29 and a gas nozzle 55 are fastened. The hose package 23 is connected via the coupling device 24 to the tube elbow 27 or the welding torch 10 .
The hose package 23 can also be connected to a torch handle, which is connected via the coupling device 24 to the tube elbow 27 . Such a coupling device 24 can also be used for connecting the hose package 23 to the torch handle. The torch handle can also be implemented as an adapter part however, and thus, for example, the welding torch 10 can be fastened to a robot via the adapter part.
The tube elbow 27 contains, inter alia, cooling ducts, supply lines for the electrical power, supply lines for the gas 8 , and in particular the supply line 12 or feed device 12 for the welding wire 13 , the so-called core or wire core, this being supplied to the tube elbow 27 via the hose package 23 . The welding wire 13 is therefore conveyed from the storage drum 14 via the feed device 12 or via a corresponding inner hole in the feed device 12 up to the contact tube 29 . This is performed at least by the wire feed unit 11 . In the contact tube 29 , the welding wire 13 is supplied with electrical power, so that an arc welding process can be performed. Accordingly, the contact tube 29 is manufactured from an electrically conductive and essentially wear-proof material, such as copper, copper alloys (tungsten), etc.
As is known from the prior art, the contact tube 29 has a continuous axial opening 30 along a longitudinal axis 31 of the contact tube 29 , the opening 30 being able to be divided, for example, into a guide hole 32 , a hole 33 , and an outlet opening 39 for the welding wire 13 —as shown below in FIG. 3 . For a stable welding process, it is significant that the contacting of the welding wire 13 always occurs as much is possible in the outlet opening 39 , the welding wire 13 being able to run freely over at least a short distance up to there, for example, the length of the hole 33 . The guide hole 32 in the contact tube 29 can also be dispensed with, of course. In these cases, the feed device or wire core 12 already essentially ends in the torch body 28 , i.e., before the welding wire 13 enters the contact tube 29 . The welding wire 13 accordingly runs freely up to the outlet opening 39 , since the hole 33 is implemented as substantially larger than the diameter of the welding wire 13 . Therefore, no contacting of the welding wire 13 with the material of the contact tube 29 typically occurs in the area of the hole 33 , and therefore also no premature current transfer.
According to the invention, the contact tube 29 is implemented correspondingly, to be able to achieve the contacting, which is required for a stable welding process, by a force on the welding wire. The exertion of the force can be supported by additional auxiliary means. Through the contact tube 29 according to the invention it is ensured that the welding wire 13 is always contacted at the same point and permanently.
The contact tube 29 according to the invention is also implemented so that it can replace a typical contact tube, which is fastened using a screw connection to the torch body 28 .
An embodiment of the contact tube 29 is shown schematically in a sectional view in FIGS. 3 through 9 . The contact tube 29 according to the invention has a slot 34 in the outlet area 35 and a slot 36 in the inlet area 37 . A web 38 , which is used as a pivot point, is formed between the slot 34 in the outlet area 35 and the at least one slot 36 in the inlet area 37 . The slot 34 in the outlet area 35 runs along the longitudinal axis 31 up to shortly before the outlet opening 39 of the contact tube 29 and subsequently diagonally to this axis. Therefore, two different jaws 40 , 41 result in the outlet area 35 , one jaw 40 being implemented as essentially L-shaped and containing the outlet opening 39 . It is important that the contact tube 29 is further implemented in one piece.
The slot 34 in the outlet area 35 and the slot 36 in the inlet area 37 are better visible from the perspective view of the contact tube 29 according to FIG. 4 . It may also be seen that the slot 34 and the slot 36 are connected and/or separated by a web 38 , the web 38 representing the connection between the inlet area 37 and the outlet area 35 . The opening 30 of the contact tube 29 is formed by the guide hole 32 , the hole 33 , and the outlet opening 39 . The guide hole 32 , the hole 33 , and the outlet opening 39 are each situated concentrically having a conical taper. This is significant in particular for a low-friction and centered transition of the welding wire 13 into the outlet opening 39 of the contact tube 29 , which is implemented in one piece. It is also essential that the diameters of the hole 33 and the guide hole 32 are selected so that no contacting of the welding wire 13 occurs in the hole 33 , but rather first in the outlet opening 39 . For example, the diameter of the hole 33 is three to ten times as large as the diameter of the welding wire 13 . It is thus achieved by the welding wire 13 , which runs freely in the hole 33 , that the welding wire 13 is only contacted in the outlet opening 39 . This has a positive effect in particular on the material transfer and therefore on the entire welding process, since the welding wire 13 is always contacted at the same point.
In order that the contacting of the welding wire 13 always occurs at the same point, i.e., in the outlet opening 39 , the effect of the slot 36 in the inlet area 37 is significant. This essentially allows the introduction of a force onto the contact tube 29 and/or the welding wire 13 running therein. The force on the welding wire 13 can be set using a union nut 42 (described below), which is used for fastening the contact tube 29 to the welding torch 10 .
It is obvious from FIG. 9 that the contact tube 29 is mounted using the union nut 42 on an adapter part 49 , which is in turn installed on the torch body 28 . In this case, forces still do not act on the contact tube 29 or on the welding wire 13 guided therein. If the contact tube 29 is fastened on the adapter part 49 , as shown in FIG. 10 , through the force shown by the arrows 56 , which results through the complete fastening of the union nut 42 , the inlet area 37 is spread apart—as shown by the double arrow 57 , and the slot 34 in the outlet area 35 is compressed and/or the jaws 40 , 41 are moved toward one another. For complete fastening of the contact tube 29 , the union nut 4 . 2 is rotated until it stops on the stop surface 44 of the ring-shaped expansion 52 of the contact tube 29 . The contact tube 29 has a fixed pre-tension, which allows a variable contact force via the mobile or flexible jaws 40 , 41 . The welding wire 13 is therefore contacted using the optimum contact force essentially over its entire service life of the contact tube 29 . The contact force for permanent contacting of the welding wire 13 is shown by the arrows 58 . In particular, the jaw 40 , which is formed by the slot 34 in the outlet area 35 , and the jaw 41 in the area of the outlet opening 39 are moved toward one another, so that a diameter of the outlet opening 39 results which is smaller than the diameter of the welding wire 13 . The welding wire 13 conveyed through the outlet opening 39 , as shown in FIG. 11 , is therefore essentially clamped or the welding wire 13 must press the jaws 40 , 41 apart. This causes the welding wire 13 to be permanently contacted at the same point. The outlet area 35 therefore produces a defined contact area having at least two contact points formed from the jaws 40 , 41 . These contact points are located directly adjacent to the hole 33 , i.e., in a first part of the outlet opening 39 . The second part of the outlet opening 39 is located in the L-shaped jaw 40 , which completely encloses the second part of the outlet opening 39 and is essentially used as a guide for the welding wire 13 . This guide can also be insulated correspondingly.
The above-described effect is independent of the direction in which the welding wire 13 is conveyed through the opening 30 of the contact tube 29 . The contact tube 29 according to the invention can thus also be used for a CMT (cold metal transfer) welding process, in which the welding wire 13 is conveyed both in the direction of the workpiece 16 and also away from the workpiece 16 .
The web 38 is used in such a contact tube 29 as a pivot point and allows the mirror-inverted movement of the parts of the contact tube 29 in the inlet area 37 and outlet area 35 . If the inlet area 37 is spread open, the outlet area 35 or the jaws 40 , 41 are compressed. The jaws 40 , 41 are accordingly movable in the defined contact area. The forces required for this purpose are thus transmitted by the web 38 from the inlet area 37 to the outlet area 35 , so that permanent contacting of the welding wire 13 is ensured. The required forces are adapted to the diameter or to a defined range of diameters of the welding wire 13 . In general, the forces result from the relationship between the width of the slot 34 and the width of the slot 36 . The wider the slot 36 in the inlet area 37 , the wider the jaws 40 , 41 may move away from one another. In contrast, the width of the slot 34 affects how far apart the jaws 40 , 41 may be pressed by the welding wire 13 and for which welding wire diameter the contact tube 29 is designed, or for which range of welding wire diameters it can be used. These relationships are also dependent on the width of the web 38 or the distance between the slot 34 and the slot 36 . In the case of a narrow web 38 , more force can be transmitted and vice versa. Because of these relationships, the contact tube 29 according to the invention can thus be manufactured, which is adapted to one specific welding wire diameter or to multiple welding wire diameters lying in one range. Permanent contacting can thus be ensured for these welding wires 13 .
In addition, however, the exposed slot 34 is not to be contaminated, as is frequently the case by welding spatters, for example. These could also stick together the slot 34 , for example, so that the effect according to the invention would no longer be provided. This is solved according to the invention in that the slot 34 only runs along the longitudinal axis 31 essentially up to the middle of the outlet opening 39 and subsequently runs diagonally to the longitudinal axis 31 , as already noted. The slot 34 thus runs behind the L-shaped jaw 40 and protects it from contamination.
As already noted, the contact tube 29 is fastened using the union nut 42 on the torch body 28 or on the adapter part 49 , since the contact tube 29 according to the invention does not have a separate fastening capability, such as a screw connection or a similar feature. The union nut 42 is described in detail in FIGS. 5 and 6 . The union nut 42 can have a hexagon for operation using a corresponding tool.
Fundamentally, the union nut 42 has the form of a dome nut, which on one side has an opening 43 having a diameter, which corresponds to the external diameter of the contact tube 29 , so that the union nut 42 can be pushed over the outlet area 35 of the contact tube 29 up to a stop surface 44 . The stop surface 44 is situated in the inlet area 37 or directly forms the beginning of the inlet area 37 . The contact tube 29 has, in the inlet area 37 , a ring-shaped expansion 52 , whose diameter is greater than the external diameter of the remaining contact tube 29 . The diameter of the stop surface 44 is greater than the external diameter of the contact tube 29 , the diameter of the stop surface 44 corresponding to the internal diameter of the union nut 42 . The contact tube 29 can thus be fastened by the union nut 42 on the torch body 28 . This is preferably performed by a corresponding internal thread 45 in the union nut 42 and an external thread 46 corresponding thereto on the torch body 28 . The ring-shaped expansion 52 of the contact tube 29 has an inner surface 47 , which is implemented as conical toward the opening 33 of the contact tube 29 . This conical inner surface 47 is required to achieve the desired spreading of the inlet area 37 . For this purpose, a conical adapter part 49 corresponding to the conical inner surface 47 is provided. The cone 48 of the adapter part 49 has a minimally greater diameter than the inner diameter of the ring-shaped expansion 52 . When the union nut 42 and thus the contact tube 29 is screwed onto the torch body 28 , the slot 36 is thus pressed or spread apart in the inlet area 37 . This in turn causes the jaws 40 , 41 in the outlet area 35 to move toward one another and a permanent contact of the welding wire 13 to be achieved. The union nut 42 accordingly exerts a force via the cone 48 of the adapter part 49 on the contact tube 29 , through which a contact force results in the outlet area 35 , as was already described in detail. This contact force finally allows the permanent contacting of the welding wire 13 .
Of course, the stop surface 44 can also be in the area of the web 38 , the conical inner surface 47 always being maintained directly at the beginning of the inlet area 37 . The height of the ring-shaped expansion 52 is varied accordingly. Therefore, the placement of the stop surface 44 on the contact tube 29 is preferably adapted to the configuration of the contact tube 29 in the welding torch 10 , the number of the contact tubes 29 in the welding torch 10 , etc. The configuration of the stop surface 44 is dependent in particular on the type of the welding torch 10 and is adapted accordingly thereto.
It is also dependent on the type of the torch 10 whether the torch body 28 has a corresponding external thread 46 for receiving the union nut 42 . However, it is currently the case in commercially-available welding torches 10 that they have an internal thread in the torch body 28 instead of the required external thread 46 .
Accordingly, the use of the adapter part 49 is necessary, which is screwed into the commercially-available internal thread of the burner body 28 and has the external thread 46 required for receiving the union nut 42 . For such a screw connection, corresponding notches are provided on the adapter part 49 , so that it can be fastened using an open-ended wrench or the like, for example. Therefore, nearly any commercially-available welding torch 10 can be retrofitted with the contact tube 29 according to the invention using the adapter part 49 according to the invention. The adapter part 49 can also be viewed as an adapter. The adapter part 49 is shown in detail in FIGS. 7 and 8 . The external thread 46 and a second external thread 50 as well as the cone 48 situated on the front side of the adapter part 49 are obvious therefrom. The external thread 50 is used for fastening in the internal thread of the torch body 28 and the external thread 46 is used for fastening the union nut 42 . The cone 48 on the front side of the adapter part 49 causes, during the fastening of the contact tube 29 on the threaded pin 49 using the union nut 42 , the inlet area 37 to be spread apart, so that the outlet opening 39 is adapted to the diameter of the welding wire 13 . The cone 48 on the adapter part 49 and the conical inner surface 47 are adapted to one another in such a way that the outlet opening 39 is adapted to the diameter of the welding wire 13 . Of course, the adapter part 49 also has an opening 51 along its longitudinal axis, which is used for the passage of the welding wire 13 .
The adapter part 49 does not have to be implemented as an expendable part, but rather is to be viewed as part of the torch body 28 and not as part of the contact tube 29 or an expendable part. The adapter part 49 is thus a type of extension of the torch body 28 , which relays the welding current to the contact tube 29 and dissipates the heat of the contact tube 29 .
The contact tube 29 according to the invention is shown in FIG. 9 , as it is fastened using the union nut 42 on the adapter part 49 , and the adapter part 49 is connected to the torch body 28 . It is obvious therefrom that the contact tube 29 according to the invention is only fastened using a screw connection on the torch body 28 . No additional effort or disadvantage with respect to typical contact tubes 29 and therefore arises in the case of maintenance or replacement.
Further embodiments of contact tubes 29 are shown in FIGS. 12 through 14 . A so-called tandem welding torch 10 is shown in FIG. 12 , which has two contact tubes 29 according to the invention. The contact tubes 29 essentially correspond to the above-described embodiment, which are screwed diagonally into an extension 53 of the torch body 28 . A body 54 having a thread can also be implemented, on which the contact tube 29 is in turn diagonally fastened. A union nut 42 which is situated over the outlet area 35 of the contact tube 29 can also be used. The protection from contamination can thus be improved still further. The contact tube 29 is thus essentially enveloped entirely by the union nut 42 , only one opening for the welding wire 13 being provided in the union nut 42 .
In addition, it is obvious from the contact tubes 29 shown herein that the slot 34 in the outlet area 35 has a club-like form in the area of the web 38 . This embodiment of the contact tube 29 is shown in detail in FIGS. 13 and 14 . The mobility of the outlet area 35 or the jaws 40 , 41 is made easier by the club-like form, since less material is provided in this area. The contact force on the welding wire 13 can also be adapted and/or set and/or influenced by the size of the club-like form of the web 38 . A further feature of this embodiment is the curved inner surface 47 of the ring-shaped expansion 52 . In this manner, independently of the tightening force of the union nut 42 , a contact is always produced between the inner surface 47 and the cone 48 of the adapter part 49 . The current transfer and the heat dissipation between torch body 28 and contact tube 29 is accordingly decisively improved and continuously ensured. This is essentially to be attributed to a consistent contact surface, which is also not changed by manufacturing tolerances, but rather at most displaced. The friction force during the fastening of the contact tube 29 to the union nut 42 is also reduced by the curved inner surface 47 , so that the defined pre-tension always remains consistent, even during a replacement of the contact tube 29 . This can also be provided in the above-described embodiment of the contact tube 29 .
In the contact tube 29 according to the invention, the union nut 42 is used as a means for introducing a force onto the contact tube 29 , by which the inlet area 37 is spread apart. Through the force, the outlet area 35 or the jaws 40 , 41 are compressed, a contact force is exerted on the welding wire 13 , and the welding wire is permanently contacted over the entire service life of the contact tube 29 . Of course, a corresponding gas nozzle 55 which is known from the prior art is also usable in each case.
In general, it is also to be noted that the contact tube 29 according to the invention essentially causes a constriction of the outlet opening 39 , so that during conveyance of the welding wire 13 through the outlet opening 39 , a required contact force acts on the welding wire 13 . The contact tube 29 is also movable in a defined area, essentially in the outlet area 35 , because of the acting force. The jaws 40 , 41 are the basic requirement for the mobility of the contact tube 29 . The contact force can be adjusted by changing the lever conditions on the contact tube 29 . This is performed, for example, by a corresponding configuration of the pivot point (web 38 ) and the force introduction.
Known grinding out of the outlet opening 39 is also compensated for in the case of the contact tube 29 according to the invention, since in spite of the grinding out caused by the conveyed welding wire 13 , permanent contacting of the welding wire is ensured. This is to be attributed to the contact force acting on the welding wire 13 being readjusted. For this purpose, the above-described mobility of the contact tube 29 or the fact that the jaws 40 , 41 always attempt to move toward one another is decisive.
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The invention relates to a contact tube ( 29 ) for a welding torch ( 10 ), having a longitudinal axis ( 31 ) along which a through-opening ( 30 ) for guiding a welding wire ( 13 ) from an inlet region ( 37 ) to an outlet region ( 35 ) and from an outlet opening ( 39 ) towards a workpiece ( 16 ) is provided, wherein at least one slot ( 34 ) is provided in the outlet region ( 35 ) for making contact with the welding wire ( 13 ). A contact tube ( 29 ) with improved contacting of the welding wire ( 13 ) is obtained by providing at least one further slot ( 36 ) in the inlet region ( 37 ) of the contact tube ( 29 ), wherein the slot ( 36 ) in the inlet region ( 37 ) is arranged in line with the slot ( 34 ) in the outlet region ( 35 ), and a web ( 38 ), which serves as a pivot point, is formed between the slot ( 34 ) in the outlet region ( 35 ) and the at least one slot ( 36 ) in the inlet region ( 37 ).
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FIELD OF THE INVENTION
[0001] The present invention relates to the field of fenestration. More particularly, the invention relates to a method and apparatus for rotating a waterproof window pane assembly 360 degrees with respect to a fixed frame, wherein the thermal and optical performance of the window pane assembly depends on the orientation of the glass surfaces contained therein. The rotatable window pane assembly also allows for improved accessibility to the exterior face of the glass surfaces of conventional windows to enable the cleaning thereof.
BACKGROUND OF THE INVENTION
[0002] Glazed openings permit the flow of energy between an interior and an exterior by conduction, convection and radiation. Ordinary, nearly transparent, standard double-strength sheet glass allows about 87% of the solar radiation (ASHRAE (1989), 1989 Fundamentals Handbook, ASHRAE, Atlanta) to pass. The uncontrolled influx of solar energy through large glazed openings has numerous drawbacks, for example: 1) extreme overheating in the summer; and 2) visual discomforts of glare both in summer and in winter. Furthermore, direct sunlight has a deleterious effect on furniture and objects located near the opening.
[0003] The traditional response to these problems has been to incorporate shading devices, which reduce the exposed area of the glazing.
[0004] Fixed shading devices are generally installed on the exterior of the windows. Usually they do not require maintenance, but they cannot be adapted to changing meteorological conditions, and, while screening out direct solar radiation, have little effect on diffuse or reflected radiation.
[0005] Operable shading devices on the exterior of windows are designed to allow control of the incoming radiation at all times. They may have complex mechanisms which require maintenance or replacement, and require either user intervention to operate properly, or expensive automatic control systems.
[0006] The effect of shading devices installed on the interior of the building, such as roller shades, curtains or venetian blinds, depends on their ability to reflect incoming solar radiation back through the window before it can be absorbed and converted to heat. Drapes may reduce annual cooling loads by 5-20% (Rudoy & Duran, 1975, “Effect of Building Envelope Parameters on Annual Heating/Cooling Load”, ASHRAE Journal 7:19), and serve mainly to improve visual comfort and reduce the effect of radiant energy on building occupants near the windows. Integrated shading devices, i.e. venetian blinds placed between glass sheets in a double glazed unit or between the frames of a double window, are also in use.
[0007] All shading devices interfere with one of the main purposes of windows—the provision of visual contact with the outdoors; and since their response is based on simple geometry, they are not selective in their effect. They either block out all of the incident radiation or allow it to pass through a given element of the window. The limitations of shading devices led to the development of new types of glazing materials. Modern glazing design involves the use of multiple panes of glass, with panes of differing properties combined in one window assembly. Selective transmission of light and heat may be achieved in response to changing environmental conditions. The annual energy consumption for a given enclosure may be reduced, with a concomitant improvement in illumination, by reversing the relative position of each window pane during specific periods of the year.
[0008] Reversible windows for solar heating and cooling are well known in the art. For example, U.S. Pat. No. 3,925,945 discloses a glass wall assembly having a pivotally mounted frame which carries a pane of heat absorbing glass spaced from an insulating panel comprised of panes of clear glass. The heat energy absorbed by the glass may be converted into convective heat and conducted to the outside of the building during the summer months or to the interior during the winter months, after the glass wall assembly has been reversed so that the insulating panel faces the exterior side.
[0009] U.S. Pat. No. 4,365,620 discloses a window which comprises a first pane that blocks infrared radiation and a second pane that transmits it and can be rotated about a horizontal axis so that the first pane faces outwardly in the summer and the second pane faces outwardly in the winter. Similarly, European Publication No. EP 922829 teaches a reversible ventilated glazing system.
[0010] Although the aforementioned patents teach windows in which the orientation of the panes is reversible, the windows are nevertheless not capable of being reversed quickly and easily. They cannot be rotated on a daily basis or for a short period of time to allow for convenient and cost-effective washing of both faces of a glass window from the building interior. In order for a prior art window to be water impermeable, a sealing element such as a gasket has to be permanently affixed between the pivotally mounted frame, which carries the window, and the wall in which the frame is mounted. The sealing element therefore has to be removed, e.g. with a hand-held implement, in a time-consuming procedure. Alternatively, if the sealing element is not permanently affixed, absolute sealing is not effected due to air pockets that remain between the sealing element and the external wall. A clearance between the sealing element and the external wall, when a permanent gasket is not affixed, must be maintained to allow for the rotation of the pivotally mounted frame.
[0011] U.S. Pat. No. 4,521,991 discloses a window apparatus that includes a pair of window frame assemblies which are capable of sliding and inwardly tilting relative to a jamb assembly, thereby facilitating opening and indoor cleaning. The window frames are provided with locking members to prevent tilting, and the window apparatus can withstand relatively high wind loads encountered on the upper floors of a high building due to the low stress of the locking members. Even though this window apparatus can be used for indoor window cleaning at a high level, it is not adaptable for reversing the orientation of the window panes.
[0012] All the structures described above do not allow for the reversing of the relative position of each window pane during specific periods of the year in an immediate and simple manner, while maintaining the window pane assembly impervious to water and gusts of wind in either orientation.
[0013] It is an object of this invention to provide a window pane assembly comprised of panes having different optical properties.
[0014] It is an additional object of this invention to provide a method and apparatus for effortlessly and speedily reversing the relative position of the window panes during specific periods of the year, such that the window pane assembly is impervious to water and gusts of wind in either orientation.
[0015] It is an additional object of the present invention to provide a method and apparatus for a window pane assembly that allows for indoor window washing of both sides of each pane retained in the assembly, regardless of the height above ground level.
[0016] It is yet an additional object of this invention to provide a cost-effective window apparatus.
[0017] Other objects and advantages of the invention will become apparent as the description proceeds.
SUMMARY OF THE INVENTION
[0018] The present invention relates to a window apparatus comprising:
[0019] i. a fixed frame having an interior surface which defines an aperture;
[0020] ii. a window pane assembly comprising a frame and at least one window pane mounted in said frame, said pane having a first and a second surface, said window pane assembly being rotatably supported in said fixed frame and being rotatable with respect to said fixed frame from a first position wherein said at least one window pane is parallel to said aperture defined by said fixed frame and wherein said first surface of said at least one window pane faces the outside to a second position wherein said at least one window pane is parallel to said aperture defined by said window frame and said second surface of said at least one window pane faces the outside, said window pane assembly being further rotatable from said second to said first position; and
[0021] iii. a seal assembly comprising a seal frame and at least one pliable seal carried by and exteriorly positioned with respect to said seal frame, said seal assembly being located on the inside with respect to said fixed frame and sealing said aperture from the inside, being hingedly supported in said fixed frame, and being pivotally displaceable independently of the position of said window pane assembly from a closed position in which said seal frame is parallel and adjacent to said aperture defined by said interior surface of said fixed frame to an open position in which said seal frame is spaced from and at an angle to said aperture.
[0022] Preferably, a pliable seal of the seal assembly, when the frame thereof is in the closed position, is in compressed engagement with both the interior of said fixed frame and with said window pane assembly, whereby to provide a water impermeable seal.
[0023] The window pane assembly may be manually rotated or remotely rotated by an actuating means.
[0024] As referred to herein, the terms “outside”, “inside”, “interior” and “exterior” relate to the structure in which the window is mounted. Thus, if the window is mounted in a wall or skylight or other surface of a building, the spaces within the building constitute the inside and the space about and above the building constitute the outside.
[0025] In a preferred embodiment, the window apparatus further comprises a glazing unit hingedly attached to the window pane assembly, said glazing unit being provided with at least one pane of glass parallel to, when in a closed position, and having different optical properties than the at least one pane carried by the window pane assembly, whereby said glazing unit is rotatable together with the window pane assembly, so that said glazing unit is exteriorly disposed at said first position and interiorly disposed at said second position relative to the at least one pane carried by the window pane assembly.
[0026] In a winter mode, the at least one pane of glass, provided with the glazing unit, which is preferably capable of absorbing solar radiation, faces the inside. Solar radiation between 0.3-4 microns is transmitted through the at least one pane carried by the window pane assembly, which is clear and faces the outside. The at least one pane of glass provided with the glazing unit is capable of partially absorbing 30-90 percent of the energy of the incoming solar radiation, depending on local climatic conditions. The at least one pane of glass provided with the glazing unit is consequently heated and subsequently releases energy to the inside by long-wave radiation or by convective heating. At least one gap is formed between the at least one pane carried by the window pane assembly and the at least one pane of glass provided with the glazing unit, whereby heated air is able to circulate through said gap into an enclosure proximate to the window apparatus. Space heating is thereby achieved, while significantly reducing visual discomfort and damage to furnishings.
[0027] In a summer mode, the window pane assembly is rotated so that the at least one pane of glass provided with the glazing unit faces the outside. Most of the short wave solar radiation between 0.3-4 microns is absorbed by the at least one pane of glass provided with the glazing unit, and is prevented from being transmitted to the inside, through the at least one pane carried by the window pane assembly, since the at least one pane of glass provided with the glazing unit is nearly opaque to a wavelength greater than 4 microns. While being heated, the energy absorbed by the at least one pane of glass provided with the glazing unit is released to the outdoors by convection or by long wave radiation. Therefore, overheating of the inside is prevented and visual comfort is improved.
[0028] The present invention also relates to a method of repositioning a window pane assembly, comprising providing a window pane assembly which carries at least one window pane and which is rotatable with respect to a fixed frame; providing a mounting for a water impermeable sealing element hingedly attached to the interior of the frame; opening said mounting; applying a force to said window pane assembly to thereby displace the latter from a first position at which one side of said at least one window pane is parallel to and facing a plane formed by the exterior of the frame to a second position at which the other side of said at least one window pane is parallel to and facing a plane formed by the frame exterior, or from said second position to said first position; and closing said mounting.
[0029] This method allows for the washing of windows indoors, which is particularly advantageous at the upper floors of a high building for which outdoors window washing is a costly and dangerous task.
[0030] In a preferred embodiment of the invention, the method further comprises providing a glazing unit hingedly attached to the window pane assembly and which is provided with a pane of glass parallel to when in a closed position and having different optical properties than the at least one pane carried by the window pane assembly and rotating said glazing unit when in a closed position, together with the window pane assembly, from the first position to the second position, or vice versa.
[0031] This method enhances winter heating and summer cooling. The glazed unit preferably faces the frame exterior during the summer months to prevent the influx of solar radiation and preferably faces the frame interior during the winter months.
[0032] In one aspect, the window pane assembly is rotated by means of a microprocessor to facilitate rotation of the window pane assembly from the first position to the second position, or vice versa, in response to predetermined sensed conditions of illumination and/or temperature.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] In the drawings:
[0034] FIG. 1 is a perspective view of a first embodiment of the window apparatus of the invention in which a window pane assembly is in an intermediate position;
[0035] FIG. 2 is a perspective view of the window apparatus of FIG. 1 in which the window pane assembly is in a closed position;
[0036] FIG. 3 is a vertical cross section of the window apparatus of FIG. 2 taken on plane A-A;
[0037] FIG. 4 is a horizontal cross section of the window apparatus of FIG. 2 taken on plane B-B;
[0038] FIG. 5 is a perspective view of a window apparatus according to a second embodiment of the invention, in which the glazing unit is shown in an open position;
[0039] FIG. 6 is a perspective view of the window apparatus of FIG. 5 in which the window pane assembly is in a closed position;
[0040] FIG. 7 is a vertical cross section of the window apparatus of FIG. 6 taken on plane C-C; and
[0041] FIG. 8 is a horizontal cross section of the window apparatus of FIG. 6 taken on D-D.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0042] FIGS. 1-4 relate to one preferred embodiment of the window apparatus, generally designated by 3 . As shown in FIG. 1 , fixed frame 7 is permanently attached to wall 5 of the structure that supports window apparatus 3 . A window pane assembly, generally designated by 9 , is rotatably displaceable about an axle (not shown) with respect to fixed frame 7 , wherein the axle is pivotally mounted in the latter. The axle may be mounted in a vertical disposition, as depicted in the drawing by the rotational direction of window pane assembly 9 , or in a horizontal disposition. As shown in FIGS. 2 and 3 , seal assembly 15 comprising seal frame 16 and seals 23 , 24 is pivotally attached, e.g. by means of hinges 17 , to the interior side of fixed frame 7 . When seal assembly 15 is closed, frame 16 thereof is parallel with, and pressed against, frame 10 of the window pane assembly.
[0043] Fixed frame 7 , window pane assembly 9 and seal assembly 15 are rectangularly shaped. It is clear that the actual size and shape of the window apparatus are not critical, and the configuration of the present invention may be applied, mutatis mutandis, to any other size or shape. Similarly the frames shown, namely fixed frame 7 , window frame 10 , and seal assembly frame 16 or any other number of frames employed, may be fabricated from wood, aluminum, steel, plastic, or any other suitable material, alloy or mixtures thereof.
[0044] For clarity, the following description relates to a window apparatus that is installed within an external wall of a building. It is understood, however, that the window apparatus of the present invention may also be advantageously adapted to a structure having any particular inclination, and therefore may also be used for a skylight.
[0045] As shown in FIG. 3 , window pane assembly 9 includes at least one window pane 8 , and preferably consists of a double-glazed unit. Each pane 8 is retained in a substantially vertical position by frame 10 . Gasket 11 provides an airtight and watertight seal.
[0046] Seal assembly 15 comprises supporting frame 16 as well as seals 23 and 24 affixed to the entire periphery of frame 16 . Frame 16 is unglazed to allow for accessibility to the interior face of pane 8 . Frame 16 has an L-shaped cross section, to allow for greater structural rigidity and for the mounting thereon of the compressive seals. Seal 23 is engageable with fixed frame 7 and seal 24 is engageable with window pane assembly 9 .
[0047] Seal assembly 15 is hingedly attached to fixed frame 7 by means of hinges 17 , which are located at the inside with respect to the pane assembly. The seal assembly 15 may be hinged to any of the four sides of fixed frame 7 , and may be conveniently opened and closed with a handle (not shown), or with any other opening means. When in a closed position, seal 24 is in compressed engagement with the interior side of frame 10 of the window assembly, and seal 23 is in compressed engagement with the interior side of fixed frame 7 . As shown further in FIG. 4 , seal 23 is more outwardly positioned, that is closer to frame 16 , than seal 24 . Therefore seal 23 will prevent the passage of any water which may have collected between window pane assembly 9 and seal mounting 15 , thereby providing the window apparatus with a water impermeable seal. The water impermeability is further enhanced by water drips 25 formed within fixed frame 7 , frame 10 of the window pane assembly and sill 28 , and by drainage channel 30 formed in the bottom portion of fixed frame 7 . Drainage hole 27 drains the water that collects into drainage channel 30 , e.g. from a complementary water drip 25 formed in the underside of frame 10 (see FIG. 3 ). Sill 28 is disposed underneath fixed frame 7 . Frames 10 and 16 are provided with brush seals 26 , which resiliently contact fixed frame 10 , to restrict the passage of air.
[0048] Operationally, window pane assembly 9 may be rotated only after seal assembly 15 has been opened. After applying a force to window pane assembly 9 , which in the illustrated example is provided with two window panes, the window pane assembly is rotated. The axis about which window pane assembly 9 rotates is indicated in FIG. 3 by 29 . The window pane assembly is continuously rotatable by 360 degrees since fixed frame 7 has a contour with no protrusions which would resist or interfere with such a rotation.
[0049] In order to wash both window panes 8 , window pane assembly 9 needs to be displaced from a first position, at which one of the panes is parallel to and faces the exterior of fixed frame 7 , to a second position at which the other pane is parallel to and faces the exterior of fixed frame 7 . Similarly window pane assembly 9 at times needs to be displaced from the second position to the first position. Window pane assembly 9 is configured to come as close as possible to fixed frame 7 during rotation without contact therewith. For example, a gap of only 7 mm is needed for a 120-cm wide window pane assembly to rotate within a fixed frame having a width of 100 cm. After closing seal assembly 15 , whereby seal 23 is in compressed engagement with fixed frame 7 , seal assembly 15 may be latched shut by means of a latch (not shown) that connects frame 16 and fixed frame 7 to prevent the opening of assembly 15 due to gusts of wind. These operations allow to carry out the washing of the windows indoors, which is particularly advantageous at the upper floors of a high building for which washing windows from the outside is a costly and dangerous task.
[0050] Window pane assembly 9 may be manually rotated by exerting a force on frame 10 . Window pane assembly 9 may be remotely rotated by an actuating means, such as when the window panes are massive or when strong winds are blowing. The actuating means (not shown), e.g. a motor, may communicate with the axle(s), or may be provided with any other configuration that applies a moment to window pane assembly 9 .
[0051] FIGS. 5-8 relate to a second preferred embodiment of the present invention, in which window apparatus 33 is provided with glazing unit 42 . Since most of the components of window apparatus 33 are identical to those of window apparatus 3 , described hereinbefore with reference to FIGS. 1-4 , fixed frame 37 , window pane assembly 39 and seal assembly 45 need not be described. FIG. 5 shows glazing unit 42 in an open position, and FIG. 6 shows glazing unit in a closed position.
[0052] FIG. 7 illustrates glazing unit 42 , which is provided with pane of glass 44 having different optical properties than each pane 38 carried by window pane assembly 39 . Pane 44 may be secured, inter alia, by fixture 46 having e.g. a circular cross section and extending outward from the entire periphery of pane 44 . Fixture 46 is fabricated with two planar extensions 48 , one of which is disposed at each side of pane 44 and preferably bonded thereto at each edge thereof for support.
[0053] Rotatable frame 41 of window pane assembly 39 in this embodiment is thicker than that that of frame 10 shown in FIG. 3 , so as to allow for the placement of glazing unit 42 therein. Panes(s) 38 are laterally offset from axle(s) 43 about which window pane assembly 39 rotates. The vertical height, that is the dimension parallel to axle(s) 43 , of panes(s) 38 is greater than that of pane 44 , and consequently the height of the cavities into which panes(s) 38 and pane 44 , respectively, are insertable is also different.
[0054] As shown, glazing unit 42 is hingedly attached to window pane assembly 39 by hinges 50 . Window pane assembly 39 is provided with a cavity whose periphery corresponds to the dimensions of frame 46 of glazing unit 42 , as illustrated in FIG. 5 , so as to allow for the fixation of glazing unit 42 when closed by providing a small clearance between fixture 46 and rotatable frame 41 . A latch (not shown) is preferably provided to secure glazing unit 42 to rotatable frame 41 when the glazing unit is exteriorly positioned and exposed to a high wind load. When in a closed position, pane 44 of the glazing unit is parallel to pane(s) 38 of the window pane assembly. As a result, glazing unit 42 , when in a closed position, rotates together with window pane assembly 39 , from the first position to the second position thereof, or vice versa.
[0055] Glazing unit 42 enhances winter heating and summer cooling. The glazed unit may be advantageously repositioned by rotating window pane assembly 39 to a winter mode or a summer mode. In a summer mode, glazing unit 42 is exteriorly positioned with respect to window pane assembly 39 , such that pane 44 absorbs most of the solar radiation and prevent its transmission through clear pane(s) 38 to the interior. After being heated, pane 44 dissipates the energy absorbed to the outdoors by convection and by long wave radiation. In a winter mode, the glazing unit is interiorly positioned with respect to pane(s) 38 , as shown in FIG. 7 . After being transmitted through pane(s) 38 , solar radiation is absorbed by pane 44 . As a result pane 44 is heated, releasing the energy to the interior by long wave radiation and by convection. The provision of glazing unit 42 significantly reduces any damage to furnishings by solar radiation. In both the winter and summer modes, pane(s) 38 and pane 44 are mutually parallel.
[0056] Air channel 51 is formed between pane(s) 38 and pane 44 , due to the lateral spacing between the two sets of panes. This air channel enhances air circulation around absorptive pane 44 and into the building interior. Since the height of pane 44 is less than that of pane(s) 38 , upper gap 53 and lower gap 54 are formed by the vertical spacing between rotatable frame 41 and glazing unit 42 . During the winter mode, tinted pane 44 of the glazing unit absorbs most of the solar radiation that is transmitted through clear pane(s) 38 . Pane 44 is therefore heated, following which air channel 51 is heated. The heated air then circulates through upper gap 53 and through the opening defined by the frame of the seal assembly into the enclosure. In the summer mode, pane 44 is exteriorly positioned with respect to pane(s) 38 and directs the heated air through gap 53 to the outside. It would be appreciated that even though air channel 51 and gap 53 provide a means of air circulation into the enclosure during the winter mode, the window apparatus nevertheless is airtight. Gaskets 11 which secure pane(s) 38 to the window pane assembly, brush seals 26 and seals 23 , 24 prevent the infiltration of outside air, such as during gusts of wind or during a sandstorm, in both the summer and winter modes.
[0057] Window washing can be performed as follows: According to the example of the window apparatus shown in FIG. 7 , two panes 38 a and 38 b are provided in window pane assembly 39 and one glazing unit pane 44 are employed. The number of panes shown in the figures was chosen for clarity, and it is clear that any number of panes can be employed in both the window pane assembly and in the glazing unit, without any loss in efficacy or ease in repositioning. In the winter mode, in which glazing unit 42 is facing the inside, the interior face of pane 44 is washed first. Glazing unit 42 , which is hingedly attached to window pane assembly 39 , is then opened, exposing the exterior face of pane 44 and the interior face of pane 38 b for washing. Pane 44 is then closed and secured. If the exterior face of pane 38 a requires washing, seal assembly 45 is then opened and window pane assembly 39 is rotated 180 degrees to facilitate its washing by a person located within the enclosure. After being washed, window pane assembly 39 is rotated another 180 degrees, so that pane 38 a is once again exteriorly positioned, and seal assembly 45 is then closed and secured to provide a weatherproof seal. In the summer mode in which tinted pane 44 is exteriorly positioned with respect to pane(s) 38 , the steps are reversed.
[0058] In addition to the other methods of rotation described hereinbefore in relation to the embodiment of FIG. 1 , window pane assembly 39 may also be automatically rotated by a microprocessor-controlled window apparatus (not shown). During those days, in which it is would be advantageous to reposition the window pane assembly at least once a day, that is to change the relative location of glazing unit 42 with respect to panes 38 a and 38 b, to maximize comfort and energy savings, the repositioning is controllable by means of a microprocessor-controlled window apparatus. Such an apparatus may receive input from light and heat sensors disposed at predetermined locations relative to the window pane assembly. By example, if the temperature gradient between two of these sensors is greater than a predetermined value, the seal assembly is opened, e.g. by means of a pneumatic actuator, and the window pane assembly is rotated 180 degrees, after which the seal mounting is closed.
[0059] While some embodiments of the invention have been described by way of illustration, it will be apparent that the invention can be carried into practice with many modifications, variations and adaptations, and with the use of numerous equivalents or alternative solutions that are within the scope of persons skilled in the art, without departing from the spirit of the invention or exceeding the scope of the claims.
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A rotatable window pane assembly and method of repositioning the same is disclosed in which the window pane assembly comprising a frame and at least one window pane is rotatably supported in a fixed frame from a first position, such that the at least one window pane is parallel to an aperture defined by the fixed frame, to a second position, such that the at least one window pane is parallel to the aperture defined by the frame and a second surface of the at least one window pane faces the outside, or from a second to first position. A seal assembly comprising a seal frame and at least one pliable seal carried is located on the inside with respect to the fixed frame and is pivotally displaceable independently of the position of the window pane assembly, from a closed position in which the seal frame is parallel and adjacent to the aperture defined by the interior surface of the fixed frame to an open position in which the seal frame is spaced from and at an angle to the aperture.
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FIELD
The present application relates to a fuel injector having multiple nozzles angled in preselected directions to provide a range of spray patterns for improved fuel efficiency and combustion characteristics.
BACKGROUND AND SUMMARY
Direct-Injection Spark-Ignition (DISI) internal combustion engines, which may include Gasoline Turbocharged Direct Injection (GTDI) combustion engines, may provide more precise control over the amount, and timing of the fuel provided for combustion according to engine load. DISI engines generally provide increased fuel efficiency and improved emissions control as compared with engines without DISI.
Efforts have been made to provide even greater levels of fuel efficiency and improved emissions control using DISI and/or GTDI. For example, U.S. Pat. No. 7,418,940 discloses a fuel injector spray pattern for direct injection spark ignition engines having a first plurality of jets oriented to spray fuel generally downward toward the piston bowl and a second plurality of jets oriented to spray fuel generally across the cylinder toward the exhaust valves. However, the inventors herein have recognized at least one shortcoming with the disclosed approach.
For example, the inventors herein have discovered that the injector nozzles can be directed to provide spray patterns, within a particular range of configurations that tends to reduce valve wetting and to minimize liner and piston wetting. In addition, some of the example spray configurations disclosed herein tend to interact with the direct-injection piston bowl to produce a more stable stratified mixture around the spark plug during cold start operation for cold start combustion stability and reduced emissions.
Embodiments in accordance with the present disclosure may provide a fuel injector having an injector axis, comprising a first nozzle aiming in a first radial direction; a first nozzle pair aiming in radial directions each equally angled relative to the first direction, closest to the first radial direction, and having a longest radial offset; a nozzle second pair in radial directions each equally angled relative to the first direction; and another nozzle aiming opposite the first radial direction and having a shortest radial offset. In this way, fuel impingement on surfaces, such as the piston, intake valves, and the liner, and the like may be reduced while reducing soot formation and maintaining effective and efficient combustion.
Further embodiments in accordance with the present disclosure may provide a fuel injector system for an internal combustion engine and a fuel injector for a combustion chamber. The fuel injector system may include a fuel injector having an injector axis. Six injector nozzles may be disposed around the injector axis. Each of the six injector nozzles may be configured to direct six respective streams of fuel such that each respective stream of fuel may travel respective predetermined six radial distances from the injector axis as measured on a plane normal to the injector axis. A fourth radial distance may be a shortest distance relative to the other five radial distances. A second and a sixth radial distance may be approximately equal to each other and longer than the other four radial distances. A third and a fifth radial distance may be approximately equal to each other and may be intermediate radial distances being shorter than the second and sixth radial distance and longer than the fourth radial distance. In addition, a first radial distance may be shorter than the second and sixth radial distance and longer than the fourth radial distance. In this way, fuel impingement on surfaces, such as the piston, intake valves, and the liner, and the like may be reduced. In this way, combustion emissions may be reduced, and/or fuel economy may be improved. Also in this way, a source of soot emissions may be reduced.
It should be understood that the summary above is provided to introduce in simplified form a selection of concepts that are further described in the detailed description. It is not meant to identify key or essential features of the claimed subject matter, the scope of which is defined uniquely by the claims that follow the detailed description. Furthermore, the claimed subject matter is not limited to implementations that solve any disadvantages noted above or in any part of this disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of an example engine in accordance with the present disclosure.
FIG. 2 is a schematic perspective view of a fuel injector showing one nozzle as a generic representation of a plurality of nozzles in accordance with the present disclosure.
FIG. 3 is a plan view of an example spray pattern illustrating individual spray plumes from the six injector nozzles in accordance with the present disclosure.
FIGS. 4 and 5 are plan views similar to FIG. 3 illustrating details relative to FIG. 3 .
FIG. 6 is a side view of the spray pattern illustrated in FIG. 3 .
DETAILED DESCRIPTION
As described herein, various fuel injector nozzle configurations are described. For example, a pattern of six nozzles may be arranged in a particular way to solve issues with combustion stability, cold start emissions, soot generation, etc. In one example, the nozzles may be arranged so that five nozzles aim to one side of the injector axis, and a single nozzle aims to the other side. The single nozzle may have the shortest radial offset from the axis, while the other five nozzles are arranged with one nozzle opposite the single nozzle, and two additional pairs of nozzles flanking the one opposite nozzle.
Additional embodiments in accordance with present disclosure may provide particular radial distances by one, or both, of directing each of the six nozzles in particular angular directions as measured in a normal plane and a side plane. For example, the first radial distance may be effected by the first nozzle being oriented at a first normal plane angle of between −5 degrees and +5 degrees as measured from a centerline located to correspond with, and/or parallel with, a combustion chamber centerline with a positive direction toward one or more intake ports and a first side angle of between 10 degrees and 20 degrees as measured in a side plane that may be perpendicular to the normal plane and substantially parallel with, or coplanar with, the centerline. The second radial distance may be effected by the second nozzle being oriented a second normal plane angle of between 33.5 degrees and 53.7 degrees as measured in a way similar to the measurement of the first normal plane angle, and a second side angle of between 26.2 degrees and 36.2 degrees as measured in a way similar to the measurement of the first side angle. The third radial distance may be effected by the third nozzle being oriented a third normal plane angle of between 66.8 degrees and 76.8 degrees as measured in a way similar to the measurement of the first normal plane angle, and a third side angle of between 10.1 degrees and 20.1 degrees as measured in a way similar to the measurement of the first side angle. The fourth radial distance may be effected by the fourth nozzle being oriented a fourth normal plane angle of between 175 degrees and 185 degrees as measured in a way similar to the measurement of the first normal plane angle, and a fourth side angle of between 0 degrees and 10 degrees as measured in a way similar to the measurement of the first side angle. The fifth radial distance may be effected by the fifth nozzle being oriented a fifth normal plane angle of between 10.1 degrees and 20.1 degrees as measured in a way similar to the measurement of the first normal plane angle, and a fifth side angle of between 10.1 degrees and 20.1 as measured in a way similar to the measurement of the first side angle. The sixth radial distance may be effected by the sixth nozzle being oriented a sixth normal plane angle of between −33.5 degrees and −53.7 degrees as measured in a way similar to the measurement of the first normal plane angle, and a sixth side angle of between 26.2 degrees and 36.2 degrees as measured in a way similar to the measurement of the first side angle. In this way, the third and fifth nozzles may minimize intake valve wetting, and may provide good air-fuel mixing during homogeneous-charge operation, which may lead to reduced soot emissions and increased fuel economy.
Also in this way, the first, second, and sixth nozzles may tend to contain fuel clouds in the piston bowl which may tend to provide advantageous combustion stability for light stratified-charge at cold-start operation. Also in this way the first second and sixth nozzles may also tend to reduce piston wetting which may lead to reduced smoke emissions.
Also in this way, the fourth nozzle may tend to reach the liner first which may better fit in a smaller cylinder bore engine and may provide reduced liner wetting. In this way, oil dilution may be reduced and particulate emissions may be reduced.
FIG. 1 is a cross-sectional diagram with schematic portions, illustrating a cross-section of an engine 10 in accordance with the present disclosure. Various features of the engine 10 may be omitted, or illustrated in a simplified fashion, for ease of understanding of the current description. For example, areas may be illustrated with continuous cross hatching that may otherwise indicate a solid body, however actual embodiments may include various engine components, and/or hollow, or empty, portions of the engine.
The cross-sectional view shown in FIG. 1 may be considered taken through one cylinder 12 of the engine 10 . The cylinder 12 may be defined by or at least partially enclosed by a cylinder wall 13 . Various components of the engine 10 may be controlled at least partially by a control system that may include a controller (not shown), and/or by input from a vehicle operator via an input device such as an accelerator pedal (not shown). The cylinder 12 may include a combustion chamber 14 . A piston 16 may be positioned within the cylinder 12 for reciprocating movement therein. The piston 16 may include a piston face formed in one or more ways. For example the piston 16 may include a piston bowl 17 . The piston 16 may be coupled to a crankshaft 18 via a connecting rod 20 , a crank pin 21 , and a crank throw 22 shown here combined with a counterweight 24 . Some examples may include a discrete crank throw 22 and counterweight 24 . The reciprocating motion of the piston 16 may be translated into rotational motion of the crankshaft 18 . The crankshaft 18 , connecting rod 20 , crank pin 21 , crank throw 22 , and counterweight 24 , and possibly other elements not illustrated may be housed in a crankcase 26 . The crankcase 26 may hold oil. Crankshaft 18 may be coupled to at least one drive wheel (not shown) of a vehicle via an intermediate transmission system. Further, a starter motor may be coupled to crankshaft 18 via a flywheel to enable a starting operation of engine 10 .
Combustion chamber 14 may receive intake air from an intake passage 30 , and may exhaust combustion gases via exhaust passage 32 . Intake passage 30 and exhaust passage 32 may selectively communicate with combustion chamber 14 via respective intake valve 36 and exhaust valve 34 . Intake valve 36 and exhaust valve 34 may be configured to operatively open and close respective intake port 31 and exhaust port 33 . A throttle 35 may be included to control an amount of air that may pass through the intake passage 30 . In some embodiments, combustion chamber 14 may include two or more intake valves and/or two or more exhaust valves.
In this example, intake valve 36 and exhaust valve 34 may be controlled by cam actuation via respective cam actuation systems 38 and 40 . Cam actuation systems 38 and 40 may each include one or more cams 42 and may utilize one or more of cam profile switching (CPS), variable cam timing (VCT), variable valve timing (VVT) and/or variable valve lift (VVL) systems that may be operated by the controller to vary valve operation. The cams 42 may be configured to rotate on respective revolving camshafts 44 . As depicted, the camshafts 44 may be in a double overhead camshaft (DOHC) configuration, although alternate configurations may also be possible. The position of intake valve 36 and exhaust valve 34 may be determined by position sensors (not shown). In alternative embodiments, intake valve 36 and/or exhaust valve 34 may be controlled by electric valve actuation. For example, cylinder 16 may include an intake valve controlled via electric valve actuation and an exhaust valve controlled via cam actuation including CPS and/or VCT systems.
In one embodiment, twin independent VCT may be used on each bank of a V-engine. For example, in one bank of the V, the cylinder may have an independently adjustable intake cam and exhaust cam, where the cam timing of each of the intake and exhaust cams may be independently adjusted relative to crankshaft timing.
Fuel injector 50 is shown coupled directly to combustion chamber 14 for injecting fuel directly therein in proportion to a pulse width of a signal that may be received from the controller. In this manner, fuel injector 50 may provide what is known as direct injection of fuel into combustion chamber 14 . The fuel injector 50 may be mounted in the side of the combustion chamber 14 or in the top of the combustion chamber 14 . Fuel may be delivered via fuel line 51 to fuel injector 50 by a fuel system that may include a fuel tank, a fuel pump, and a fuel rail (not shown). The fuel line 51 may be a hose, or passage which may be coupled to a mating engine component, such as cylinder head 60 . The fuel injector 50 may have an injector axis 70 that may be oriented at an installation angle 72 relative to a reference line 74 . The reference line 74 may correspond with, or be parallel with a reference, or reference-able plane 76 in or on the engine 10 as indicated with phantom lines shown at the bottom of the crankcase 26 . Reference-able plane 76 may, for example, correspond with, or be parallel with an engine deck, or engine deck face.
Ignition system 52 may provide an ignition spark to combustion chamber 14 via spark plug 54 in response to a spark advance signal from the controller, under select operating modes. In this example the spark plug 54 is shown located at a top 55 of the combustion chamber 14 .
Cylinder head 60 may be coupled to a cylinder block 62 . The cylinder head 60 may be configured to operatively house, and/or support, the intake valve(s) 36 , the exhaust valve(s) 34 , the associated valve actuation systems 38 and 40 , and the like. Cylinder head 60 may also support the camshafts 44 . A cam cover 64 may be coupled with and/or mounted on the cylinder head 60 and may house the associated valve actuation systems 38 and 40 , and the like. Other components, such as spark plug 54 may also be housed and/or supported by the cylinder head 60 . A cylinder block 62 , or engine block, may be configured to house the piston 16 . In one example, cylinder head 60 may correspond to a cylinder 12 located at a first end of the engine. While FIG. 1 shows only one cylinder 12 of a multi-cylinder engine 10 , each cylinder 12 may similarly include its own set of intake/exhaust valves, fuel injector, spark plug, etc.
The engine 10 may include a turbocharger (not shown) having a turbo compressor disposed on an induction air path for compressing an induction fluid before the induction fluid is passed to the intake passage 30 of the engine 10 . In some applications, an inter-cooler (not shown) may be included to cool the intake charge before it enters the engine. The turbo compressor may be driven by an exhaust turbine which may be driven by exhaust gasses leaving the exhaust manifold 32 . In some cases, the throttle 35 may be upstream from the turbo compressor 94 instead of downstream as illustrated. The turbo compressor may be coupled for rotation with the exhaust turbine via a turbine shaft. Although not illustrated, the engine 10 may include an exhaust gas recirculation EGR line and/or EGR system.
The exhaust line may include one or more emission control devices (not shown), which may be mounted in a close-coupled position in the exhaust line. The one or more emission control devices may include, for example, a three-way catalyst, lean NOx trap, diesel particulate filter, oxidation catalyst, etc.
FIGS. 2-6 are various views illustrating a fuel injector system 200 for an internal combustion engine 10 in accordance with the present disclosure. FIG. 2 is a schematic perspective view of a fuel injector 50 showing one nozzle 21 X as a generic representation of a plurality of nozzles, for example six injector nozzles 211 , 212 , 213 , 214 , 215 , 216 [or jets], disposed around the injector axis 70 . Other details are illustrated in FIGS. 3-6 . FIG. 3 is a plan view of a spray pattern illustrating individual spray plumes from the six injector nozzles 211 , 212 , 213 , 214 , 215 , 216 in a plane 238 normal to the injector axis 70 at a predetermine distance downstream from the injector tip, for example at 30 mm. Normal plane angles 241 , 242 , 243 , 244 , 245 , 246 are indicated to show example orientations of each respective nozzle 211 , 212 , 213 , 214 , 215 , 216 with respect to a positive X-axis. Positive angles may be considered to be measured counterclockwise. A Y-axis may be along, or parallel with the crank shaft 18 ( FIG. 1 ), and a Z-axis may be along the injector axis 70 . Nozzle 211 , or jet 1 , may point towards the piston bowl 17 wherein jet nozzle 214 , or jet 4 , may point towards the spark plug 54 location. FIGS. 4 and 5 are plan views similar to FIG. 3 illustrating other details relative thereto. FIG. 6 is a side view of in the center of the cylinder bore with the positive direction toward the intake ports.
Various embodiments may provide a fuel injector system 200 for an internal combustion engine 10 . The fuel injector system 200 may include a fuel injector 50 having an injector axis 70 . Six injector nozzles 211 , 212 , 213 , 214 , 215 , 216 [or jets] may be disposed around the injector axis 70 . Each of the six injector nozzles 211 , 212 , 213 , 214 , 215 , 216 may be configured to direct six respective streams 221 , 222 , 223 , 224 , 225 , 226 of fuel such that each respective stream 221 , 222 , 223 , 224 , 225 , 226 of fuel may travel respective predetermined six radial distances 231 , 232 , 233 , 234 , 235 , 236 ( FIG. 4 ) from the injector axis 70 as measured on a plane 238 normal to the injector axis 70 . A fourth radial distance 234 may be a shortest distance relative to the other five radial distances 231 , 232 , 233 , 235 , 236 . A second and a sixth radial distance 232 , 236 may be approximately equal to each other and longer than the other four radial distances 231 , 233 , 234 , 235 . A third and a fifth radial distance 233 , 235 may be approximately equal to each other and may be intermediate radial distances being shorter than the second and sixth radial distance 232 , 236 and longer than the fourth radial distance 234 . In addition, a first radial distance 231 may be shorter than the second and sixth radial distance 232 , 236 and longer than the fourth radial distance 234 .
Some embodiments may provide a fuel injector system wherein the first radial distance 231 may be effected by the first nozzle 211 being oriented at a first normal plane angle 241 of between −5 degrees and +5 degrees as measured from a centerline 248 located to correspond with, and/or be parallel with, a combustion chamber centerline 249 ( FIG. 1 ) with a positive direction toward one or more intake ports 31 and a first side angle 251 of between 10 degrees and 20 degrees as measured in a side plane 250 that may be perpendicular to the normal plane 238 and substantially parallel with, or coplanar with, the centerline 248 .
The second radial distance 232 may be effected by the second nozzle 212 being oriented a second normal plane angle 242 of between 33.5 degrees and 53.7 degrees as measured in a way similar to the measurement of the first normal plane angle 241 , and a second side angle 252 of between 26.2 degrees and 36.2 degrees as measured in a way similar to the measurement of the first side angle 251 . The third radial distance 233 may be effected by the third nozzle 213 being oriented a third normal plane angle 243 of between 66.8 degrees and 76.8 degrees as measured in a way similar to the measurement of the first normal plane angle 241 , and a third side angle 253 of between 10.1 degrees and 20.1 degrees as measured in a way similar to the measurement of the first side angle 251 . The fourth radial distance 234 may be effected by the fourth nozzle 214 being oriented a fourth normal plane angle 244 of between 175 degrees and 185 degrees as measured in a way similar to the measurement of the first normal plane angle 241 , and a fourth side angle 254 of between 0 degrees and 10 degrees as measured in a way similar to the measurement of the first side angle 251 . The fifth radial distance 235 may be effected by the fifth nozzle 215 being oriented a fifth normal plane angle 245 of between −66.8 degrees and −76.8 degrees as measured in a way similar to the measurement of the first normal plane angle 241 , and a fifth side angle 255 of between 10.1 degrees and 20.1 as measured in a way similar to the measurement of the first side angle 251 . The sixth radial distance 236 may be effected by the sixth nozzle 216 being oriented a sixth normal plane angle 246 of between −33.5 degrees and −53.7 degrees as measured in a way similar to the measurement of the first normal plane angle 241 , and a sixth side angle 256 of between 26.2 degrees and 36.2 degrees as measured in a way similar to the measurement of the first side angle 251 .
In some example embodiments the first normal plane angle 241 may be approximately 0 degrees. The third normal plane angle 243 may be approximately 71.8 degrees. The fourth normal plane angle 244 may be approximately 180 degrees. The fifth normal plane angle 245 may be approximately −71.8 degrees.
In some example embodiments—the second normal plane angle 242 may be approximately 38.5 degrees, and the sixth normal plane angle 246 may be approximately −38.5 degrees. However, in some other example embodiments the second normal plane angle 242 may be approximately 48.7 degrees, and the sixth normal plane angle 246 may be approximately −48.7 degrees.
Table A illustrates example ranges of normal plane angle and side plane angles. Table B illustrates some particular example normal plane angle and side plane angles. Table C illustrates other particular example normal plane angle and side plane angles. Other ranges or particular angles may be used.
TABLE A
normal plane angle
side plane angles
Nozzle
(24X)
(25X)
211
−5 to 5
10 to 20
212
33.5 to 53.7
26.2 to 36.2
213
66.8 to 76.8
10.1 to 20.1
214
175 to 185
0 to 10
215
−66.8 to −76.8
10.1 to 20.1
216
−33.5 to −53.7
26.2 to 36.2
TABLE B
normal plane angle
side plane angles
Nozzle
(24X)
(25X)
211
0.0
15.0
212
38.5
31.2
213
71.8
15.1
214
180
5.0
215
−71.8
15.1
216
−38.5
31.2
TABLE C
normal plane angle
side plane angles
Nozzle
(24X)
(25X)
211
0.0
15.0
212
48.7
31.2
213
71.8
15.1
214
180
5.0
215
−71.8
15.1
216
−48.7
31.2
Some embodiments may provide a fuel injector 50 for a combustion chamber 14 . The fuel injector 50 may include an injector axis 70 . The fuel injector 50 may also include six nozzles 211 , 212 , 213 , 214 , 215 , 216 for spraying a fuel from the injector 50 . Each nozzles 211 , 212 , 213 , 214 , 215 , 216 may be oriented at respective predetermined normal plane angles 241 , 242 , 243 , 244 , 245 , 246 from a centerline 248 located to correspond with a combustion chamber centerline 249 with a positive direction toward one or more intake ports 31 and as measured within a normal plane 238 which may be oriented normal to the injector axis 70 . The six nozzles 211 , 212 , 213 , 214 , 215 , 216 may include: a first nozzle 211 oriented at a first normal plane angle 241 of between −5 degrees and +5 degrees; a second nozzle 212 oriented at a second normal plane angle 242 of between 33.5 degrees and 53.7 degrees; a third nozzle 213 oriented at a third normal plane angle 243 of between 66.8 degrees and 76.8 degrees; a fourth nozzle 214 oriented at a fourth normal plane angle 244 of between 175 degrees and 185 degrees; a fifth nozzle 215 oriented at a fifth normal plane angle 245 of between −66.8 degrees and −76.8 degrees; and a sixth nozzle 216 oriented at a sixth normal plane angle 246 of between −33.5 degrees and −53.7 degrees.
Some embodiments may provide a fuel injector 50 wherein each of the six nozzles 211 , 212 , 213 , 214 , 215 , 216 may also oriented at respective predetermined side angles 251 , 252 , 253 , 254 , 255 , 256 as measured in a side plane 250 that may be perpendicular to the normal plane 238 , and may be substantially parallel with the centerline 248 . The six side angles 251 , 252 , 253 , 254 , 255 , 256 may be oriented as follows: the first nozzle 211 may be oriented at a first side angle 251 of between 10 degrees and 20 degrees; the second nozzle 212 may be oriented at a second side angle 252 of between 26.2 degrees and 36.2 degrees; the third nozzle 213 may be oriented at a third side angle 253 of between 10.1 degrees and 20.1 degrees; the fourth nozzle 214 may be oriented at a fourth side angle 254 of between 0 degrees and 10 degrees; the fifth nozzle 215 may be oriented at a fifth side angle 255 of between 10.1 degrees and 20.1 degrees; and the sixth nozzle 216 may be oriented at a sixth side angle 256 of between 26.2 degrees and 36.2 degrees.
Some embodiments may provide a fuel injector 50 for a combustion chamber 14 wherein: the first nozzle 211 may be oriented at a first normal plane angle of approximately 0 degrees; the third nozzle 213 may be oriented at a third normal plane angle 243 of approximately 71.8 degrees; the fourth nozzle 214 may be oriented at a fourth normal plane angle 244 of approximately 180 degrees; and the fifth nozzle 215 may be oriented at a fifth normal plane angle 245 of approximately −71.8 degrees.
With some examples the second nozzle 212 may be oriented at a second normal plane angle 242 of approximately 38.5 degrees; and the sixth nozzle 216 oriented at a sixth normal plane angle 246 of approximately −38.5 degrees. With other examples the second nozzle 212 may be oriented at a second normal plane angle 242 of approximately 48.7 degrees; and the sixth nozzle 216 may be oriented at a sixth normal plane angle 246 of approximately −48.7 degrees.
With some example embodiments the fuel injector 50 may be installed into combustion chamber 14 at an approximately 25° installation angle 72 measured from a horizontal plane 76 of an engine deck face ( FIG. 1 ). The nozzle 211 may then point substantially toward a piston bowl 17 of a piston 16 operatively installed within the combustion chamber 14 . The fourth nozzle 214 may point substantially toward the spark plug 54 operatively installed at a top 55 of the combustion chamber 14 .
In some examples, the second nozzle 212 may be oriented at a second normal plane angle 242 of between 33.5 degrees and 43.5 degrees, and the sixth nozzle 216 may be oriented at a sixth normal plane angle 246 of between −33.5 degrees and −43.5 degrees. In other examples, the second nozzle 212 may be oriented at a second normal plane angle 242 of between 43.7 degrees and 53.7 degrees, and the sixth nozzle 216 may be oriented at a sixth normal plane angle 246 of between −43.7 degrees and −53.7 degrees.
Some embodiments may provide a fuel injector a system 200 . The system 200 may include, a cylinder 12 having a cylinder wall 13 and a cylinder axis 249 . The system 200 may also include a spark plug 54 , and a piston 16 positioned internally to the cylinder 12 . The piston 16 may have a piston bowl 17 at a top end thereof. A fuel injector 50 may have an injector axis 70 and may be positioned in the cylinder wall 13 . The fuel injector 50 may include: six nozzles 211 , 212 , 213 , 214 , 215 , 216 each oriented at respective predetermined normal plane angles 241 , 242 , 243 , 244 , 245 , 246 from the cylinder axis 249 with a positive direction toward one or more intake ports 31 and as measured within a plane normal 238 to the injector axis 70 . The six nozzles 211 , 212 , 213 , 214 , 215 , 216 may include: a first nozzle 211 oriented at a first normal plane angle 241 of between −5 degrees and +5 degrees; a second nozzle 212 oriented at a second normal plane angle 242 of between 33.5 degrees and 53.7 degrees; a third nozzle 213 oriented at a third normal plane angle 243 of between 66.8 degrees and 76.8 degrees; a fourth nozzle 214 oriented at a fourth normal plane angle 244 of between 175 degrees and 185 degrees; a fifth nozzle 215 oriented at a fifth normal plane angle 245 of between −66.8 degrees and −76.8 degrees; and a sixth nozzle 216 oriented at a sixth normal plane angle 246 of between −33.5 degrees and −53.7 degrees.
With some example of the system 200 each of the six nozzles 211 , 212 , 213 , 214 , 215 , 216 may also oriented at respective predetermined side angles 251 , 252 , 253 , 254 , 255 , 256 as measured relative to the injector axis 70 . The first nozzle 211 may be oriented at a first side angle 251 of between 10 degrees and 20 degrees. The second nozzle 212 may be oriented at a second side angle 252 of between 26.2 degrees and 36.2 degrees. The third nozzle 213 may be oriented at a third side angle 253 of between 10.1 degrees and 20.1 degrees. The fourth nozzle 214 may be oriented at a fourth side angle 254 of between 0 degrees and 10 degrees. The fifth nozzle 215 may be oriented at a fifth side angle 255 of between 10.1 degrees and 20.1 degrees. The sixth nozzle 216 may be oriented at a sixth side angle 256 of between 26.2 degrees and 36.2.
With some examples of the system 200 the first side angle 251 may be approximately 15 degrees; the second side angle 252 may be approximately 31.2 degrees; the third side angle 253 may be approximately 15.1 degrees; the fourth side angle 254 may be approximately 5 degrees; the fifth side angle 255 may be approximately 15.1 degrees; and the sixth side angle 256 may be approximately 31.2 degrees. The injector axis 70 may be oriented at approximately 25° from a horizontal plane 76 of an engine deck face.
With some examples of the system 200 the first nozzle 211 may be oriented at a first normal plane angle 241 of approximately 0 degrees; the second nozzle 212 may be oriented at a second normal plane angle 242 of approximately 38.5 degrees; the third nozzle 213 may be oriented at a third normal plane angle 243 of approximately 71.8 degrees; the fourth nozzle 214 may be oriented at a fourth normal plane angle 244 of approximately 180 degrees; the fifth nozzle 215 may be oriented at a fifth normal plane angle 245 of approximately −71.8 degrees; and the sixth nozzle 216 may be oriented at a sixth normal plane angle 246 of approximately −38.5 degrees.
With some examples of the system 200 the first nozzle 211 may be oriented at a first normal plane angle 241 of approximately 0 degrees. The second nozzle 212 may be oriented at a second normal plane angle 242 of approximately 48.7 degrees. The third nozzle 213 may be oriented at a third normal plane angle 243 of approximately 71.8 degrees. The fourth nozzle 214 may be oriented at a fourth normal plane angle 244 of approximately 180 degrees. The fifth nozzle 215 may be oriented at a fifth normal plane angle 245 of approximately −71.8 degrees. The sixth nozzle 216 may be oriented at a sixth normal plane angle 246 of approximately −48.7 degrees.
It should be understood that the systems and methods described herein are exemplary in nature, and that these specific embodiments or examples are not to be considered in a limiting sense, because numerous variations are contemplated. Accordingly, the present disclosure includes all novel and non-obvious combinations of the various systems and methods disclosed herein, as well as any and all equivalents thereof.
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A fuel injector having an injector axis, comprising a first nozzle aiming in a first radial direction; a first nozzle pair aiming in radial directions each equally angled relative to the first direction, closest to the first radial direction, and having a longest radial offset; a nozzle second pair in radial directions each equally angled relative to the first direction; and another nozzle aiming opposite the first radial direction and having a shortest radial offset.
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CROSS REFERENCE TO PRIOR APPLICATIONS
[0001] This application is a U.S. National Phase application under 35 U.S.C. §371 of International Application No. PCT/EP2008/055147, filed on Apr. 28, 2008 and which claims benefit to German Patent Application No. 10 2007 024 562.0, filed on May 25, 2007 and to German Patent Application No. 10 2007 026 601.6, filed on Jun. 8, 2007. The International Application was published in German on Dec. 4, 2008 as WO 2008/145469 under PCT Article 21(2).
FIELD
[0002] The present invention relates to a method for feedback of states of an electric component to an engine control device of an internal combustion engine, comprising the use of a control unit for the electric component, which control unit includes means for detection of faults and is connected to said engine control device via a signal line and is arranged to receive a PWM signal generated in said engine control device, said control unit being arranged to tie said signal line to ground so as to perform a feedback of data of said electric component to said engine control device.
BACKGROUND
[0003] In the field of automobile technology, there has recently developed an ever more frequent demand that electric components such as e.g. pumps and actuators, should be able to return to the engine control device a feedback message indicating states of the components. Normally, these components are driven by the engine control device through pulse width modulation. This is performed via a sole existing signal line which serves both for transmission of the desired signal in the form of a PWM coding from the engine control device to the control unit of the component and which, conversely, shall also be used for communicating a possibly existing fault state or actual state of the component to the engine control device.
[0004] Such feedbacks of states for diagnostic purposes are known as far as the component will tie the signal line to ground if any fault is present. This will be detected by the engine control device because this device is used as a master. At the same time, the engine control device will measure the voltage on the signal line so that, if the engine control device tries to output a high level while, however, the line remains on a low level because of the ground connection, this will indicate that either the component does not work properly or the line is short-circuited. In the past, for this reason, the switching of the signal line to ground as performed by the electric component has commonly been used to communicate to the engine control device that a fault has occurred.
SUMMARY
[0005] This concept suffers from the disadvantage that, if a fault of whatever variety occurs, all that is possible is to feed back this fault to the engine control device, however, without the possibility of actually identifying this fault. Further, no feedback is performed in regard to the actual state of the electric component.
[0006] An aspect of the present invention is to provide a method for feedback of states of an electric component to an engine control device of an internal combustion engine wherein, in said method, a fault occurring in the electric component will not only be transmitted to the engine control device but will also be recognized, i.e. identified in the engine control device. In addition, it shall be accomplished that also without occurrence of a fault, information on an actual state of the electric component can be communicated to the engine control device.
[0007] In an embodiment, the present invention relates to a method for feedback of states of an electric component to an engine control device of an internal combustion engine using a control unit for the electric component including a detection device configured to detect faults. The method includes configuring the control unit, connecting the control unit to the engine control device via a signal line, receiving a PWM signal generated in the engine control device, tying the signal line to ground for a feedback of data of the electric component to the engine control device, and identifying a fault based on a duration of the connection to ground.
[0008] Depending on the duration of a connection of the signal line to ground, the duration can therefore be exactly assigned to a fault whereby the engine control device can identify this fault. Such a solution requires only minimum adaptation of the components used. Accomplished thereby is a flexible diagnostic functionality wherein only minimal resources are necessitated in the control device of the electric component as well as in the external engine control device, since it will merely be required to store, in the engine control device, a corresponding comparative code with respect to the duration of the transmitted signal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The present invention is described in greater detail below on the basis of embodiments and of the drawings relating to electromotoric pump as an example in which:
[0010] FIG. 1 shows a typical protocol of a method of the present invention for feedback of states of an electric component, referring to a pump by way of example.
[0011] FIG. 2 shows the development of the method at a nominal rotational speed of the pump of 50% without occurrence of faults.
[0012] FIG. 3 shows the protocol upon occurrence of an overcurrent fault at the pump.
[0013] FIG. 4 shows a method for feedback wherein, depending on the application, different modes can be selected.
DETAILED DESCRIPTION
[0014] In an embodiment of the present invention, the duration of said ground connection is additionally used for feedback of the actual value of the electric component. The feedback of a fault or also of the actual value of the electric component can by definition be performed in a successive manner. Accordingly, it appears useful to carry out such a feedback regularly while the driving of the electric component is unchanged. The coding of this actual value of the electric component can be performed e.g. linearly so that a grounding for a defined maximum duration of e.g. one second would correspond to a 100% rotational speed and half of this duration would correspond e.g. to a 50% rotational speed. Thereby, it is rendered possible, in a very simple manner, to realize a previously unknown feedback of an actual value of the electric component to the engine control device.
[0015] For example, in a first time block, the signal line is tied to ground for a predefined length of time in order to communicate to the control device—serving as a master—that a feedback is performed. This is necessary so that possibly occurring disturbances can be differentiated from a protocol for fault- or actual-state detection. Such disturbances are normally distinctly shorter than this synchronization period.
[0016] In a subsequent second time block, the duration of the connection of the signal line to ground is used as a measure for the actual state of the electric component if no fault occurs, wherein, subsequently, the connection will be released again by the component. In a corresponding manner, the information that a direct proportionality exists between the duration of the ground connection in this second time block and the actual rotational speed, could be lodged in the engine control device.
[0017] Additionally, in case of a fault, the connection of the signal line to ground will be maintained until a duration identifying this fault has lapsed. Thus, if a corresponding code has been lodged in the engine control device, a fault detected by the control unit of the electric component can be clearly identified on the basis of the duration of the ground connection. To each individual fault which is detectable by the control unit, exactly one defined duration has been assigned. Consequently, such an identification of faults can be performed by the engine control device with minimum electronic expenditure.
[0018] In an embodiment of the present invention based on the embodiment described above, the possible faults will be classified and assigned to different groups so that, depending on the seriousness of the fault, the transmission times will become longer. Faults that have similar consequences for the function of the electric component can, for example, be combined into such groups.
[0019] Correspondingly, upon release of the connection of the signal line, the control unit of the component in the course of a first duration after said release will assume a fault belonging to a group of faults leading to a reduced operation of the electric component, while, in the course of a second duration, the control unit will assume a fault belonging to a group of faults of the electric component, and, in the course of a subsequent duration, the control unit will assume a fault belonging to a group of faults in the system, wherein the connection of the signal line to ground will be maintained until the duration defined for the occurring fault having the longest identifying duration will have lapsed. Hereby, it is safeguarded that it will really be the most serious fault which is fed back to the engine control device, so that corresponding measures can be taken.
[0020] In an embodiment of the present invention, the electric component is an electromotoric pump wherein said group of faults which cause a reduced operation of the pump is sub-divided into a time block for a first rotational-speed limitation, a time block for a second rotational-speed limitation, a time block for dry-run detection and a time block for performance limitation. These time blocks represent a first and not all too serious group of faults.
[0021] For example, if the electric component is an electromotoric pump, the group of faults of the electric component comprises at least one time block for a pump fault caused by over-current. This pump fault thus forms a second group of faults which, due to the higher weighting, will be checked for at a time subsequent to the first-mentioned group of faults.
[0022] It is also of advantage, when using an electromotoric pump, if said group of faults in the system comprises at least one time block for an occurring overvoltage, a time block for dry-run switch-off and a time block for temperature switch-off Such faults will lead to a cease of the functionality of the system so that a corresponding feedback would have to be performed by the engine control device, e.g. the driver of a truck.
[0023] The present method as well as the modified method steps are effective to safeguard in a simple manner that feedback messages on the state of the electric component will be transmitted to the engine control device. By a corresponding weighting of the communicated faults, the opportunity is provided to initiate possibly required measures. In contrast to previously known embodiments, such a feedback can be performed for the whole duration or periodically, as long as no change of the drive signal occurs. Further, the real actual state can be made available to the engine control device. For this purpose, extremely little expenditure will be required in the external control device.
[0024] The methods—as shown in the Figures—for feedback of states of an electric component to a control device of an internal combustion engine will be explained with reference to the example of an electric cooling-water pump installed in a vehicle. In said vehicle, an engine control device is arranged which is connected, via a signal line, to a control unit of said cooling-water pump. Said control unit includes various means for detection of faults of the pump and respectively for measurement of operational states. Such means from the field of circuit technology are known. Thus, for instance, the rotational speed of a pump can be detected via contactless sensors. Also the corresponding electric circuits, e.g. for detection of overcurrent, overvoltage or the like, are known.
[0025] This method now offers the possibility to exchange, via the signal line, a maximum of information between the control unit of the cooling-water pump and the engine control device.
[0026] At the signal line, merely two states can be measured by the engine control device, i.e. the high state or the low state. Normally, the control unit receives a pulse-width-modulated signal of the engine control device, wherein the signal line will alternately conduct a high level and a low level. The different duration of these times serves for rotational-speed control of the pump. However, by use of a corresponding circuit, it is possible for the control unit of the cooling-water pump to tie the signal line to ground so that, as long as the ground connection of the signal line exists, the engine control device will receive only a low signal.
[0027] Illustrated in FIG. 1 is illustrated a typical drive process 1 for the engine control device of the electromotoric cooling-water pump. For this purpose, a PWM signal 2 is transmitted from the engine control device to the control unit via the signal line. When the control unit receives such a signal, the pump will be operated with the rotational speed resulting therefrom, until a possibly changed PWM signal 2 is transmitted via the signal line. Now, the possibility exists that the control unit will tie the signal line to ground. This can be performed at fixed intervals which may also be selected to be very small. This time period 3 during which the signal line remains tied to ground, serves for feedback of states, one of them being represented with corresponding enlargement.
[0028] At a time e.g. after lapse of a predetermined duration of the PWM signal 2 , the control unit of the pump will now tie the signal line to ground. According to the example illustrated in FIG. 1 , this ground connection is first maintained for 100 ms for thus communicating to the engine control device that a feedback takes place. This span of time thus forms a synchronization time block 4 . This block is followed by an e.g. one-second-long time block 5 for the actual rotational speed. During each feedback, these two time blocks 4 and 5 will be output at least partially and be combined into a group 6 after which the transmission will end if no fault occurs. Thus, in case that only group 6 is transmitted, the pump is faultless.
[0029] This group 6 is now followed by a second group 7 for identification of a reduced operation of the pump. In the present embodiment, said second group consists of four time blocks of a length of 100 ms, wherein time block 8 serves for detecting a first rotational-speed limitation, time block 9 serves for detecting a second rotational-speed limitation, time block 10 serves for detecting a dry run and time block 11 serves for detecting a limitation of the pump performance.
[0030] Said second group is followed by a group 12 in which pump faults will be combined, wherein, in the present embodiment, this group 12 consists only of one time block 13 for detection of overcurrent and, respectively, plausibility faults 13 , said block again having a length of 100 ms.
[0031] Subsequent to the transmission of the faults of group 12 , faults of a group 14 will be transmitted, in which group a successive processing of system faults will be performed. Comprised herein are, as a first time block 15 of the system faults, the identifying of an over-voltage; as a second time block 16 , the detecting of a dry-run switch-off; as a third time block 17 , the detecting of a temperature switch-off; and, as a fourth time block 18 , the identifying of a defective power supply of the relay. These time blocks and respectively groups of time blocks 4 to 18 thus form the maximum process of performing the feedback of states of the control unit of the water pump to the engine control device.
[0032] After completion of this program, the control unit of the pump will wait at least 0.5 to 1 s before a new feedback takes place. This is to say that, after completion of the feedback, the normal connection of the signal line between the engine control device and the control unit of the pump will be established again.
[0033] FIG. 2 now illustrates the a manner in which the feedback is to proceed if the pump is operated with a rotational speed of 50% as compared to the maximum rotational speed. First, after the signal line has been switched to ground, the sync time block 4 is transmitted so that the engine control device will detect that a feedback is performed. Thereafter, in the present embodiment, the connection to ground is maintained for 0.5 s and then will be switched over again. For the engine control device, this means—if a linear correlation has been defined—that, since the signal of time block 5 of the actual rotational speed has only half the length of the possible total length of 1 s, also the rotational speed will amount to only 50% of the maximum rotational speed. Since no fault has been detected in the control unit, the connection of the signal line to ground will be terminated at this point so that, via the signal line, there will again be transmitted the PWM signal 2 from the engine control device to the control unit of the water pump.
[0034] For further explanation, FIG. 3 illustrates how the program will proceed if the control unit has detected, among said group 12 of pump faults, an overcurrent indicated by time block 13 . In this case, the connection of the signal line to ground will be maintained until the lapse of the duration of time block 4 , i.e. the synchronization time block, as well as time block 5 for the actual rotational speed, as well as time block 8 for the first rotational speed limitation, time block 9 for the second rotational speed limitation, time block 10 for dry-run detection, time block 11 for performance limitation and, finally, time block 13 for overcurrent. This means that the connection to ground is maintained for 1.6 s. The engine control device will now detect that, after 1.6 s, the normal connection of the signal line between the engine control device and the electric component is established again, and will be able, on the basis of a comparison code lodged in the engine control device, to determine that an overcurrent fault has evidently occurred which corresponds to a grounding for a duration of 1.6 s.
[0035] From the above, it also becomes evident that, in case that a fault occurs, no actual rotational speed can really be fed back. However, it will still be possible for the engine control device to now transmit a corresponding fault message to the conductor of a vehicle.
[0036] If such a process has been lodged, it can of course also be freely selected in which modes such a system is used e.g. for different vehicles or internal combustion engines. For instance, in the first fault case 19 , as shown in FIG. 4 , there is selected a mode in which a protocol transmission will take place if the pump is faultless, and also upon occurrence of a fault from group 7 , i.e. in case of reduced operation, as well as upon occurrence of a fault from any one of groups 12 , 14 , i.e. in case of pump or system faults. In line 20 , it is shown that a transmission will be performed only in case of a pump or system fault, i.e. in case of a relatively serious error according to any one of groups 12 or 14 .
[0037] In the following line 21 , a third mode is represented wherein a transmission of the protocol is performed in each fault case, i.e. both upon occurrence of an error from group 7 indicating reduced operation, and upon occurrence of a pump error or a system error, i.e. an error from any one of groups 12 or 14 . There could also be provided a complete deactivation of the transmission of the protocol according to line 22 without the need to perform changes on the hardware or software. Thereby, adaptation to different customer wishes is made possible because of the ability to switch between the different modes.
[0038] It is obvious that, by such a method for feedback of states, a very flexible diagnostic functionality is realized, while requiring only a minimum of additional resources in the component, the control unit or the engine control device. The transmission of such a protocol as described by way of the above exemplary embodiment retains its compatibility with the known state of the art while, however offering the possibility to transmit additional information, particularly with respect to the actual value. No protocol monitoring will be required anymore. Further, by a corresponding grouping of the faults, it is guaranteed that blind periods of the control will be minimized Depending on the electric component used, adaptations can be performed, and other kinds of subdivisions into groups or other sequences in the processing of possible faults may be selected. Also, it will be left to the respective user's discretion to what extent all of the definable groups shall really be used, or whether additional groups or time blocks shall be defined.
[0039] The present invention is not limited to embodiments described herein; reference should be had to the appended claims.
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The present invention relates to a method for feedback of states of an electric component to an engine control device of an internal combustion engine using a control unit for the electric component including a detection device configured to detect faults. The method includes configuring the control unit, connecting the control unit to the engine control device via a signal line, receiving a PWM signal generated in the engine control device, tying the signal line to ground for a feedback of data of the electric component to the engine control device; and identifying a fault based on a duration of the connection to ground.
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The benefits under 35 U.S.C. 119 are claimed of provisional patent application 60/965,316 filed Aug. 20, 2007.
TECHNICAL FIELD
The present invention relates to the collection and disposal of animal waste, and more particularly to an apparatus for collection and disposing of canine fecal matter without human contact.
BACKGROUND ART
Each day, in complete disregard of county health ordinances, condominium rules, or park regulations, dog owners fail to pick up fecal matter deposited by their pets. Because of the unpleasantness and potential health risk of retrieving such matter there is a natural aversion to this odious chore and as a result, there have been innumerable devices invented to help minimize this problem.
The most popular and most portable retrieval device is the simple plastic bag such as those found in most pet related stores or the plastic grocery bag, both of which require the user to stoop and physically touch the droppings while the hand is protected by the integrity of the thin plastic. The primary problem with this method is that a second bag must be used to hold the contained drooping until a proper container can be found; not to mention the development of a threshold for the task.
The scoop and handle design, such as the “S.A.S.I. Scoop” has the convenience of using plastic grocery bags, but does not work well in taller grasses or plant beds. If the waste is not firm, removing the bag can be a very messy proposition.
Those devices using separated fingers operated by a squeeze handle, including the “Poop Hound” are often difficult to use with one hand and have the disadvantage of having the moving set of fingers come in direct contact with the fecal matter.
The rake and scoop products, such as the “FlexRake Scoop”, while effective and easy to use, come in direct contact with the fecal matter and require the additional step of bagging the waste before depositing it in the trash.
SUMMARY OF THE INVENTION
The present invention solves significant problems in the art by providing a canine fecal matter collection device where neither the operator nor the device is in direct contact with the animal waste.
Generally described, the present invention provides a means for holding a simple plastic bag over a plurality of fingers or panels that fully encompass the waste material during the retrieval process in a manner similar to that of the human hand.
The collection mechanism includes a lobed knob connected by a combination of concentric tubes of a specified length to a dual housing arrangement, the inner housing of which holds a set of panels that can be opened or closed by the linear movement of the smaller of the two tubes in combination with a panel actuating ring affixed to this inner shaft. The operation of the panels can best be described as that of a collapsible vegetable steamer.
The unit is spring loaded and is latched in the operating position—panels extended—by holding the larger tube and pushing the knob linearly toward the panel housing. This feature allows the unit to be operated by one hand when collecting the waste material.
When a release button, located in the side of the knob, is actuated, the complimenting panels close around the fecal matter in such a manner that no material is extruded between the individual panels.
With the panels closed, and the protective collection bag secured by a simple clamp on the side of outer housing, the knob can be rotated in either direction. This action causes the waste filled collection bag inside the cavity formed by the closed panels to turn while the portion of the bag outside of the panels remains fixed to the outer housing until the wrapping action pulls the bag from the clamp.
The fecal material, secured in the disposable collection bag, can then be disposed of, when desired, by simply cocking the apparatus as described above and releasing it into an appropriate waste container.
Other objects, features, and advantages of the present invention will become apparent upon reading the following detailed description of embodiments of the invention when taken in conjunction with the accompanying drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 . is a sectioned view of the apparatus showing individual part location.
FIG. 2A . is an exploded view of the elements of the apparatus shown in FIG. 1 .
FIG. 2B . is a top view of the outer housing shown in FIG. 2A .
FIG. 2C . is a bottom view of knob shown in FIG. 2A .
FIG. 3A . is a sectioned view showing a portion of the apparatus with the panels in the open, or extended position.
FIG. 3B . is a sectioned view showing a portion of the apparatus with the panels in the closed position.
FIG. 4A . is a pictorial view of the protective collection bag.
FIG. 4B . is an isometric view of the apparatus in the closed position.
FIG. 4C . is a depiction of the apparatus with the collection bag positioned over the closed panels and under the retention clamp.
FIG. 4D . is a diagrammatic view of the installed collection bag with the apparatus panels extended.
FIG. 5A . is a diagrammatic view depiction a post collection view of the apparatus and the result of rotating the lobed knob after waste collection with a portion of the collection bag still under the retention clip.
FIG. 5B . is a diagrammatic view depicting the collection bag free of the retention clip as a result of continued knob rotation.
FIG. 5C . is a bottom view of FIG. 5B .
FIG. 5D . is a diagrammatic view of the waste collection bag as it is ejected from the apparatus.
DETAILED DESCRIPTION
Referring to the drawing, in which like numerals refer to like parts throughout the several views, FIGS. 1 and 2 A- 2 C show a housing 15 into which a cylindrical outer tube 13 of a specified length having preformed end tabs 24 which are inserted into corresponding openings 25 in the housing 15 top for the purpose of securing the housing 15 to the outer tube 13 by twisting the tabs 24 . A spring cover 9 is installed over the outer tube 13 prior to installing the locating bushing 8 in the open end 26 of the outer tube 13 .
A cylindrical inner tube 12 of a specified length having two small through holes 27 and 28 for the insertion of retaining pins 11 and 19 , a larger through hole 29 at 90 degrees to holes 27 and 28 , and a rectangular hole 30 at 90 degrees to holes 27 & 28 , is installed over a centrally located protrusion 31 of the actuating ring 18 and is affixed to the ring 18 by aligning tube hole 27 and the corresponding hole 32 in the actuating ring 18 and installing a spring pin 19 .
A latch 10 is installed in the open end 33 of the inner tube 12 and positioned so that a small tab 35 located on an edge of the latch 10 is aligned with the rectangular opening 30 in the wall of the inner tube 12 . A cylindrical pin 11 is directed through the first side of the tube hole 28 and through the hole 36 located at the base of the latch 10 ; the pin 11 is then extended through the tube 12 . Those skilled in the art will recognize that the pin 11 now becomes a pivot point for the latch 10 and that the edge tab 35 , when properly positioned, may extend through the rectangular opening 30 .
Referring FIGS. 1 and 2 A., the inner tube assembly 70 shown in FIG. 2A , can now be inserted vertically through the housing 15 , through the outer tube 13 , and guided through the locating bushing 8 .
A compression spring 5 is installed over the open end 33 of the inner tube 12 , part of the inner tube assembly 70 , and is seated in a shallow recess 37 in top of the locating bushing 8 . A simple flat washer 6 having a center hole 38 of sufficient size to fit over the inner tube 12 is placed on the top of compression spring 5 . Compressing the compression spring 5 and guiding the washer 6 over the open end 33 of the tube 12 exposes the through hole 29 in the top end of the inner tube 12 and a portion of the top end 39 of the latch 10 .
A short cylindrical tube 2 having a narrow slot 40 the full length of the part is orientated such that the slot 40 is in a position that when the tube 2 is inserted into the hole 29 , the tip 39 of the latch 10 will pass through the slot 40 . Extending the tube 2 fully through the hole 29 secures the compression spring 5 and the washer 6 .
As depicted in FIG. 2 A., a small compression spring 4 , of sufficient length, when inserted into the left end of the short tube 2 and confined by the lobed knob 1 will act to rotate the latch 10 about the pivot pin 11 causing the edge tab 35 of the latch 10 protrude through the rectangular opening 30 in the side of the inner tube 12 . Inversely, a cylindrical button 3 of proper length, when inserted in the right end of the tube 2 , and extended through a hole 41 in the side of the lobed knob 1 will, with sufficient force, rotate the latch 10 in the opposite direction and cause the edge tab 35 to move away from the rectangular opening 30 in the side of the inner tube 12 .
Referring to FIG. 2 C., two protrusions 42 extending from the inside of the lobed knob 1 and two similar saddle like forms 43 extending from the flanged portion 44 of the spring cover 9 provide a means of securing the cylindrical tube 2 to the lobed knob 1 when the spring cover 9 and the lobed knob 1 are joined by fasteners 7 .
Referring to FIGS. 1 , 2 A and 3 A & B, the equally spaced alignment ribs 45 extending inward and vertically from the cylindrical inside wall of the panel mounting housing 17 when aligned with the identically positioned “v” grooves 46 located on the perimeter of the actuating ring 18 , part of assembly 70 , allows the panel mounting housing 17 to be inserted into the open bottom of the outer housing 15 . The panel mounting housing 17 is captured by equally spaced tabs 48 which are part of the housing 15 and by a circular retaining plate 22 that is connected to a multiple of bosses 61 at the bottom of the housing 15 by a like number of threaded fasteners 21 installed through equally spaced slots 49 in the perimeter of the retaining plate 22 .
Referring to FIGS. 3A and 3B , those skilled in the art will recognize the advantage of having the alignment ribs 45 of the panel mounting housing 17 pass through the “v” grooves 46 in the actuating ring 18 . More specifically, any rotational movement of the actuating ring 15 , is coupled directly to the panel mounting housing 17 and therefore any part attached to the housing 17 . This coupling feature is effective whether the driving force of the actuating ring 18 is at the bottom of the alignment ribs 45 , FIG. 3 A., or at the top of each rib 45 , FIG. 3B .
FIG. 2A , shows a multiple of rectangular openings 50 in the perimeter of the actuating ring 18 through which the triangular lever arm 51 of a panel 23 is inserted before positioning the opening 52 in the panel 23 over a panel mounting tab 53 which projects inwardly from the inner wall of the panel mounting housing 17 . Each successive panel 23 is installed in a clockwise direction (as viewed from the bottom) to insure that the extended side 54 of each panel 23 overlaps the previously installed panel 23 . Upon the installation of all panels 23 a retaining ring 20 is inserted into a lateral groove 55 located at the inside base of the panel 23 lever arm 51 .
Referring to FIG. 3B , inward movement of each panel 23 is prevented by retaining ring 20 , upward movement of the retaining ring 20 and thus each panel 23 is prevented by the overlapping of the retaining ring 20 by an extension 62 of each alignment rib 45 . All downward movement of the panels is prevented by the panel mounting tabs 53 of the panel mounting housing 17 .
Referring to FIGS. 3 A and 3 B., it can be demonstrated that the tip 56 of the triangular protrusion 57 located on the lower side of the panel lever arm 51 and touching the upper curved surface 59 of the actuating ring 18 , will, with any vertical movement of the actuating ring 18 , cause the panel 23 to rotate on the radial surface 58 , which is a feature of the opening 52 of each panel 23 . It can also be shown that the rate of rotation of the panel 23 is increased due the movement of tip 56 as it moves upward over the curved surface 59 of the actuating ring 18 . This increased rate diminishes as the tip 56 reaches the apex 60 of the curved surface 59 . This feature allows the panel 23 to rotate further when the compressed spring 5 is at is maximum potential. Additional vertical movement of the actuating ring 18 causes the tip 56 to descend from the apex 60 and this ramp action of the tip 56 on the curved surface 59 increases the mechanical advantage of the lever arm 51 when the compression spring 5 is at a lower potential.
FIG. 1 shows the compression spring 5 locked in a compressed position which causes actuating ring 18 to move to its lowest position and the panels 23 to open as depicted due to the force exerted on the lever arm 51 by the perimeter of the actuating ring 18 . This locked position is attained by holding the large outer tube 13 and pressing the lobed knob 1 linearly toward the housing 15 (arrow 67 FIG. 4D ). As the knob 1 is pushed, the angled portion of the latch tab 35 , a feature of the latch 10 , is eventually forced against the inside surface of guide bushing 8 which causes the latch 10 to rotate about pin 11 and the latch tab 35 to move inside the rectangular opening 30 located in the side of the inner tube 12 . This action likewise compresses the button return spring 4 . When the latch tab 35 clears the bottom 68 of the guide bushing 8 , it immediately returns to its initial position due to the action of spring 4 , and the now extended tab 35 is fixed against the bottom edge 68 of the guide bushing 8 , thus holding the mechanism in this position until the release button 3 is pressed and the action is reversed.
Referring to FIGS. 4A-4D , a geometrically shaped collection bag 64 , constructed of a thin, typically plastic, material and having a single opening 66 , is placed over the housing assembly 65 , and under the retention clamp 14 to which is affixed, through a hole 47 at the free end of the clamp 14 , a friction bumper 16 which is constructed of a material that when deformed has the ability to recover.
FIG. 4D , shows the apparatus and collection bag 64 with the panels in the extended position in preparation of the collection of waste material. This action is accomplished by holding the outer shaft 13 and pushing the knob 1 approximately 1¼ inches in the direction of the arrow 67 .
Referring to FIGS. 5A-5D , FIG. 5A depicts the apparatus in the panel closed position after the release button 3 has been depressed, and the knob 1 turned in the direction of the arrow 68 until such time the collection bag 64 is about to pull free of the retention clamp 14 .
FIGS. 5B and 5C , depict the apparatus with the collection bag free of the retention clamp 14 .
FIG. 5D , depicts the ejection of the waste filled collection bag 64 as a result of a partial or full extension of the collection panels 23 .
While the present invention has been illustrated by description of several embodiments and while the illustrative embodiments have been described in detail, it is not the intention of the applicant to restrict or in any way limit the scope of the appended claims to such detail. Additional modifications will readily appear to those of ordinary skill in the art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and methods, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of applicant's general inventive concept.
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A device for removing canine fecal matter includes a lobed knob connected by concentric tubes to a dual housing, the inner of which holds a set of panels that are opened or closed by the linear movement of the smaller tube in combination with a panel actuating ring affixed to the inner shaft. The panels are extended by holding the larger tube and pushing the knob toward the panel housing. When a release button is actuated, the panels close around the fecal matter and, with the panels closed, a protective collection bag is secured by a clamp on the outer housing. With the collection bag inside the cavity formed by the closed panels. The knob can be rotated in either direction to turn the collection bag which causes the collection bag to pull away from the clamp for the purpose of disposal.
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FIELD OF THE INVENTION
[0001] This invention relates generally to electrical systems of motor vehicles, especially motor vehicles that are capable of towing trailers and that have receptacle sockets with which trailer connector plugs are mated when the trailers are being towed. More particularly, the invention relates to a circuit for configuring such a receptacle socket to accommodate various trailers having diverse circuits depending upon the particular electrical equipment in a particular trailer.
BACKGROUND OF THE INVENTION
[0002] Certain motor vehicles, such as medium duty trucks for example, are capable of towing various types of non-fifth-wheel trailers. Such a towing vehicle has a trailer hitch at the rear, a pintle- or ball-type hitch for example, and such a trailer has a coupling at its front that releasably connects to the vehicle hitch.
[0003] Regardless of the particular trailer type or model, a trailer's electrical equipment will include various exterior lamps, including lamps capable of signaling a stop, a right turn, and a left turn. The right turn and left turn lamps are also used for hazard warning. Additional lamps that are typically present include: clearance, side marker, and identification lamps; and tail and license plate lamps. For placing such lamps under the control of the correct circuits in the towing vehicle, the trailer electrical system comprises a connector plug, typically forming a termination for one end of a multi-conductor cable, that mates with a receptacle socket in the towing vehicle.
[0004] Trailers that are equipped with certain types of brakes have circuits that require proper connection with circuits in the towing vehicles, and those connections occur through mated connector plugs and receptacle sockets.
[0005] A trailer that has electric trailer brakes requires electric current from an electric trailer brake controller in the towing vehicle. The electric trailer brake controller may be coupled with the vehicle service brake system to apply the trailer brakes in correlation with how hard the driver is applying the service brakes and/or have a separate actuator that allows the driver to apply the trailer brakes independently of application of the vehicle service brakes. The current to the trailer brakes passes through mated terminals in the plug and socket in an amount correlated with the how hard the driver is applying the service brakes in the vehicle, or optionally how hard the driver is applying the trailer brakes via the manual actuator of the trailer brake controller.
[0006] A trailer that has air-actuated trailer brakes requires air from the towing vehicle brake system in order to apply the trailer brakes. While that by itself does not involve any connection between the trailer electric system and the towing vehicle electric system, the presence of an ABS controller as part of the trailer air brake system does.
[0007] The industry has adopted certain standards for such receptacle sockets, and an example of one such standard is SAE (Society of Automotive Engineers) Standard J560. A receptacle socket compliant with that standard is sometimes referred to as a seven-pin, or seven-terminal, trailer socket, or connector. The standard specifies certain “pin-outs” for the seven individual terminals. Six terminals are arrayed in a circle at 60° intervals while the seventh is located at the center of the circle. Which circuits in the towing vehicle are connected to which terminals in the receptacle socket depends on the particular circuits in a particular trailer.
[0008] According to SAE Standard J560, the receptacle socket terminals are designated numerically in order, No. 1 through No. 7. Viewed axially in the direction looking at the open end of the receptacle socket, terminal No. 1 is at the 12:00 position, terminal No. 2 is at the 2:00 position, terminal No. 3 is at the 4:00 position, terminal No. 4 is at the 6:00 position, terminal No. 5 is at the 8:00 position, terminal No. 6 at the 10:00 position, and terminal 7 No. 7 is at the center.
[0009] The Standard specifies that: terminal No. 1 is a ground return from the trailer to the towing vehicle; terminal No. 2 is a feed for clearance, side marker, and identification lamps; terminal No. 3 is a feed for a left turn signal; terminal No. 4 is a feed for a stop signal; terminal No. 5 is a feed for a right turn signal; and terminal No. 6 is a feed for tail and license plate lamps. When a trailer is equipped with electric trailer brakes, terminal No. 7 is a feed for electric current that actuates the trailer brakes. When a trailer is equipped with air brakes, terminal No. 7 may not necessarily be used; however, when an ABS controller is associated with the trailer air brakes to endow them with ABS capability, terminal No. 7 provides a continuous D.C. power supply voltage for the ABS controller.
[0010] Hence, the Standard recognizes two distinct possibilities for trailer electric systems based on type of trailer brake system.
[0011] There are also two distinct possibilities for stop and turn signal lamp circuits in a trailer: 1) circuits that serve separate stop and turn signal lamps; and 2) circuits that serve combination stop and turn signal lamps.
[0012] A trailer that has separate stop and turn signal lamps has: 1) at least one right stop lamp, or lamp assembly; 2) at least one left stop lamp, or lamp assembly; 3) at least one right turn signal lamp, or lamp assembly; and 4) at least one left turn signal lamp, or lamp assembly.
[0013] A trailer that has combination stop and turn signal lamps has: 1) at least one right combination stop/turn signal lamp, or lamp assembly; and 2) at least one left stop/turn signal lamp, or lamp assembly.
[0014] These possibilities for different stop/turn signal lamps and different brakes lead to four possible circuit configurations for a trailer.
[0015] Configuration No. 1: Electric trailer brakes and combination stop and turn signal lamps.
[0016] Configuration No. 2: Electric trailer brakes and separate stop and turn signal lamps.
[0017] Configuration No. 3: Air trailer brakes and separate stop and turn signal lamps.
[0018] Configuration No. 4: Air trailer brakes and combination stop and turn signal lamps.
[0019] The receptacle socket in a towing vehicle is typically hard-wired for a particular one of these four configurations, enabling the vehicle to tow a trailer having that particular configuration. If a towing vehicle were to tow a vehicle having a different configuration, it has been the practice to provide an additional receptacle socket that is properly hard-wired for that different configuration. Hence, towing vehicles may have multiple receptacle sockets, each for properly connecting the particular electric system in a trailer to the towing vehicle electric system.
[0020] Certain passenger vehicles (many domestic-built) have combination stop and turn signal lamps while others (many non-domestic-built) have separate stop and turn signals. Domestic laws and regulations typically mandate that stop lamps be red. Consequently, combination stop and turn signal lamps in a motor vehicle will illuminate red whenever the driver is applying the brakes. Should the driver give a turn signal while applying the brakes, the lamp toward the side of the turn will flash red, while the opposite lamp remains continuously on as long as the brakes continue to be applied. Should the driver give a turn signal while not applying the brakes, the lamp toward the side of the turn will flash red, while the opposite lamp remains off. Combination stop and turn signal lamps in a trailer can simply be connected in parallel with the combination stop and turn signal lamps in the towing vehicle via the mated connector plug and receptacle socket.
[0021] The operation of stop lamps in a motor vehicle having separate stop and turn separate stop lamps is obviously independent of operation of the turn signal lamps, and vice versa. Separate stop and turn signal lamps in a trailer towed by such a vehicle can simply be connected in parallel with the separate stop and turn signal lamps in the vehicle via the mated connector plug and receptacle socket so that their operation is essentially slaved to that of the stop and turn signal lamps in the vehicle.
[0022] The rear turn signal lamps in a vehicle that has separate stop and turn signal lamps may have a color other than red, amber being an example of such an alternate color. Amber turn signal lamps may also be used in trailers having separate stop and turn signal lamps. So long as the towing vehicle has separate stop and turn signal lamps, the particular color of the separate trailer turn signal lamps is unimportant. That is not the case however when the towing vehicle has combination stop and turn signal lamps.
[0023] Were a receptacle socket in a vehicle having combination stop and turn signal lamps to be used to feed the stop and turn signal lamps in a trailer having separate stop and turn signal lamps, the trailer turn signal lamps would illuminate concurrently with the stop lamps. But should the trailer turn signal lamps be amber, a color that by itself is permissible under certain government regulations for signaling a turn, the unintended happenstance of amber turn signal lamps also signaling a stop may be impermissible, and hence should be avoided.
[0024] Were a receptacle socket in a vehicle having separate stop and turn signal lamps to be used to feed the stop and turn signal lamps in a trailer having combination stop and turn signal lamps, the trailer stop lamps would not illuminate concurrently with the stop lamps in the vehicle. That would also be impermissible, and hence should be avoided.
SUMMARY OF THE INVENTION
[0025] The present invention relates to a circuit for configuring a receptacle socket in a towing vehicle to properly accommodate the particular one of several possible electric circuit configurations in the particular trailer that is being towed by the towing vehicle, the particular electric circuit configuration in the trailer depending on the particular electrical equipment in the trailer.
[0026] The present invention serves to accommodate each of the four numbered configurations identified above so that when a towing vehicle that has combination stop and turn signal lamps is used to tow a trailer whose electric system fits any one of the four configurations, the trailer electric system will properly relate to the towing vehicle electric system.
[0027] The invention avoids the need to provide a towing vehicle with multiple receptacle sockets, each hard-wired for a particular trailer circuit configuration. The invention comprises a switch-controlled circuit by which the driver of the towing vehicle selects a receptacle socket configuration appropriate to the particular stop/turn signal lamp configuration in the trailer to be towed.
[0028] Proper configuring of the center terminal in the seven-terminal receptacle socket for the particular type of trailer brakes is accomplished automatically. The default configuration is for a trailer having electric trailer brakes. When a trailer has air brakes, the tractor protection valve must be depressed to release the trailer parking brakes. That action operates a pressure switch, or sensor, in an air line in the vehicle that re-configures the center terminal for trailer air brakes.
[0029] The invention is believed to provide a better solution for accommodating various trailer electric systems without having a separate receptacle socket for each possible trailer circuit configuration. It avoids the possibility that a connector plug in a trailer will be plugged into an incorrect receptacle socket in a towing vehicle where all socket receptacles have the same geometry. The invention also aids in helping to avoid unintended accidental violations of applicable government regulations.
[0030] One general aspect of the invention relates to a towing vehicle for towing a trailer. The trailer has right and left stop and turn signal lamps, and those lamps may be either combination lamps or separate lamps. The towing vehicle has a combination right rear stop and turn signal lamp, a combination left rear stop and turn signal lamp, a separate right front turn signal lamp, and a separate left front turn signal lamp.
[0031] A right feed terminal in a receptacle socket in the towing vehicle feeds a right lamp of the trailer to signal a right turn. A left feed terminal feeds a left lamp of the trailer to signal a left turn. A selector in the towing vehicle selects either combination stop and turn signal lamps on the trailer or separate stop and turn signal lamps on the trailer.
[0032] The towing vehicle has a first circuit device operated by the selector to connect the combination right rear stop and turn signal lamp to the right feed terminal when the selector is selecting combination stop and turn signal lamps on the trailer and to connect the right front turn signal lamp to the right feed terminal when the selector is selecting separate stop and turn signal lamps on the trailer.
[0033] The towing vehicle also has a second circuit device operated by the selector to connect the combination left rear stop and turn signal lamp to the left feed terminal when the selector is selecting separate stop and turn signal lamps on the trailer and to connect the left front turn signal lamp to the left feed terminal when the selector is selecting separate stop and turn signal lamps on the trailer.
[0034] Another general aspect of the invention relates to a towing vehicle for towing a trailer having brakes that may be either electric brakes or ABS-controlled air brakes. The towing vehicle has a receptacle socket comprising a brake feed terminal for brakes in the trailer. A circuit device in the towing vehicle selectively connects the brake feed terminal to battery voltage in the towing vehicle when the trailer brakes are ABS-controlled air brakes and to an electric trailer brake controller in the towing vehicle when the trailer brakes are electric trailer brakes.
[0035] The foregoing, along with further aspects, features, and advantages of the invention, will be seen in the following disclosure of a presently preferred embodiment of the invention depicting the best mode contemplated at this time for carrying out the invention. The disclosure includes drawings, briefly described as follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] FIG. 1 is a view looking at the open end of a seven-terminal receptacle socket for receiving a mating trailer connector plug.
[0037] FIG. 2 is a schematic diagram of a circuit associated with the receptacle socket in a towing vehicle in accordance with principles of the invention.
[0038] FIG. 3 is a schematic diagram showing the condition of the circuit of FIG. 2 with the electric system of a trailer having electric trailer brakes and separate stop and turn signal lamps connected to the towing vehicle by plugging a connector plug in the towing vehicle into the receptacle socket.
[0039] FIG. 4 is a schematic diagram showing the condition of the circuit of FIG. 2 with the electric system of a trailer having electric trailer brakes and combination stop and turn signal lamps connected to the towing vehicle by plugging a connector plug in the towing vehicle into the receptacle socket.
[0040] FIG. 5 is a schematic diagram showing the condition of the circuit of FIG. 2 with the electric system of a trailer having air brakes and combination stop and turn signal lamps connected to the towing vehicle by plugging a connector plug in the towing vehicle into the receptacle socket.
[0041] FIG. 6 is a schematic diagram showing the condition of the circuit of FIG. 2 with the electric system of a trailer having air brakes and separate stop and turn signal lamps connected to the towing vehicle by plugging a connector plug in the towing vehicle into the receptacle socket.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0042] FIG. 1 shows a receptacle socket 10 compliant with SAE Standard J560 comprising six terminals 12 , 14 , 16 , 18 , 20 , and 22 arrayed in a circle at 60° intervals and a seventh terminal 24 located at the center of the circle. The trailer connector plug that plugs into receptacle socket 10 is not shown.
[0043] According to SAE Standard J560, terminal 12 is a ground return from the trailer to the towing vehicle; terminal 14 is a feed for clearance, side marker, and identification lamps; terminal 16 is a feed for a left turn signal, terminal 18 is a feed for a stop signal; terminal 20 is a feed for a right turn signal, and terminal 22 is a feed for tail and license plate lamps.
[0044] When a trailer is equipped with electric trailer brakes, terminal 24 is a feed for electric current that actuates the trailer brakes. When a trailer is equipped with air brakes, terminal 24 may not necessarily be used; however, when an ABS controller is associated with the trailer air brakes to endow them with ABS capability, terminal 24 provides a continuous D.C. power supply voltage for the ABS controller.
[0045] FIG. 2 shows a presently preferred embodiment of inventive circuit 26 to comprise three relays 28 , 30 , 32 and a selector switch 34 . Switch 34 is shown as one of several switches in a multiplexed switch pack. The other circuit device shown in FIG. 2 is an electric system controller 36 of the towing vehicle. The electric system of the towing vehicle comprises a negative ground D.C. power supply comprising a battery 38 .
[0046] The towing vehicle has combination stop and turn signal lamps at the right and left rear of the vehicle. The right rear combination stop and turn signal lamp is marked by the reference numeral 40 , and the left rear combination stop and turn signal lamp, by the reference numeral 42 . At its right front the vehicle comprises a right turn signal lamp 44 , and at its left front, a left turn signal lamp 46 .
[0047] Stop and turn signal switches (not specifically shown) control lamps 40 , 42 , 44 , and 46 in the following manner.
[0048] When no turn signal is given, application of the vehicle service brakes will cause lamps 40 and 42 to illuminate continuously as long as the service brakes continue to be applied. If the turn signal switch is operated to signal a turn while the service brakes are being applied, the lamp 40 or 42 to the side of the turn will begin to flash while the opposite lamp 40 or 42 continues to remain continuously on. The front turn signal lamp 44 or 46 to the side of the turn will also flash while the corresponding rear lamp is flashing, but the opposite front turn signal lamp will remain off.
[0049] If the turn signal switch is operated to signal a turn while the service brakes are not being applied, both the lamp 40 or 42 to the side of the turn and the corresponding front lamp 44 or 46 will begin to flash while the opposite rear lamp 40 or 42 and the opposite front lamp 44 or 46 remain off.
[0050] The presence of a hazard warning switch in the vehicle electric system will also operate lamps 40 , 42 , 44 , 46 by causing all of them to flash when the hazard warning switch is switched on. The hazard warning function in effect overrides brake and turn signal functions.
[0051] Relay 28 comprises a solenoid coil 28 SC and a movable contact 28 MC that is operated by coil 28 SC. When coil 28 SC is not energized, contact 28 MC completes a circuit between a terminal 28 T 1 and a terminal 28 T 2 . When coil 28 SC is energized, contact 28 MC breaks the circuit from terminal 28 T 2 to make a circuit between a terminal 28 T 1 and a terminal 28 T 3 .
[0052] Relay 30 comprises a solenoid coil 30 SC and a movable contact 30 MC that is operated by coil 30 SC. When coil 30 SC is not energized, contact 30 MC completes a circuit between a terminal 30 T 1 and a terminal 30 T 2 . When coil 30 SC is energized, contact 30 MC breaks the circuit from terminal 30 T 2 to make a circuit between a terminal 30 T 1 and a terminal 30 T 3 .
[0053] Relay 32 comprises a solenoid coil 32 SC and a movable contact 32 MC that is operated by coil 32 SC. When coil 32 SC is not energized, contact 32 MC completes a circuit between a terminal 32 T 1 and a terminal 32 T 2 . When coil 32 SC is energized, contact 32 MC breaks the circuit from terminal 32 T 2 to make a circuit between a terminal 32 T 1 and a terminal 32 T 3 .
[0054] Coil 28 SC is connected between terminals 28 T 4 and 28 T 5 in relay 28 . Terminal 28 T 4 is connected to the positive power supply voltage in the vehicle. Terminal 28 T 5 is connected to a terminal 36 T 1 of system controller 36 .
[0055] Coil 30 SC is connected between terminals 30 T 4 and 30 T 5 in relay 30 . Terminal 30 T 4 is connected to the positive power supply voltage in the vehicle. Terminal 30 T 5 is connected to terminal 36 T 1 . This places the two coils in parallel under the control of controller 36 .
[0056] Controller 36 comprises another terminal 36 T 2 that is connected to switch 34 . When switch 34 is operated to a first position, controller 36 assumes a state that does not energize coils 28 SC, 30 SC. When switch 34 is operated to a second position, controller 36 assumes a state that does energize coils 28 SC, 30 SC.
[0057] Coil 32 SC is connected between terminals 32 T 4 and 32 T 5 in relay 32 . Terminal 32 T 4 may or may not be connected to the vehicle ignition switch (not specifically shown). If the towing vehicle has air brakes, as will be seen in the configurations of FIGS. 5 and 6 , terminal 32 T 4 will be connected to the ignition switch via wiring in the vehicle. Terminal 32 T 5 will also be connected through a pressure switch to ground. If the towing vehicle lacks air brakes, no switch 48 will be present and so terminal 32 T 5 is left unconnected. Terminal 32 T 4 may or may not be connected. A towing vehicle that lacks air brakes is unlikely to tow a trailer that does. A trailer that has electric brakes will be connected to an electric trailer brake controller in the towing vehicle via relay 32 , as will be seen in the configurations of FIGS. 3 and 4 .
[0058] Terminal 32 T 3 is connected to the positive power supply voltage, and when the towing vehicle lacks air brakes and is to tow a trailer that has electric trailer brakes, terminal 32 T 2 is connected to an electric trailer brake controller in the towing vehicle.
[0059] Terminal 32 T 1 is connected to terminal 24 in receptacle socket 10 ; terminal 28 T 1 to terminal 20 ; and terminal 30 T 1 to terminal 16 .
[0060] FIG. 3 shows the relevant portion of the electric system of a trailer having electric trailer brakes 50 and separate stop and turn signal lamps on right and left sides, lamp 52 being the right stop lamp, lamp 54 being the left stop lamp, lamp 56 being the right turn signal lamp, lamp 58 being the left turn signal lamp. The trailer comprises a connector plug 60 at an end of a multi-conductor cable having conductors connected with brakes 50 and lamps 52 , 54 , 56 , 58 , as shown.
[0061] Because stop lamps 52 , 54 are separate from turn signal lamps 56 , 58 , the stop lamps are connected to a terminal in plug 60 that mates with terminal 18 in receptacle socket 10 . The stop lamp feed to terminal 18 in the towing vehicle is identified by the numeral 61 . Stop lamps 52 , 54 will thereby illuminate concurrently with vehicle stop lamps 40 , 42 when the driver of the towing vehicle applies the vehicle service brakes. Turn signal lamps 56 , 58 are connected via respective conductors to respective terminals in plug 60 that mate with respective terminals 20 , 16 in receptacle socket 10 .
[0062] FIG. 3 also shows the condition of circuit 26 for this trailer configuration. Because the trailer has separate stop and turn signal lamps, selector switch 34 has been placed in its second position, causing coils 28 SC, 30 SC to be energized. That causes the respective feeds for trailer turn signal lamps 56 , 58 to come from the front turn signal lamps 44 , 46 respectively in the towing vehicle. Because the operation of turn signal lamps 44 , 46 is unaffected by application of the vehicle service brakes, actuation of the brakes does not affect lamps 56 , 58 . Hence, lamps 56 , 58 can be any color compliant with applicable regulations.
[0063] FIG. 3 also shows an electric trailer brake controller 62 in the towing vehicle. With the towing vehicle lacking air brakes, coil 32 SC is not energized, and consequently the output of controller 62 is fed through to electric trailer brakes 50 via terminal 24 in receptacle socket 10 and a terminal in plug 60 mating with terminal 24 .
[0064] FIG. 4 shows the relevant portion of the electric system of a trailer having electric trailer brakes 50 and combination stop and turn signal lamps 72 , 74 on right and left sides respectively. The trailer comprises a connector plug 60 at an end of a multi-conductor cable having conductors connected with brakes 50 and lamps 72 , 74 as shown.
[0065] Lamp 72 is connected to a terminal in plug 60 that mates with terminal 20 in receptacle socket 10 . Lamp 74 is connected to a terminal in plug 60 that mates with terminal 16 in receptacle socket 10 .
[0066] FIG. 4 also shows the condition of circuit 26 for this trailer configuration. Selector switch 34 has been placed in its first position, causing coils 28 SC, 30 SC not to be energized. That causes the respective feeds for receptacle socket terminals 20 and 16 to come from the rear vehicle lamps 40 , 42 respectively, slaving lamp 72 to lamp 40 and lamp 74 to lamp 42 . Trailer lamps 72 , 74 will therefore operate in the exact same manner as the combination rear stop and turn signal lamps in the vehicle, rendering the trailer lamps compliant with applicable regulations. When no separate stop lamp or lamps is or are present in the trailer, the trailer electric system has no need for the stop lamp feed provided by terminal 18 .
[0067] FIG. 4 also shows an electric trailer brake controller 62 in the towing vehicle. With the towing vehicle lacking air brakes, coil 32 SC is not energized, and consequently the output of controller 62 is fed through to electric trailer brakes 50 via terminal 24 in receptacle socket 10 and a terminal in plug 60 mating with terminal 24 .
[0068] FIG. 5 shows the relevant portion of the electric system of a trailer having air brakes 80 and combination stop and turn signal lamps 72 , 74 on right and left sides respectively. The trailer comprises a connector plug 60 at an end of a multi-conductor cable having conductors connected with lamps 72 , 74 as shown. FIG. 5 shows the trailer having an ABS controller 82 associated with air brakes 80 . Another conductor of the multi-conductor cable connects ABS controller 82 to a terminal in plug 60 that mates with terminal 24 .
[0069] Because a trailer having air brakes is unlikely to be towed by a towing vehicle lacking air brakes, it is understood that the towing vehicle in FIG. 5 does have air brakes and that the air line or lines are properly connected between the towing vehicle and the trailer. The air brake system in the towing vehicle comprises a tractor protection valve 85 and a trailer charge valve 87 arranged as shown in the relevant portion of the air brake included in FIG. 5 . Charge valve 87 is depressed when a trailer having air brakes is coupled to the towing vehicle and serves to supply air to tractor protection valve 85 , which then applies air pressure to a line 89 leading to the trailer brakes to release the trailer brakes. The pressure in line 89 is sensed by a pressure switch 84 in the towing vehicle. Switch 84 is connected between terminal 32 T 5 and ground. Terminal 32 T 4 is connected to the ignition switch 86 in the towing vehicle.
[0070] Consequently, when ignition switch 86 is turned on and the trailer charge valve 87 is depressed, coil 32 SC is energized, causing positive battery voltage to be delivered to terminal 24 , thereby supplying battery voltage for ABS controller 82 . Line 89 is not pressurized when a non-air brake trailer is coupled to the towing vehicle. It is also not pressurized when no trailer is coupled to the towing vehicle.
[0071] Because FIG. 5 shows the same circuit configuration for the combination stop and turn signal lamps as in FIG. 4 , a description of the operation of those lamps need not be repeated.
[0072] FIG. 6 shows the relevant portion of the electric system of a trailer having air brakes 80 and separate stop and turn signal lamps 52 , 54 , 56 , 58 . The operation of the respective lamp and brake circuits shown in FIG. 6 can be understood from previous descriptions of FIGS. 3 and 5 , and so no description will be given here in the interest of brevity.
[0073] For any of the four described trailer configurations, all that a driver of the towing vehicle need do is operate switch 34 to select the proper lamp configuration in the trailer to be towed. If the trailer has air brakes, the proper circuit for them will be achieved automatically when the driver turns on the ignition switch, and the tractor protection valve is depressed.
[0074] While a presently preferred embodiment of the invention has been illustrated and described, it should be appreciated that principles of the invention are applicable to all embodiments that fall within the scope of the following claims.
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A circuit ( 26 ) for configuring a seven-terminal receptacle socket ( 10 ) in a towing vehicle to properly accommodate the particular one of several possible electric circuit configurations in a particular trailer that is being towed by the towing vehicle. The particular electric circuit configuration in the trailer—FIGS. 3, 4, 5, 6 are four possible configurations—depends on the particular lamps ( 52, 54, 56, 58, 72, 74 ) and brakes ( 50, 80 ) in the trailer.
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BACKGROUND OF THE INVENTION
This invention relates to a throttle valve made of resin used in a throttle body made of resin. Research and development activities have reduced the weight of automobiles to reduce fuel consumption. A conventional throttle body, one of the components of an intake system, is manufactured by aluminum die casting. Efforts have been made in recent years to provide lightweight, low-cost throttle bodies by forming throttle bodies of resins.
This invention relates to a throttle valve made of resin used in a throttle body made of resin. Research and development activities have reduced the weight of automobiles to reduce fuel consumption. A conventional throttle body, one of the components of an intake system, is manufactured by aluminum die casting. Efforts have been made in recent years to provide lightweight, low-cost throttle bodies by forming throttle bodies of resins.
The bore of a throttle body must be formed so that the gap between the bore wall defining the bore of the throttle body and a throttle valve placed in the bore of the throttle body is in the range of 80 to 100 μm. The bore of a conventional throttle body formed by die casting is finished by machining to form the bore to the desired accuracy. If a resin throttle body can be formed such that its bore is formed at an accuracy that insures the gap in the aforesaid range, machining is unnecessary. The roundness of the bore after molding shrinkage, the roundness of the throttle valve (hereinafter, roundness is used to represent variations in diameter), and errors in the inside diameter of the bore must be equal to those of an aluminum throttle valve formed by die casting. It is necessary to prevent the interference between the bore wall and the throttle valve, and an excessive increase in the gap between the throttle body and the throttle valve due to thermal deformation caused by the variation of temperature between a very low temperature and a high temperature exceeding 100° C.
A method of preventing irregular deformation proposed in JP-A No. 169473/1998 places a filler in an orientation in a bore part of a throttle body defining a bore. It is thought that the gap can be reduced when a metal throttle valve formed by machining is placed in such a bore part.
For cost reduction, the throttle valve must be formed of resin to omit a machining process. When both a throttle body having a bore and a throttle valve to be placed in the bore are formed of resins, the throttle body and the throttle valve can be formed of different resins having similar coefficients of expansion. Hence the initial gap between the bore wall and the throttle valve can be substantially maintained. When the throttle valve is formed of a resin having a thermal conductivity lower than those of metals, it is possible to prevent freezing that occurs in metal throttle valves during operation. Even if both the throttle body and the throttle valve are formed of the same resin containing the same amount of filler, the throttle body and the throttle valve will have different coefficients of linear expansion, and deform by different amounts due to the difference between the throttle body and the throttle valve in the orientation of the filler. Consequently, there is the possibility that the throttle valve will interfere with the bore wall, and thus the gap between the bore wall and the throttle valve increases.
Recent internal combustion engine design has tended to reduce the idle throttle valve opening to reduce idle speed. When the idle throttle valve opening is reduced, the possibility increases that contaminants, such as carbon contained in the recirculated exhaust gas, and oils contained in the blowby gas, will adhere to the periphery of the throttle valve. If those contaminants deposited on the throttle valve are solidified by the heat of the internal combustion engine, the throttle valve locks to the bore wall and, in the worst case, the throttle valve will not move even if the accelerator pedal is operated.
BRIEF SUMMARY OF THE INVENTION
This invention provides a throttle body such that the thermal deformation of the bore wall of the throttle body is substantially equal to that of a throttle valve at temperatures in the range of a very low temperature to a temperature exceeding 100° C. The gap between the bore wall and the throttle valve is the same as the gap between the bore wall of a conventional throttle body and a conventional throttle valve, and provides a low-cost, high-performance throttle body. The invention also reduces the roundness of a bore after molding shrinkage and reduces the gap between a throttle valve and the bore. In addition, it prevents the fixation of the throttle valve as sometimes caused by solid deposits such as carbon and oils.
To solve the foregoing problems, according to the present invention, a filler contained in a resin is oriented in a circumferential direction to make the linear expansion coefficient of a throttle valve in a radial direction approach that of a bore. This makes the thermal deformation of the throttle valve approach that of the bore to prevent the aforesaid interference and the enlargement of the gap.
To solve the foregoing problems, a throttle body according to an embodiment of the present invention includes a throttle shaft extended substantially diametrically across an intake cylinder (bore); and a throttle valve fixed to the throttle shaft and contained in the bore, wherein the bore and the throttle valve are made of a resin containing filler, and the difference between circumferential deformation of the bore and radial deformation of the throttle valve is in the range of 0 to 40 μm at temperatures in the range of −40° C. to 120° C. In addition, a throttle body according an embodiment of the present invention includes an intake cylinder (bore); and a throttle valve, wherein the throttle valve and the bore are formed of resins containing filler, the difference between the linear expansion coefficient of the throttle valve and that of the bore being in the range of 0 to 4×10 −6 /° C.
Preferably, in the throttle body according to an embodiment of the present invention, the fillers in the bore and the throttle valve are oriented in substantially the same direction, or are randomly oriented in the bore and the throttle valve. In addition, in some embodiments, the throttle valve is provided with circumferential grooves or ribs, and the filler is substantially circumferentially oriented.
To form the throttle body, the throttle valve is made by sandwiching an aggregate formed by circumferentially arranging the filler between resin layers. Preferably, the throttle valve is made of a resin different in filler content from that forming the bore to make the radial thermal expansion coefficient of the throttle valve nearly equal to the circumferential linear expansion coefficient of the bore. Furthermore, in the throttle body according to the present invention, at least a peripheral part of the throttle valve facing the bore wall of the bore is made of a resin containing a fluorocarbon resin or is coated with a fluorocarbon resin.
A preferred embodiment of the throttle body according to the present invention includes a throttle shaft extended substantially diametrically across an intake cylinder (bore); and a throttle valve fixed to the throttle shaft and contained in the bore; wherein the bore is made of a resin, and an annular rib of a fixed or continuously changing width, or parts of such an annular rib, are formed in a part corresponding to the throttle shaft of the bore to counterbalance the effect of sinks due to bosses. Typically in the throttle body the minimum thickness is ⅔ of maximum thickness or below.
To solve the foregoing problems, in the throttle body according to the present invention, ribs are formed in parts of the bore around the throttle shaft such that the product of maximum height and thickness is in the range of 15 to 40% of the heights and the mean thickness of the bosses and the product of minimum height and thickness is in the range of 20 to 80% of the product of maximum height and thickness. The bore is provided in a part thereof with a rib capable of limiting the roundness (diameter) of a part of the bore in the range of ±5 mm along the center axis of the bore from a position corresponding to the throttle shaft to 80 μm or below. The ribs are formed in the parts of the intake cylinder defining the bore around the throttle shaft to reduce the roundness of the bore after mold shrinkage. The present invention also often adds an additive to the resin to suppress the adhesion of carbon and oils to the throttle valve.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a throttle valve in a first embodiment according to the present invention;
FIG. 2 is a side elevation of a throttle body;
FIG. 3 is a plan view of the throttle body;
FIG. 4 is a schematic view to assist in explaining a method of molding a disk-shaped part;
FIG. 5 is a schematic view to assist in explaining a method of molding a cylindrical part;
FIG. 6 is a sectional view taken on line A—A in FIG. 1 ;
FIG. 7 is a graph showing the relation between the depth of grooves and linear expansion coefficient in the throttle valve according to the first embodiment;
FIG. 8 is a graph showing the relation between the depth of a groove and gap in the throttle valve in the first embodiment;
FIG. 9 is a schematic diagram showing a throttle valve in a modification of the first embodiment;
FIG. 10 is a sectional view of another throttle valve according to the first embodiment, taken on line A—A in FIG. 9 ;
FIG. 11 is a typical view of a throttle valve in a second embodiment according to the present invention;
FIG. 12 is a sectional view of a mold for molding the throttle valve in the second embodiment;
FIG. 13 is a perspective view of an analytic model of a throttle body;
FIG. 14 is a top view of the analytic model shown in FIG. 13 ;
FIG. 15 is a fragmentary perspective view of a throttle body in a fourth embodiment according to the present invention;
FIG. 16 is a top view of the throttle body shown in FIG. 15 ;
FIG. 17 is a fragmentary top view of the throttle body in the fourth embodiment;
FIG. 18 is a fragmentary top view of the throttle body in the fourth embodiment;
FIG. 19 is a fragmentary top view of the throttle body in the fourth embodiment;
FIG. 20 is a view of to assist in explaining a deformation mode of the throttle body in the fourth embodiment;
FIG. 21 is another example of a section on line A—A in FIG. 9 ; and
FIG. 22 is a table showing measured coefficients of linear expansion.
DETAILED DESCRIPTION OF THE INVENTION
Preferred embodiments of the present invention will be described hereinafter with reference to the accompanying drawings. Referring to FIGS. 2 and 3 , a throttle body 3 has a throttle valve 1 contained in a space surrounded by a bore wall 4 a of a bore 4 , and a throttle shaft 5 . The throttle valve 1 is fastened to the throttle shaft 5 with screws 22 . Throttle shaft 5 is extended substantially diametrically across bore 4 . A throttle lever 7 is connected to one end of the throttle shaft 5 . A return spring 6 is extended between throttle lever 7 and a stopper 8 . A throttle-valve position sensor 9 is attached to the other end of throttle shaft 5 .
When the driver depresses an accelerator pedal, not shown, throttle lever 7 is moved and throttle shaft 5 is moved accordingly to open throttle valve 1 . When the force applied to the accelerator pedal is removed, throttle valve 1 is closed by the resilience of return spring 6 . In a state where throttle valve 1 is closed, the gap between circumference 1 a of throttle valve 1 and bore wall 4 a is, for example, in the range of 80 to 100 μm to reduce idle speed, fuel consumption and noise during idling. This gap enables the smooth movement of throttle valve 1 . In FIG. 3 , the gap is exaggerated to facilitate understanding.
When throttle body 3 is heated by the heat generated by the engine, part of the gap between circumference 1 a of the throttle valve and bore wall 4 a decreases, and the throttle valve 1 bites into the bore wall. This phenomenon is liable to occur mostly during idling.
The linear expansion coefficient of a resin containing a fibrous filler in a direction parallel to the extending direction of the filler is small, and that of the same in a direction perpendicular to the extending direction of the filler is large. FIG. 4 is a schematic view of assistance in explaining a method of molding a common disk, in which a filler is indicated at 10 , a disk is indicated at 11 and a runner is indicated at 12 . A resin flows through runner 12 to a position corresponding to the center of disk-shaped part 11 . As shown in FIG. 4 , filler 10 is oriented radially from the center when the thickness of disk-shaped part 11 is small. Filler 10 is enlarged in FIG. 4 to facilitate recognizing the direction of orientation. Therefore, it is expected that radial thermal deformation is smaller than circumferential thermal deformation. FIG. 5 is a schematic view of assistance in explaining a method of molding a cylindrical part. Gates symmetrical with respect to a circumferential direction are formed to improve roundness. Shown in FIG. 5 are a cylindrical part 13 , a gate 14 and a runner b 15 . In this case, filler 10 extends in a flowing direction and is generally axially oriented. It is expected that circumferential and radial coefficients of thermal deformation are large, an axial thermal deformation is small. FIG. 22 shows measured coefficients of linear expansion of a cylindrical part and a disk-shaped part made of a resin containing filler 10 .
The circumferential linear expansion coefficient of the cylindrical part is 1.6 times the axial linear expansion coefficient of the same, and the circumferential linear expansion coefficient of the disk-shaped part is 1.4 times the radial linear expansion coefficient of the same, which substantiates the aforesaid expectation. Suppose that the cylindrical part is a bore, and the disk-shaped part is a throttle valve. Then, the circumferential linear expansion coefficient of the cylindrical part, and the radial linear expansion coefficient of the disk-shaped part are related with the gap. There is a large difference between the circumferential linear expansion coefficient of the cylindrical part of 28.8×10 −6 /° C. and the radial linear expansion coefficient of the disk-shaped part of 18.8×10 −6 /° C. When the inside diameter is 60 mm, a difference between sizes in the working temperature range of −40 to 120° C. is 96 μm. Thus, it is important to make the coefficients of linear expansion the same in both parts. In this case, the difference between the respective deformations of the bore and the throttle vale must be smaller than 80 μm. The deformation difference of 80 μm corresponds to a difference of about 8×10 −6 /° C. in linear expansion coefficient when the inside diameter is 60 mm and the working temperature range is −40 to 120° C. Thus, to prevent galling of the bore and throttle valve, the difference between the respective coefficients of linear expansion of both parts must not be greater than about 8×10 −6 /° C. More preferably, in view of changes in roundness, it is desirable that the deformation difference is 40 μm or below.
In this embodiment, a method of increasing the radial linear expansion coefficient of throttle valve 1 , which is easier to deal with than the throttle body 3 , has been devised. Preferred embodiments of the present invention will be described with reference to the accompanying drawings.
First Embodiment
FIG. 1 is a typical view of a throttle valve 1 in a first embodiment according to the present invention. Shown in FIG. 1 are a throttle valve 16 , some of grooves 17 arranged on concentric circles, and holes 24 for attaching throttle valve 16 to a shaft 5 . FIG. 6 is a sectional view taken on line A—A in FIG. 1 . A filler may also be added, and oriented.
Filler 2 can be oriented mostly in a circumferential direction by arranging grooves 17 on concentric circles. Grooves 17 are in a zigzag arrangement in this embodiment to make a resin flow through thin parts of each groove without fail. Thus, the radial flow of the resin is disturbed to make the extension of the filler in radial directions difficult, and the probability of the filler extending in a circumferential direction increase.
The filler can be more randomly oriented by changing the depth, size and pitches of grooves 17 . When the filler is oriented mostly in a circumferential direction, it is desirable that the linear expansion coefficient of throttle valve 1 is close to that of bore 4 .
The difference in the linear expansion coefficient between throttle valve 1 and bore 4 can be made smaller than that when the filler is radially oriented in the throttle valve by randomly orienting the filler, which is within the scope of the present invention.
Consequently, as mentioned above, the radial linear expansion coefficient of the throttle valve can be made to approach that of bore 4 to suppress the variation of the gap between throttle valve 16 and bore 4 according to temperature variation. Throttle valve 16 in this embodiment can be easily made by injecting a thermoplastic resin into a cavity of a mold provided with protrusions corresponding to the grooves.
FIG. 7 shows the coefficients α of linear expansion of four types of disk-shaped parts of a thickness of t 0 =3 mm and an outside diameter of 60 mm, respectively provided with grooves of depths of 0.5 mm, 0.75 mm. and 1.0 mm, Minimum thicknesses t of the disk-shaped parts, which are associated with these depths of the grooves, are 2.0 mm, 1.5 mm, and 1.0 mm, respectively. The thickness ratio t/t 0 is measured on the horizontal axis, and the linear expansion coefficient ratio α/α 0 , i.e., the ratio of the linear expansion coefficient α of the throttle valve to the linear expansion coefficient α 0 of the bore, is measured on the vertical axis. The effect of the grooves is significant and the linear expansion coefficient ratio α/α 0 approaches 1 when the thickness ratio t/t 0 is smaller than ⅔; that is, the respective linear expansion coefficients of the disk-shaped part and the bore approach each other.
FIG. 8 shows calculated gap information between the disk-shaped part and the bore in the temperature range of −40 to 120° C. The gap is 49 μm when the disk-shaped part is not provided with any grooves. The gap is as small as 18 μm when the disk-shaped part is provided with grooves of 1 mm in depth. In this embodiment, the gap can be limited to 40 μm or below (0 to 40 μm) when the temperature of the disk-shaped part is in the temperature range of −40 to 120° C. by forming grooves in the disk-shaped part such that the minimum thickness is ½ of the original thickness or below. This corresponds to a linear expansion coefficient difference of about 4×10 −6 /° C. (0 to 4×10 −6 /° C.) when the inside diameter is 60 mm.
The linear expansion coefficient α of 23.7×10 −6 /° C. of the disk-shaped part in this embodiment is greater than the linear expansion coefficient of 18.1×10 −6 /° C. of a disk-shaped part shown in FIG. 22 and is near the linear expansion coefficient of 28.8×10 −6 /° C. of the bore. It is inferred that this is the result of the increase of a part not subject to the influence of shearing with a wall surface resulting from an increased thickness in the range of 1.5 to 3.0 mm and increased ratio of circumferentially oriented fibers.
Referring again to FIG. 1 , to prevent galling of the throttle valve and bore 4 , practical throttle valve 16 is in contact with bore 4 in a position inclined at several degrees to the axis of the bore and not perpendicular to the axis of the bore. Therefore, practical throttle valve 16 is not a perfectly circular disk, but an elliptic plate that is tapered. The mold is made to conform to the shape of throttle valve 16 .
Although grooves 17 are formed in the opposite surfaces, grooves 17 may be formed in only one of the opposite surfaces for the same effect. However, when grooves 17 are formed in only one of the opposite surfaces, measures to prevent the warp of the throttle valve, such as heating different parts of the mold at different temperatures, respectively, must be taken. Although grooves 17 are in a zigzag arrangement in this embodiment, the grooves may be radially arranged. The throttle valve may be provided with concentric circular grooves. Grooves 17 may be formed only in a peripheral part for the same effect.
Throttle valve 1 is bent around the throttle shaft by a negative pressure during idling. As mentioned above, since throttle valve 11 is not perpendicular to the axis of the bore and is inclined at an angle to the axis of the bore, the half of the throttle valve closer to the engine is bent so as to recede from the bore wall. The other half of the throttle valve farther from the engine is bent to come into the bore wall. Consequently, the throttle valve and the bore gall, and there is the possibility, in the worst case, that the throttle valve will become uncontrollable.
As shown in FIG. 9 , ribs are formed on the half of the throttle valve farther from the engine (right half in FIG. 9 ) instead of the grooves so that the filler is circumferentially oriented. FIG. 10 shows grooves 17 and ribs 23 . Thus, the reduction of the thickness due to the formation of the grooves is avoided and the rigidity of this half is increased. FIG. 10 is a sectional view taken on line A—A of FIG. 9 . Most of filler 10 is circumferentially oriented in the half of the throttle valve provided with ribs 23 shown in FIG. 10 . Therefore, the linear expansion coefficient of throttle valve 1 can be made near or substantially equal to that of the bore. Consequently, the strength of throttle valve 1 can be increased and, at the same time, the difference in the linear expansion coefficient between the throttle valve and the bore can be reduced to a value not greater than the predetermined value, which can solve the problem with galling of throttle valve 1 and bore 4 .
The ribs may be formed on either one or both of the opposite surfaces. If the ribs are formed on only one of the surfaces, flow resistance can be reduced by forming protrusions on the side of the engine. FIG. 21 shows another section of a throttle valve corresponding to the section taken on line A—A of FIG. 9 . FIG. 21 shows grooves 17 and ribs 23 . The ribs are formed in the right half of the throttle valve such that the height of the rib nearer to the circumference is greater than that of the rib farther from the circumference to enhance the bending rigidity of the rib. The adhesion of carbon and oils to a peripheral part 30 can be avoided without forming any ribs in peripheral part 30 .
Possible filler materials for the resin used in this embodiment are, for example, glass fibers, carbon fibers, boron fibers, aramid fibers, carbon silicate fibers, alumina fibers and potassium titanate (K n O•nTiO 2 ) whiskers.
Second Embodiment:
FIG. 11 is a typical view of throttle valve 1 to assist in explaining a method of manufacture in a second embodiment according to the present invention. FIG. 12 is a sectional view of a mold used in manufacturing throttle valve 1 . There are shown an aggregate 18 formed by circumferentially arranging filler 18 , a lower mold 19 , and an upper mold 20 . The aggregate of filler is placed in a recess formed in lower mold 19 , and a thermosetting resin is poured in the recess to impregnate the filler with the thermosetting resin. The lower mold 19 and upper mold 20 are joined together, and the mold is heated to set the thermosetting resin. In throttle valve 1 in the second embodiment, the filler is arranged circumferentially. The linear expansion coefficient of the second embodiment, like that of the first embodiment, can be made to approach the linear expansion coefficient of bore 4 , so that it is possible to prevent the variation of the gap between throttle valve 1 and bore 4 according to the variation of temperature.
Although the aggregate of filler is used in the second embodiment, a filling member formed by arranging strings of filler 2 in concentric circles or in a spiral may be used. Even a filling member like a fabric formed by weaving threads of filler is somewhat effective. A throttle valve 1 having the same properties can be manufactured by using a cold-setting resin, a photocurable resin or a thermoplastic resin instead of the thermosetting resin. If a photocurable resin is used, upper mold 20 must be a glass mold.
Third Embodiment:
The radial linear expansion coefficient of a throttle valve 1 can be made to approach the circumferential linear expansion coefficient of a bore 4 by another method that forms throttle valve 1 with a resin having a filler content different from that of a resin forming bore 4 . Generally, the linear expansion coefficient of a resin having a small filler content is large. The linear expansion coefficient of throttle valve 1 in this embodiment can be made to approach the circumferential linear expansion coefficient of bore 4 by forming throttle valve 1 of a resin having a small filler content. Consequently, the variation of the gap between throttle valve 1 and bore 4 according to the variation of temperature can be suppressed.
The radial linear expansion coefficient of the throttle valve can be made to approach the circumferential linear expansion coefficient of the bore by forming the throttle valve and the bore of different resins, respectively.
Fourth Embodiment:
FIG. 13 shows perspective view of an analytic model to assist in explaining the postmolding shrinkage that occurs after injection molding of a throttle body in a fourth embodiment according to the present invention. A bore 4 , bearing housings 25 for housing bearings supporting a throttle shaft, and through holes 26 through which the throttle shaft is extended are shown. The bore is 50 mm in diameter and 100 mm in height; the housing is 20 mm in diameter and 10 mm in height; the through holes are 10 mm in diameter, and the bore has a wall thickness of 2 mm.
Flow, holding and warp during injection molding were analyzed using this model and general-purpose resin flow analyzing software (MOLDFLOW). A PEI (polyetherimide) containing 25% glass fibers and 20% mica as filler (ULTEM 3452 made by GE Plastics) was used.
FIG. 14 shows the results of the analysis. Broken lines 27 indicate, in an enlarged view, the position of the bore corresponding to the position of the center of the throttle shaft after shrinkage. As obvious from FIG. 14 , the shrinkage of the part corresponding to the bearing housings 25 is large and the bore 4 has a laterally elongate elliptic shape. To form this part in a shape having a satisfactory roundness, an annular rib 28 of 2 mm in thickness and 10 mm in width was formed around a part corresponding to the center of the throttle shaft. FIG. 16 shows the results of analysis performed using the model shown in FIG. 15 . Broken lines 29 indicate, in an enlarged view, the position of the bore corresponding to the position of the center of the throttle shaft after shrinkage. As obvious from FIG. 16 , the shrinkage of the bore is different from that of the bore shown in FIG. 14 , and a part corresponding to the bearing housings and the bore has a longitudinally elongate elliptic shape. It was inferred that such shrinkage occurred because the shrinkage of the annular rib is greater than a part corresponding to the bearing housings.
It is known from the foregoing results that the roundness of the bore after shrinkage can be improved by properly determining the shape of the annular rib. FIG. 17 shows a bore provided with partial ribs. The partial ribs narrow the ranges of the shrinking effect of the ribs. FIG. 18 shows a rib having a narrow width. FIG. 19 shows ribs having a continuously changing width. The roundness of the bore can be greatly improved by these ribs.
FIG. 20 is a diagram to assist in explaining the dependence of deformation due to postmolding shrinkage on the shape of the rib, in which the ratio h/h 0 , i.e., the ratio of the maximum width h of the rib to the height h 0 of the boss, is measured on the horizontal axis, and the ratio hb/h, i.e., the ratio of minimum width hb of the rib to the maximum width h of the rib, is measured on the vertical axis. The bore is deformed in a laterally elongate elliptic shape, in a longitudinally elongate elliptic shape, and in a nearly square shape when any ribs are not formed, when a large rib is formed, and when a rib having a comparatively narrow, uniform width is formed, respectively. The roundness after molding shrinkage is the smallest in the vicinity of the boundaries of those three deformation modes. The roundness is 80 μm or below in a range where the maximum width is in the range of 15 to 40% of the height of the boss, and the minimum width is in the range of 20 to 80% of the maximum width. In FIG. 20 , the respective mean wall thicknesses of the rib and the bore are substantially equal. It is considered that sinks are dependent not only on the width of the rib and the height of the boss, but also on the volume. When the rib and the boss differ from each other in wall thickness, the deformation mode will be similar to the case where the width of the rib and the height of the boss are multiplied by the wall thickness. The same effect as that obtained when the rib and the boss have the same wall thickness is expected when the rib is formed such that the product of the maximum width and wall thickness of the rib is in the range of 15 to 40% of the product of the height and the mean wall thickness of the boss, and the product of the minimum width and wall thickness of the rib is in the range of 20 to 80% of the product of the maximum width and wall thickness of the rib.
Since the throttle valve is inclined at an angle in the range of 5° to 7° when closed, the roundness must be 80 μm or below in a range of ±5 mm along the center axis of the bore from a position corresponding to the throttle shaft. The results of the analysis showed that the roundness is substantially 80 μm or below in the aforesaid ranges. Although the rib is formed in one layer at a position corresponding to the center of the throttle shaft in this embodiment, ribs may be formed in two or more layers at positions around the center of the throttle shaft. Since the rib enhances the rigidity of the bore, the wall thickness of the bore may be reduced.
The results of the analysis showed that the roundness of a part corresponding to the throttle shaft is scarcely improved when the rib is formed in axial range other than an axial range corresponding to the boss. Therefore, the rib must be formed in the axial range corresponding to the boss. The concept of the shape of the rib in this embodiment applies also to a case where a resin and fiber content different from those in this embodiment are used.
Fifth Embodiment:
When an internal combustion engine, not shown, operates, exhaust gas and blowby gas sometimes flow from the internal combustion engine toward a throttle valve 1 . These gases contain carbon and oils. If the gap between a throttle valve 1 and a bore wall 4 a is narrow, the carbon and the oils adhere to and solidify on a peripheral part of throttle valve 1 facing bore wall 4 a . Consequently, throttle valve 1 becomes unmovable.
The adhesion of oils or carbon can be prevented by forming throttle valve 1 of a resin which prevents the adhesion of oils, carbons or any adhesive substance containing oils and carbon. More specifically, water repellency can be increased and the adhesion of oils or carbon to the throttle valve can be prevented by adding a fluorocarbon resin, such as PTFE (polytetrafluoroethylene resin) to the resin. Formation of a peripheral part of throttle valve 1 of a resin containing a fluorocarbon resin by two-color molding provides a similar effect. Alternatively, coating the surface of throttle valve 1 with a fluorocarbon resin provides a comparable effect.
According to the present invention, bore 4 and throttle valve 1 are substantially the same in linear expansion coefficient, keeping the gap between bore wall 4 a and circumference 1 a of throttle valve 1 uniform, and avoiding the interference between bore 4 and throttle valve 1 . Also according to the present invention, the roundness of the portion of the bore around the throttle shaft after molding shrinkage can be reduced.
Thus, the gap between bore wall 4 a and circumference 1 a of the throttle valve during idling can be limited to a very small value, so that a high-performance resin throttle body that permits only a small amount of air leakage can be obtained. Thus, according to the present invention, the adhesion of carbon and oils to throttle valve 1 can be suppressed by adding an additive to the resin and, consequently, faulty operation of throttle valve 1 can be prevented.
INDUSTRIAL APPLICABILITY
The present invention is applicable to the throttle body included in the intake system of an automobile, and is particularly of service when the bore and the throttle valve of the throttle body are made of resins.
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A lightweight, low cost throttle body and throttle valve placed in the body, both formed of resins, that resolve the problem of excessively large gap formation is disclosed. Circumferentially oriented filler contained in a resin forming a throttle valve compensates to make the radial linear expansion coefficient of the throttle valve substantially equal to that of a bore. Grooves are formed on concentric circles in the throttle valve to orient filler circumferentially. A throttle valve provided with circumferentially oriented filler can be formed by impregnating an aggregate formed by circumferentially arranging the filler with a resin and curing the resin. A rib is formed in a part near a throttle shaft to control molding shrinkage so that the roundness of the bore is small.
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BACKGROUND
[0001] With mass production of mobile phone related components and systems, it has become economically feasible to explore other uses of mobile phone technology beyond its well-known typical use, that is, for person to person conversations and Internet browsing. In addition, text messaging is also a popular use of mobile phones. Text messaging is universally available in that text messaging services are offered by virtually all commercial mobile service providers. Text messaging is also referred to as Short Message Service (SMS). Standards related to SMS are defined by Global System for Mobile Communications (GSM) series of standards. These standards limit the message size to 160 characters. The standards also allow sending larger messages using multipart sub-messages each of them are limited to 160 characters.
[0002] In recent years, automobiles and many different types of machines are being equipped with sophisticated electronics controls. Many newer automobiles include one or more microcontrollers, variety of electrical and electronic sensors and control software that control and monitor internal operations of these automobiles. In addition, these electronics systems also collect variety of information through sensors for diagnostic purposes. Some informational data is also collected. For example, temperatures at different locations inside the engine compartment and/or cabin are collected by automobile control systems. Error conditions and occurrence of faults are another set of information that is actively collected by automobile or machine control systems. Typically, a special data reader is connected to a special interface (e.g., On Board Diagnostic or OBD) provided inside an automobile to retrieve at least some of the collected data from an automobile control system.
SUMMARY
[0003] 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 or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.
[0004] In one embodiment, a system incorporated in a vehicle is disclosed. The system includes a communication system including a text messaging communication hardware to receive a message via a text messaging service. The message includes a command. The system also includes a microcontroller, coupled to the communication system and a machine control system, to execute the command through the machine control system. The machine control system is configured to control components of the vehicle. The microcontroller is configured to determine if a configuration allows execution of the received command and to return a response to the communication system.
[0005] In another embodiment, a method is disclosed. The method includes receiving a message, wherein the message includes a request for performing an operation, determining if the request is sent by an authorized sender, determining if a configuration allows execution of the operation through a control system that is embodied in a vehicle, upon determining that the request is sent by the authorized sender the configuration allows the execution of the operation, performing the operation through the control system that is configured to monitor and control components of the vehicle, and sending results of the operation back to the authorized sender in form of a Short Messaging Service (SMS) message.
[0006] In yet another embodiment, a computer program product comprising program code stored in a computer readable medium other than a signal per se, the program code being executable by a processor of a camera device to cause the camera device to implement an operation, the operation comprising. The operation includes receiving a message, wherein the message includes a request for performing an operation, determining if the request is sent by an authorized sender, determining if a configuration allows execution of the operation through a control system that is embodied in a vehicle, upon determining that the request is sent by the authorized sender the configuration allows the execution of the operation, performing the operation through the control system that is configured to monitor and control components of the vehicle, and sending results of the operation back to the authorized sender in form of a Short Messaging Service (SMS) message.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments. Advantages of the subject matter claimed will become apparent to those skilled in the art upon reading this description in conjunction with the accompanying drawings, in which like reference numerals have been used to designate like elements, and in which:
[0008] FIG. 1 is an exemplary block diagram showing on board components of an automobile control system in accordance with an embodiment of the present disclosure; and
[0009] FIG. 2 illustrates an exemplary flow diagram illustrating operations of communicating with the automobile control system via text messaging in accordance with an embodiment of the present disclosure.
DETAILED DESCRIPTION
[0010] Computing systems built into modern automobiles collects variety of information as for example, status of components that require regular service or replacement, error conditions and more. A user or operator of an automobile can benefit if the user can communicate with the automobile without using specialized equipment or readers. The benefits are ever greater if this communication can take place remotely. While the word “automobile” is being used to describe various aspects of the invention, it should be noted that the embodiments described herein may also be applicable to other types of machines, such as a manufacturing system.
[0011] The use of text messaging or SMS offers many advantages over the use of the Internet for the type of remote communication described herein. First, implementing the Internet communication requires additional hardware and software, thus increasing cost. Second, the Internet communication requires a real time connection that may not be available if the automobile is located in a remote location or where there is no Internet connectivity, whereas text messaging can work offline in that a request for information may be transmitted without knowing anything about the status of the automobile. Further, the Internet service is expensive and typically requires monthly subscription charges whereas text messaging is typically charged at peruse basis or may be available for free as a part of a regular phone service subscription. Operations of text messaging transmission and underlying systems are well known, therefore, in order not to obfuscate the present disclosure, a detailed discussion of Short Messaging Service (SMS) or text messaging service is being omitted.
[0012] FIG. 1 discloses an exemplary diagram broadly showing various on board components of an automobile control system 100 . The automobile control system 100 may include a GPS hardware 104 to provide location data. A GSM/GPRS hardware 106 is also included in the automobile control system 100 . A security module 108 may also be included to track stolen or lost automobile or to provide security related services to GSM/GPRS hardware 106 .
[0013] In one embodiment, the GPS hardware 104 and the GSM/GPRS hardware 106 may be fabricated inside a same integrated circuit (e.g., in a same chip). In another embodiment, the security module 108 may also be included in the same chip. A controller 102 is provided to control and synchronize operations of the included hardware. In an embodiment, the controller 102 may also be fabricated in the same chip as the GPS hardware 104 and the GSM/GPRS hardware 106 . Alternatively, the controller 102 and the GSM/GPRS hardware 106 may be fabricated in a same chip while the GSM hardware 104 is fabricated in a separate chip.
[0014] The controller 102 includes a processor to execute programming instructions based on pre-set configurations and collected data. The controller 102 may collect messages or data from other system components such as the GPS hardware 104 , the GSM/GPRS hardware 106 , etc. The controller 102 is also coupled to a control system 110 that controls various functions and systems of a machine such as an automobile. In another embodiment, a plurality of control systems may be provided to control or operate different parts and sub-systems of the automobile. For example, a first control system may be provided for the drive train and a second control system may control for the remaining systems such as anti-lock brakes, fuel injection, etc. In one embodiment, the control system 110 and the controller 102 may be combined into one processing unit and may be fabricated together on a same board or alternatively, on the same chip.
[0015] In one embodiment, the control system 110 is connected to one or more sensors and operators 112 that are mounted on or inside the machine. For example, a sensor 112 may be used for sensing coolant temperature and another sensor may be used for monitoring fluid level of a fluid used in the machine. The operators may be used to drive various parts of the machine based on instructions received from the control system 110 . For example, an operator may be used to control fuel injection, another operator may be used to activate anti-lock braking system when instructed by the control system 110 .
[0016] In one embodiment, the GSM/GPRS hardware 106 includes a feature to allow the user of the automobile to insert a smart card (e.g., a SIM card). A smart card is typically used for carrying an identification number unique to a GSM hardware and storing personal data. The operations of the GSM hardware 106 are prevented if the smart card is removed. In another embodiment, in which a CDMA service is used, the GSM hardware 106 may be activated to use the CDMA mobile network using a special identifier associated with the GSM hardware 106 . Once a smart card is inserted and the mobile service is activated, the GSM hardware 106 is able to communicate with other phones via the text messaging service. In one embodiment, the automobile control system 100 may also include an antenna 114 to enable various components to connect with radio waves for the purpose of communicating with external networks and devices.
[0017] In some embodiments, instead of using a separate smart card for the GSM/GPRS hardware 106 , the user may be allowed to couple his phone to the GSM/GPRS hardware 106 using standard communication interfaces such as Bluetooth or Wi-Fi. A connector may also be provided in the car to enable the user to docket his phone to couple the phone to the GSM/GPRS hardware 106 . In these embodiments, the GSM/GPRS hardware 106 uses the identity and network services of the user's phone.
[0018] FIG. 2 illustrates an exemplary flow diagram to illustrate operations of communicating with the automobile control system 100 via text messaging to obtain data (such as diagnostic data) or to send control commands (such as perform diagnostic or turn on/off a system in the machine, turn on/off the machine). Accordingly, at step 200 , the GSM/GPRS hardware 106 receives a request from an external phone or device via text messaging. The received data includes a request for informational or diagnostic data. The informational data may include information such as engine temperature, fluid levels, tire pressure, whether car doors are locked/unlocked, whether doors are open or closed, whether car windows are up or down, fuel in the fuel tank, mileage the car can run in the remaining fuel, position of the car, external temperature, cabin temperature, miles to filter change, miles to brake pads change, etc. It should be noted that the controller 102 may be programmed to provide support for other user defined data depending on the available features of the automobile. The request is limited to 160 characters. For security purposes, the data in the request may be encoded that can be decoded or parsed by the controller 102 .
[0019] At step 202 , the request is passed through the security module 108 to ascertain that the request is originated form an authorized user or device. The controller 102 , with the help of the security module 108 or programmable instructions set in the controller 102 , may execute a pre-configured security rule on the received request to ascertain if the request is from an authorized sender. In one embodiment, however, the controller 102 may be programmed to serve requests for at least some types of data without an authorization check or when the authorization fails. At step 204 , the controller 102 also determines if the request can be served based on the configuration of the controller 102 . In one embodiment, the request may include an identifier to enable the security module 108 to identify the requester. In another embodiment, the phone number of the sender of the request may be used for ascertaining if the request from an authorized source. Alternatively, upon receiving a request, the controller 102 may send a challenge back to the sender via text messaging and if the sender sends back a valid code in response to the challenge code, the controller 102 assumes that the request is from an authorized sender. In another embodiment, in addition to a command, a request may also include a secret code that the controller 102 can match with stored codes of authorized users. If at step 204 , the controller 102 determines that the request cannot be served, at step 206 , based on a configuration, the controller 102 determines if a response shall be sent. For example, if the request includes matter that does not resemble as a command that the controller 102 , a response may not be sent back. At step 210 , for example, if the request does not include at least one keyword that a valid command should include, the controller 102 may not respond to the request. Otherwise, at step 208 , the controller 102 , via the GSM/GPRS hardware 106 , sends a failure message back to the sender.
[0020] Going back, if at step 204 , the controller 102 makes a determination, based on the configuration and programming modules of the controller 102 , at step 212 , the controller 102 queries the control system 110 to retrieve data that is needed for serving the request.
[0021] In one embodiment, a command in the request includes a predefined structure. For example, the request will include a text “GET EXT TEMP” or “GET POSITION” or “PERORM AC ON” or “PERFORM AC OFF”, etc. It should be noted that the controller 102 may be configured to use different keywords and commands as determined by the programmer of the controller 102 .
[0022] In one embodiment, in addition to request data from the controller 102 , a sender of the request may also execute other operations. For example, the exemplary request “RUN DIAG” would instruct the controller 102 to perform predefined diagnostic procedures and return the result back to the sender of the request.
[0023] At step 214 , the controller 102 runs a pre-programmed routine of the received request using the data retrieved form the control system 110 and data available to the controller 102 through a configuration. At step 216 , the controller 102 formats a response to the request and transmits the response back to the sender as a text message via the GSM/GPRS hardware 106 . If the response is more than 160 characters long, the response is broken up into multiple messages, each including less than or equal to 160 characters.
[0024] In one embodiment, if an error is encountered during steps 212 or 214 , the controller 102 sends back a predefined error message including a brief description of the error.
[0025] Going back to step 208 , if the controller 102 determines that the request is invalid, the controller 102 may send a list of valid commands to the sender via one or more text messages. Also, if a sender sends multiple commands in one request or in many requests successively, the controller 102 may provide one single response to all commands.
[0026] The use of the terms “a” and “an” and “the” and similar referents in the context of describing the subject matter (particularly in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. Furthermore, the foregoing description is for the purpose of illustration only, and not for the purpose of limitation, as the scope of protection sought is defined by the claims as set forth hereinafter together with any equivalents thereof entitled to. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illustrate the subject matter and does not pose a limitation on the scope of the subject matter unless otherwise claimed. The use of the term “based on” and other like phrases indicating a condition for bringing about a result, both in the claims and in the written description, is not intended to foreclose any other conditions that bring about that result. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention as claimed. Preferred embodiments are described herein, including the best mode known to the inventor for carrying out the claimed subject matter. Of course, variations of those preferred embodiments will become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventor expects skilled artisans to employ such variations as appropriate, and the inventor intends for the claimed subject matter to be practiced otherwise than as specifically described herein. Accordingly, this claimed subject matter includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed unless otherwise indicated herein or otherwise clearly contradicted by context.
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A system incorporated in a vehicle is disclosed. The system includes a communication system including a text messaging communication hardware to receive a message via a text messaging service. The message includes a command. The system also includes a microcontroller, coupled to the communication system and a machine control system, to execute the command through the machine control system. The machine control system is configured to control components of the vehicle. The microcontroller is configured to determine if a configuration allows execution of the received command and to return a response to the communication system.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from Japanese Patent Application Nos. 2011-197077 filed on Sep. 9, 2011, 2012-176839 filed on August 9, 2012, and 2012-197187 filed on Sep. 7, 2012. The entire contents of the priority applications are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a technology of monitoring a state of an electric storage device.
BACKGROUND OF THE INVENTION
[0003] A battery monitor executes a voltage measurement mode and a sleep mode alternately to reduce power consumption of a secondary battery.
[0004] While the secondary battery is used, the battery monitor that monitors the secondary battery usually receives an actuation signal from a load side and is actuated to be switched from the sleep mode to the voltage measurement mode. Therefore, the battery monitor continuously monitors the state of the secondary battery while the secondary battery is used.
[0005] However, if the secondary battery is separated from the load to be used or an error or a problem occurs in the communication between the secondary battery and the load, the battery monitor cannot receive the actuation signal from the load side. There has been no consideration for dealing with such a case. This kind of problem occurs in other elements than the secondary battery, for example, capacitors.
SUMMARY OF THE INVENTION
[0006] The present technology has been made in view of the above, and it is an object of the technology to deal with a state that a monitor cannot receive an actuation signal from the load side.
[0007] The present invention provides a monitor monitoring an electric storage device that includes a measurement unit, a power supply switch portion, a wakeup timer, and a control unit. The measurement unit is configured to detect a state of the electric storage device and obtain a detected value. The power supply switch portion is configured to switch a power supply state of the monitor between a monitoring state and a low power consumption state that requires lower power than the monitoring state. An actuation time is set to the wakeup timer and the wakeup timer is configured to start counting time in response to switching to the low power consumption state by the power supply switch portion and continue counting time until reaching the setting time and output an actuation signal if reaching the setting time. The power supply switch portion switches the power supply state of the monitor from the low power consumption state to the monitoring state every time the wakeup timer outputs the actuation signal. The control unit is configured to control the measurement unit to detect the state of the electric storage device and obtain the detected value when the power supply state of the monitor is set in the monitoring state by the power supply switch portion. The control unit is further configured to compare the detected value and a reference value and change the actuation time according to a comparison result of the detected value and the reference value.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a block diagram illustrating an electric configuration of a monitor according to a first embodiment;
[0009] FIG. 2 is a flowchart illustrating a flow of processing of an actuation period change sequence;
[0010] FIG. 3 is a graph illustrating an actuation period with which the monitor is actuated if a battery voltage is not changed;
[0011] FIG. 4 is a graph illustrating an actuation period with which the monitor is actuated if the battery voltage is changed;
[0012] FIG. 5 is a flowchart illustrating a flow of processing of an actuation period change sequence according to a second embodiment;
[0013] FIG. 6 is a graph illustrating an actuation period of a monitor;
[0014] FIG. 7 is a graph illustrating charging characteristics of an olivine iron-type lithium-ion secondary battery;
[0015] FIG. 8 is a flowchart illustrating a flow of processing of an actuation period change sequence according to a third embodiment; and
[0016] FIG. 9 is a flowchart illustrating a flow of processing of an actuation period change sequence according to another embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] According to the present technology, if the detected value is changed, the actuation time is also changed. Thus, the monitor may monitor the electric storage device more frequently. Accordingly, it is promptly detected that the electric storage device such as a secondary battery is used in a condition that the monitor cannot receive an actuation signal from the load side. Further, even if the state of the electric storage device such as a secondary battery is changed, it is less likely to occur that the electric storage device is not monitored for a long time. Therefore, the electric storage device is less likely to be in an abnormal state such as an overcharged or over discharged state. In this description, when the detected value changes, it means that the detected value changes from an objective value such as a previous value that is detected prior to a detected value.
First Embodiment
[0018] A first embodiment will be described with reference to FIGS. 1 to 4 .
[0019] A monitor 30 is connected to a secondary battery 10 and integrally provided therewith. The secondary battery 10 is an example of an electric storage device. The monitor 30 monitors a state of the secondary battery 10 , specifically, voltage, temperature, and current values of the battery. As illustrated in FIG. 1 , the monitor 30 includes a CPU 31 , a clock signal oscillator 33 , a wakeup timer 35 , a watchdog timer 37 , a measurement unit 41 , an A/D converter 43 , a RAM 45 , a ROM 47 , and a communication interface 49 and a power supply switch portion 51 . The CPU 31 is an example of a control unit and the RAM 45 is an example of a memory.
[0020] The measurement unit 41 detects voltage (inter-terminal voltage), temperature, and current values of the secondary battery 10 . The A/D converter 43 converts detected values of the voltage, the temperature, and the current of the secondary battery 10 into digital values and outputs them to the CPU 31 . The CPU 31 receives information such as the voltage and the current of the secondary battery 10 via the A/D converter 43 and analyzes them to monitor the state of the secondary battery 10 and check if the battery is in an abnormal state or not. The RAM 45 is used as a working memory of the CPU 31 and the RAM 45 stores the detected values. The ROM 47 stores a program that performs an actuation period change sequence and data necessary for various calculations.
[0021] The power supply switch portion 51 receives an internal actuation signal S 1 , a sleep signal Sa and an external actuation signal Sb. Upon receiving one of the signals, the power supply switch portion 51 switches a power supply state of the monitor 30 between a monitoring state and a sleep state. The sleep state is an example of a low power consumption state. The monitor 30 has two modes including a measurement mode and a sleep mode that is a low power consumption mode. In the measurement mode, the power supply state of the monitor 30 is maintained in the monitoring state and the monitor 30 detects the voltage, temperature, and current values of the secondary battery 10 to continuously monitor the state of the battery and power is supplied to all components of the monitor 30 .
[0022] In the sleep mode, the monitor 30 is set to alternately in the monitoring state and the sleep state. In the sleep state, the monitor 30 is in a standby state. In the sleep mode, the power supply switch portion 51 temporally switches the power supply state of the monitor 30 from the sleep state to the monitoring state every actuation period T the power supply switch portion 51 receives the internal actuation signal S 1 from the wakeup timer 35 . The monitor 30 monitors the state of the battery only in the monitoring state, and thereafter, the monitor 30 is switched to be in the sleep state. The wakeup timer 35 counts time and if the time counted by the wakeup timer 35 reaches the actuation period T, the wakeup timer 35 outputs the internal actuation signal S 1 to the power supply switch portion 51 . Accordingly, the monitor 30 is switched from the sleep state to the monitoring state with the certain actuation period T. In the monitoring state, the measurement unit 41 of the monitor 30 detects a voltage, a current, and a temperature of the secondary battery 10 .
[0023] In the sleep state, only the clock signal oscillator 33 , the wakeup timer 35 , the communication interface 49 , and the power supply switch portion of the monitor 30 are supplied with power and supply of power to the other components is stopped, thereby reducing power consumption in the secondary battery 10 . The monitor 30 is supplied with power from the secondary battery 10 and therefore, if the monitor 30 is in the sleep state, the consumption power in the secondary battery 10 can be reduced.
[0024] The monitor 30 is switched between the measurement mode and the sleep mode according to two control signals including the sleep signal Sa and the external actuation signal Sb output from a control system of the load side. In a case that the secondary battery 10 is mounted to a vehicle, a vehicle-mounted ECU selectively outputs one of the two control signals Sa, Sb. If the secondary battery 10 is not used for a certain time period and the battery 10 is not required to be charged, the control system of the load side detects conditions for switching the monitor 30 to the sleep mode and determines that the monitor 30 is to be switched to the sleep mode. In such a case, the control system of the load side outputs the sleep signal Sa to the monitor 30 and the CPU 31 of the monitor 30 receives the sleep signal Sa via the communication interface 49 . Accordingly, the monitor 30 is switched to be in the sleep mode. Namely, the state of the battery 10 is basically not changed while the monitor 30 is in the sleep mode.
[0025] The load-side control system outputs the external actuation signal Sb to the monitor 30 to use the battery 10 and the monitor 30 receives the external actuation signal Sb via the communication interface 49 . Accordingly, the monitor 30 is switched to be in the measurement mode. Therefore, if the monitor 30 is properly connected to the load and can receive the external actuation signal Sb from the load, the monitor 30 monitors the state of the secondary battery 10 that is being used.
[0026] However, if the secondary battery 10 is separated from the load to be used or an error or a problem occurs in the communication between the monitor 30 and the load side, the monitor 30 does not receive the external actuation signal Sb from the load side. Therefore, the monitor 30 remains in the sleep mode and monitors the battery repeatedly with the certain period. If the secondary battery 10 is charged improperly, the battery 10 maybe in an abnormal state such as overcharge or over discharge during a period between a current monitoring and a subsequent monitoring.
[0027] In the present embodiment, if determining that a current detected battery voltage of the secondary battery 10 is changed from a previous detected battery voltage in the sleep mode, the monitor 30 changes the actuation period T. Specifically, in response to such determination, the CPU 31 shortens the actuation period T so that the monitor 30 monitors the secondary battery 10 more frequently with a shorter period. Accordingly, it can be detected promptly that the secondary battery 10 is used in a condition that the monitor 30 cannot receive the external actuation signal Sb from the load side. Further, the voltage of the secondary battery 10 does not reach the prohibited level.
[0028] An actuation period change sequence will be explained with reference to FIG. 2 . In the actuation period change sequence, the actuation period T of the monitor 30 is changed. It is assumed that the secondary battery 10 , the charger 20 , the relay R, and the monitor 30 are mounted to the load side and a time set to the wakeup timer 35 , that is, the initial value of the actuation period T is 60 seconds, for example. A number of continuous changes K that will be described later is zero.
[0029] The actuation period change sequence starts in response to detection of conditions for switching the monitor 30 from the measurement mode to the sleep mode and output of the sleep signal Sa from the load side to the monitor 30 .
[0030] If the CPU 31 receives the sleep signal Sa, the monitor 30 is switched to the sleep mode and set to be in the sleep state that reduces consumption power. In the sleep mode, only the clock signal oscillator 33 , the wakeup timer 35 , the communication interface 49 , and the power supply switch portion 51 are supplied with power to be operated and supply of power to the other components is stopped (S 10 ).
[0031] After the monitor 30 is switched to the sleep state, the wakeup timer 35 starts counting time and detects whether the counted time reaches the set time. If the time counted by the wakeup timer 35 reaches the set time (S 20 ), the wakeup timer 35 outputs the internal actuation signal S 1 to the power supply switch portion 51 . The initial value of the set time is 60 seconds. If 60 seconds passes after the monitor 30 becomes in the sleep state, the wakeup timer 35 outputs the internal actuation signal S 1 to the power supply switch portion 51 .
[0032] If receiving the internal actuation signal S 1 , the power supply switch portion 51 supplies power to each component of the monitor 30 to actuate the monitor 30 (S 20 , S 30 ). Then, the measurement unit 41 detects voltage, temperature, and current values of the secondary battery 10 (S 40 ).
[0033] The values detected by the measurement unit 41 are converted into digital values by the A/D converter 43 and transferred to the CPU 31 and stored in the RAM 45 (S 40 ). The CPU 31 determines whether the current detected value changes (S 50 ). Specifically, the CPU 31 compares the current detected value and a previous detected value stored in the RAM 45 and determines whether the current detected value of the secondary battery 10 changes from the previous detected value (S 50 ). If the current detected voltage of the secondary battery 10 changes from the previous detected voltage by at least a predetermined value (for example, 0.05 V), it is preferably determined that the detected battery value is changed. Accordingly, it is not erroneously determined that the battery value is changed according to very small change in the battery voltage that may be caused due to a situation or an environment in which the monitor 30 is used. Such a very small change in the battery voltage may be caused even if improper charging is not executed.
[0034] No previous detected value is stored in the RAM 45 in the first determination just after the monitor 30 is switched to the sleep mode. Therefore, the detected value that is most recently detected in the measurement mode immediately before the monitor 30 is switched to the sleep mode is used as the previous detected value. If the CPU 31 determines that the current detected value does not change from the previous detected value (S 50 ), the process proceeds to S 70 .
[0035] In S 70 , the set time of the wakeup timer 35 is maintained to be the initial value. Then, the process returns to S 10 and the monitor 30 is switched to the sleep state again. Then, if the wakeup timer 35 determines that the counted time reaches the set time, the timer 35 outputs the internal actuation signal S 1 to the power supply switch portion 51 and accordingly, the monitor 30 is actuated (S 20 , S 30 ).
[0036] In such a manner, the monitor 30 is actuated and detects the voltage, temperature, and current values of the secondary battery 10 . If no change is detected in voltage of the secondary battery 10 , a negative decision (NO) is made in S 50 and the number of continuous changes K is set to be zero (S 60 ). Therefore, the set time of the wakeup timer 35 is maintained to be the initial value (S 70 ).
[0037] Therefore, as long as the detected value of the battery voltage is not changed from the previous detected value, the monitor 30 is repeatedly actuated to monitor the state of the secondary battery 10 at the initial interval as illustrated in FIG. 3 .
[0038] The secondary battery 10 , the charger 20 , the relay R and the monitor 30 may be removed and separated from the load, and the secondary battery 10 may be charged with power supplied from an external device or may be charged by a charger other than the built-in charger 20 . In such a case, even if the monitor 30 is in the sleep mode, the voltage of the secondary battery 10 rises as illustrated in FIG. 4 and it is determined that the current detected voltage is changed from the previous detected voltage in S 50 . Accordingly, the number of continuous changes K is increased by one (S 80 ), and it is determined that the increased number of continuous changes K is less than a threshold number of changes Kth (for example two) in S 90 . Further, it is determined that the current detected value is equal to or less than the threshold voltage Vth (S 100 : No). Then, the CPU 31 changes the set time of the wakeup timer 35 to a first change value (for example, 30 seconds) and shortens the actuation period T of the monitor 30 in S 110 . For example, as illustrated in FIG. 4 , the CPU 31 changes the set time of the wakeup timer 35 from 60 seconds to 30 seconds and changes the actuation period T of the monitor 30 from the initial value of 60 seconds to 30 seconds.
[0039] After changing the actuation period T to the first change value, the monitor 30 is actuated at an interval of the first change value in subsequent monitoring. After changing the actuation period T, the process returns to S 10 . Then, the process proceeds to S 20 , S 30 and S 40 and if it is determined that the battery voltage does not change (S 50 : No), the CPU 31 resets the number of continuous changes K to be zero (S 60 ) and also resets the set time period of the wakeup timer 35 to the initial value (S 70 ). If it is again determined that the current battery voltage changes from the previous detected value (S 50 : Yes), and it is determined that the current detected value detected in S 40 is equal to or less than the threshold voltage Vth (S 100 : No), the CPU 31 does not change the set time of the wakeup timer 35 and keeps the first change value (S 110 ). The threshold voltage Vth is preferably close to the full charge voltage of the secondary battery 10 .
[0040] If the battery voltage of the secondary battery 10 continuously changes with respect to a time axis as illustrated in FIG. 4 , for example proportionally, the monitor 30 is repeatedly actuated at an interval of 30 seconds to monitor the secondary battery 10 .
[0041] If the detected battery voltage changes consecutively several times, the CPU 31 determines that the secondary battery 10 is used in condition where the monitor cannot receive the external actuation signal Sb from the load side. If determining that the number of continuous changes K is over the threshold number Kth (S 90 : No), the CPU 31 changes the set time of the wakeup timer 35 to be a second change value that is shorter than the first change value (for example, 20 seconds) in S 120 . Accordingly, the actuation period T of the monitor 30 is further shortened. Therefore, the voltage is detected for several times at a shortened actuation period T. This reduces time required to determine that the secondary battery 10 is used in an improper state.
[0042] In the present embodiment, the actuation period T is changed to be shortened if the secondary battery 10 is improperly used. Therefore, compared to a case where the actuation period T of the monitor 30 is not changed from the initial value even if the secondary battery 10 is improperly used, it is promptly detected that the secondary battery 10 is used in an improper state that the monitor 30 cannot receive the external actuation signal Sb from the load side. If detecting that the secondary battery 10 is used in an improper condition that the monitor 30 cannot receive the external actuation signal Sb from the load side, the CPU 31 of the monitor 30 performs an informing process that informs an error using an error notification lamp or a buzzer for example (S 130 ).
[0043] If the actuation period T is kept to be long, the secondary battery 10 is not monitored by the monitor 30 for a long time. Thus, if the secondary battery 10 is charged for a long time without monitoring and the battery voltage reaches a prohibited level, overcharge or over discharge may be caused in the secondary battery 10 and the secondary battery 10 may become in an abnormal state. However, in the present embodiment, the actuation period T of the monitor 30 is shortened and this shortens a monitoring interval of the secondary battery 10 . Therefore, the CPU 31 may disconnect the relay R (S 130 ) to stop charging before the secondary battery 10 is overcharged. Therefore, the secondary battery 10 is not overcharged.
[0044] In determining that the number of continuous changes K is less than the threshold number Kth (S 90 : Yes) and determining that the current detected value that is detected in S 40 is greater than the threshold voltage Vth (S 100 : Yes), the CPU 31 changes the set time of the wakeup timer 35 to the second change value (S 120 ). Accordingly, as illustrated in FIG. 4 , the CPU 31 may further shorten the actuation period T of the monitor 30 , and the secondary battery 10 is not overcharged.
Second Embodiment
[0045] Next, a second embodiment will be described with reference to FIGS. 5 to 7 . In the first embodiment, the voltage of the secondary battery 10 proportionally changes with respect to the time axis and changes the actuation period T of the monitor 30 from 60 seconds to 30 seconds.
[0046] In the second embodiment, the CPU 31 compares the current detected voltage and the previous detected voltage and obtains a change amount of the battery voltage every time determining that the current voltage changes from the previous voltage. Specifically, if determining that the current detected voltage changes from the previous detected voltage (S 50 : Yes), the CPU 31 computes a change amount between the previous detected voltage and the current detected voltage (S 210 ). As the change amount becomes greater, the CPU 31 changes the set time of the wakeup timer 35 to be a shorter value (S 220 ). Accordingly, the greater the change amount of the detected battery voltage values is, the shorter the actuation period T becomes. For example, if the battery voltage changes along a substantially quadratic curve with respect to the time axis as illustrated in FIG. 6 , the actuation period T of the monitor 30 is changed to be shorter as time passes.
[0047] In the second embodiment, if the change amount of the battery voltages becomes larger and the current detected voltage is close to the full-charge voltage, the actuation period T is further shortened. Therefore, the monitor 30 monitors the secondary battery 10 more frequently. Therefore, the secondary battery 10 is not overcharged. An olivine-type lithium-ion iron second battery has characteristics as illustrated in FIG. 6 , and in the olivine-type lithium-ion iron second battery, the voltage rises drastically at a terminal stage of charging. The olivine-type iron battery is a kind of lithium-ion batteries and has a positive electrode made of olivine-type iron phosphate, that is, lithium iron phosphate (LiFePO4) and a negative electrode made of, for example, carbon. The olivine-type lithium-ion iron secondary battery has a full-charge voltage of about 3.5 V as illustrated in FIG. 7 . Therefore, if the olivine-type lithium-ion iron secondary battery is set such that the voltage drastically rises in a range between 3.45 V and 3.5 V that is close to the full-charge voltage, the actuation period T is also shortened at the voltage between 3.45 V and 3.5 V. Accordingly, the olivine-type lithium-ion iron secondary battery 10 can be monitored more frequently at the voltage close to the full-charge voltage. Therefore, the olivine-type lithium-ion iron secondary battery is not overcharged.
Third Embodiment
[0048] Next, a third embodiment will be described with reference to FIG. 8 . An actuation period change sequence of the third embodiment is substantially same as the sequence of the second embodiment including steps S 10 to S 220 and additionally includes processing of S 3 and S 5 in FIG. 7 . Therefore, the processing of S 3 and S 5 will be explained.
[0049] As shown in FIG. 8 , in the third embodiment, if the CPU 31 detects that the conditions for switching the monitor 30 to the sleep mode are satisfied and receives the sleep signal Sa output from the load side, the CPU 31 of the monitor 30 determines whether the most recent battery voltage of the secondary battery 10 detected in the measurement mode is close to a full-charge voltage or not (S 3 ). Specifically, the CPU 31 compares the most recent battery voltage to a threshold voltage Vth that is previously set (a value close to the full-charge voltage). If determining that the most recent battery voltage is higher than the threshold voltage Vth, the CPU 31 determines that the most recent battery voltage is close to the full-charge voltage (S 3 : Yes). If determining that the most recent battery voltage is less than the threshold voltage, the CPU 31 determines that the most recent battery voltage Vth is not close to the full-charge voltage (S 3 : No).
[0050] If the CPU 31 determines that the most recent battery voltage is not close to the full-charge voltage (NO: S 3 ), the process proceeds to S 10 . Processing executed after S 10 is same as that in the second embodiment. In the sleep state, if the detected voltage of the secondary battery 10 is not changed from the previous detected value (S 50 : No), the monitor 30 is actuated with an actuation period T of 60 seconds to monitor the secondary battery 10 (S 70 ). If the current detected voltage is changed from the previous detected value (S 50 : Yes), the actuation period T is changed (S 60 ).
[0051] Next, if the CPU 31 determines that the most recent battery voltage is close to the full-charge voltage (YES: S 3 ), the process proceeds to S 5 . In S 5 , the CPU 31 changes the set time of the wakeup timer 35 to a time shorter than an initial value. The initial value of the set time of the wakeup timer 35 is 60 seconds, and the set time is changed to a time shorter than that. For example, 30 seconds is set to the wakeup timer 35 in S 5 . Accordingly, immediately after being switched to the sleep mode, the monitor 30 is actuated with an actuation period T that is shorter than the initial setting and monitors the secondary battery 10 .
[0052] In such a manner, if the voltage of the secondary battery 10 is close to the full-charge voltage before the monitor 30 being switched from the measurement mode to the sleep mode, the actuation period T of the monitor 30 is set to a small value. Therefore, the secondary battery is not overcharged.
Other Embodiments
[0053] The present invention is not limited to the above description and the drawings. For example, the following embodiments are covered by the technological scope of the invention.
[0054] (1) In the above embodiments, the monitor 30 monitors the state of the secondary battery 10 . However, the target to be monitored by the monitor 30 is necessarily a storage element (electricity storing element), and the state of a capacitor may be monitored by the monitor 30 . Further, in the above embodiments, the control device is the CPU 31 . However, the control device may be a hardware circuit.
[0055] (2) In the above embodiments, if the voltage of the secondary battery 10 is changed from the previous detected value, the actuation period T of the monitor 30 is changed. For example, the CPU 31 may detect a temperature of the secondary battery 10 and determine whether the detected temperature of the secondary battery 10 is changed from the previous detected value. If determining that the detected temperature is changed from the previous value, the CPU 31 may change the actuation period T of the monitor 30 .
[0056] Besides the battery temperature, the information denoting the state of the secondary battery 10 may include any information from which the CPU 31 can detect the possibility of occurring abnormality of the battery such as a state of charge (SOC), a current value, or an internal pressure of the battery.
[0057] A current of the secondary battery 10 may be detected to detect the state of the battery 10 . A dark current dissipated by the battery 10 while a vehicle being parked may be detected to determine whether the actuation period T may be changed or not. Specifically, in a system in which the dark current dissipated by the secondary battery 10 while a vehicle being parked is 100 mA or less, if determining that the dark current is a normal value and is less than 100 mA, the CPU 31 sets the actuation period T of the monitor 30 to 60 seconds that is an initial value.
[0058] If determining that the dark current is 100 mA or higher, the CPU 31 may change the actuation period T of the monitor 30 from 60 seconds to 30 seconds or may shorten the actuation period T in a stepwise manner according to the level of the dark current. For example, in the secondary battery 10 having a capacity of 60 Ah, the actuation period T is changed according to the level of the dark current as follows. If the dark current is from 100 mA to 0.1 CA (6A), the actuation period T is set to 30 seconds. If the dark current is from 0.1 CA (6A) to 0.5 CA (30A), the actuation period T is set to 20 seconds. If the dark current is 0.5 CA (30A) or greater, the actuation period T is set to 10 seconds.
[0059] The actuation period T may be determined based on a plurality of detected values. For example, a current and a battery voltage may be detected and the CPU 31 may detect whether each of the values of the current and the battery voltage is equal to or greater than a corresponding certain level. If both of the detected values of the current and the battery voltage are the certain level or greater, the actuation period T may be further shortened as compared to a case in which only one of them is greater than the corresponding certain level. In such a case, the measurement unit 41 is a current sensor that detects a current flowing through the secondary battery 10 , and a current is detected by the current sensor and the detected value corresponds to a detected current.
[0060] (3) In the above embodiments, the actuation period T of the monitor 30 is changed if the detected value of the secondary battery 10 is changed from the previous detected value. The target value to be compared with the current detected value of the secondary battery 10 may be a value that is detected prior to the last value that is detected at last or a reference value that is previously stored in the RAM 45 . Therefore, if the current detected value of the secondary battery 10 is changed from the value detected prior to the last value or the reference value, the actuation period T of the monitor 30 maybe changed.
[0061] (4) In the above embodiments, the voltage of the secondary battery 10 is increased from the previous detected value (charging). However, the voltage of the secondary battery 10 may be decreased from the previous detected value (discharging). Also in the case where the voltage of the secondary battery 10 is decreased from the previous detected value, the actuation period T may be shortened to shorten the monitoring interval at which the monitor 30 is monitored.
[0062] (5) In the above embodiments, the monitor 30 is switched from the measurement mode to the sleep mode if the CPU 31 of the monitor 30 receives the sleep signal Sa output from the side of load. However, the monitor 30 may detect the conditions for switching to the sleep mode without receiving any signal from the external device and if detecting the conditions, the monitor 30 may be switched to the sleep mode.
[0063] (6) In the above embodiments, each of the sleep signal Sa and the external actuation signal Sb is an independent signal. However, the two signals Sa and Sb may be configured with a single signal. The single signal may be set to a high level or a low level to control switching the mode of the monitor 30 .
[0064] (7) In the above embodiments, the actuation period T of the monitor 30 is changed if the voltage of the secondary battery 10 is changed from the previous detected value. In addition to this, the CPU 31 may further detects if a current is flowing through the secondary battery 10 to determine whether to change the actuation period T or not. The CPU 31 changes the actuation period T of the monitor 30 if detecting that the current detected voltage of the secondary battery 10 is changed from the previous detected value and a current is flowing through the secondary battery 10 .
[0065] Accordingly, the following effects are obtained. Generally, the battery voltage changes for a while after completion of charging or discharging. Therefore, if the actuation period T is changed only based on a change in the battery voltage, the actuation period T may be changed even in an ordinary state where the battery is not charged improperly. However, if the actuation period is changed based on a change in the battery voltage and detection that the current is flowing through the battery, the actuation period T is not changed in the ordinary state. Thus, the actuation period T is changed only when the battery is used (charged) improperly.
[0066] (8) In the second embodiment, the larger the change amount of the measured battery voltage value is, the more the actuation period T is shortened. The actuation period T may be changed in any other methods according to the change amount of the detected value. For example, the actuation period T of the monitor 30 may be changed in accordance with any one of the following patterns.
[0067] As illustrated in FIG. 7 , in the olivine-type lithium ion iron secondary battery, the full-charge voltage is about 3.5 V, and the battery is preferably used with the charged voltage being between 3.3 V and 3.5 V. In this case, a range of use E of the battery is 200 mV from 3.3 V to 3.5 V and the battery can be preferably used in this range, and 10% thereof is 20 mV. If the detected value is not changed from the previous value and the actuation period T is set to the initial value of 60 seconds, the actuation period T may be changed in the following methods.
[0068] Pattern 1: If the detected value is changed from the previous detected value by 20 mV that is 10% of the range of use, the actuation period T is changed from 60 seconds to 30 seconds that is a half of the initial value.
[0069] Pattern 2: If the detected value is changed from the previous detected value by 40 mV that is 20% of the range of use, the actuation period T is changed from 60 seconds to 15 seconds that is a quarter of the initial value.
[0070] Pattern 3: If the detected value is changed from the previous detected value by 20 mV and the actuation period T is changed from the initial value of 60 seconds to 30 seconds and then the subsequent detected value is changed from the previous value by 40 mV, the actuation period T is changed from 30 seconds to 15 seconds that is a half of 30 seconds. If the detected value is changed by the change amount same as the previous change amount of 20 mV, the actuation period T is not changed and maintained to be 30 seconds.
[0071] The actuation period T may be changed by multiplying the actuation period T by a constant (½ or ¼) corresponding to the change amount of the detected value as described above, and further, the actuation period T may be changed by subtracting a constant (20 seconds or 40 seconds) that is determined corresponding to the change amount of the detected value from the current actuation period T.
[0072] (9) In the above embodiments, the actuation period T of the monitor 30 is changed if the battery voltage of the secondary battery 10 is changed from the previous detected value. However, the actuation period T may be changed if the CPU 31 detects that the battery voltage of the secondary battery 10 is not changed from the previous detected value or a reference value.
[0073] Specifically, if the current detected value is not changed from the previous detected value, it is unlikely that the secondary battery 10 is used improperly. Thus, even if the actuation period of the monitor 30 is extended, it is unlikely that any error is caused in the secondary battery 10 . The actuation period T is 60 seconds that is the initial value and if the current detected value is not changed from the previous value, the actuation period T may preferably be set to 90 seconds or 120 seconds that is longer than the initial value. The actuation period T becomes longer and this reduces the power consumption of the monitor 30 .
[0074] The actuation period T maybe changed if the battery voltage of the secondary battery 10 is not changed from the previous detected value or the reference value, and also the actuation period T may be changed if the current detected value is changed from the previous detected value.
[0075] As illustrated in FIG. 9 , if determining that the current detected voltage changes (S 50 : Yes), the CPU 31 computes a change amount between the previous detected value and the current detected value (S 210 ), and the CPU 31 changes the set time of the wakeup timer 35 to be a shorter value as the computed change amount is greater (S 220 ). If determining that the current detected voltage does not change (s 50 : No), the CPU 31 may change the set time of the wakeup timer 35 to be a value that is longer than the initial value.
[0076] According to the present technology, the monitor can deal with a case that the monitor cannot receive an actuation signal from the load side.
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An electric storage device monitor includes a measurement unit detecting and obtaining a detected value, a power supply switch portion switching a power supply state of the monitor between a monitoring state and a low power consumption state, a wakeup timer to which an actuation time is set and starting counting time in response to switching to the low power consumption state and continuing counting time and outputting an actuation signal if reaching the actuation time, and a control unit. The switch portion switches from the low power consumption state to the monitoring state every time the wakeup timer outputs the actuation signal. The control unit controls the measurement unit to detect and obtain the detected value in the monitoring state, compares the detected value and a reference value, and changes the actuation time according to a comparison result of the detected value and the reference value.
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BACKGROUND OF THE INVENTION
[0001] Field of the Invention
[0002] This invention relates to a device and a method for installing a sink.
[0003] Background—Prior Art
[0004] Sinks are in almost every single home and building that have been constructed in the last hundred years. There are an almost infinite number of different types of sinks. One type of a very common and popular sink is an under-mounted sink. Under-mounted sinks are installed below the countertop surface. The edge of the countertop material is exposed where a hole has been created for the sink. The under-mounted sink is then attached to the underside of the countertop or the cabinet.
[0005] Installing under-mounted sinks is extremely difficult. When a typical sink is installed, its rim rests on top of the countertop. This allows the installer to make small adjustments to the location of the sink and then glue or attach the sink to the countertop or cabinet. With under-mounted sinks, the rim of the sink is under the countertop. Thus, the under-mounted sink has nothing to support it when it is first installed. The installation of an under-mounted sink generally requires two installers.
[0006] To install an under-mounted sink, first an adhesive is generally placed on the rim of the under-mounted sink. Next, one installer is required to hold the sink in place, while the second installer clamps the sink on to the countertop or cabinet. Once the sink is clamped, the installers can only make minor adjustments to the location of the sink. If the installers fail to place the under-mounted sink in the correct position, or if they need to make adjustments, the clamps must be completely removed and the installers must start over again. If the adhesive is dry, the adhesive must be removed before an attempt is made to reset the under-mounted sink. The other option is to simply replace the sink. Both options are very costly and time-consuming. Once the sink is in the correct position, a silicone-based sealant is usually used to ensure a waterproof joint between the sink and the countertop material.
[0007] The previously described method of installing an under-mounted sink has several limitations. The method is extremely labor-intensive and takes two installers. Once the sink is set, only minor adjustments can be made to the sink's location. Making major adjustments requires resetting the sink, which is even more labor-intensive. If the sink is not correctly installed, the sink and the countertop may need to be completely replaced. In addition, if the sink is not correctly installed, the junction between the countertop and the under-mounted sink may leak.
[0008] While there have been some attempts to resolve these issues, the prior systems are very costly, complicated, and large. There remains a need for a device that reduces the labor time needed to install an under-mounted sink and that only requires a single installer. In addition, the device should allow the installer to make both minor and large adjustments to the sink's position quickly and easily. Furthermore, the device must be easily storable. Such a device would decrease the cost of under-mounted sinks while also increasing the quality of the installation.
SUMMARY OF THE INVENTION
[0009] The invention is a sink clamp that utilizes a quick bar clamp, a sink hook, and a countertop support bar. The quick bar clamp is comprised of a slide bar and a bar clamp. The bar clamp is attached to the countertop support bar. The sink hook is attached to the end of the slide bar.
[0010] In operation, the sink hook and a portion of the slide bar are slotted through the drain opening in a sink. The countertop support bar rests on top of a countertop. When an installer activates the bar clamp, the slide bar moves through the bar clamp. The movement of the slide bar causes the sink to raise toward the underside of the countertop.
[0011] Another aspect of the invention is that the device can be easily switched from a storage configuration to an operational configuration. In a storage configuration, the countertop support bar and the sink hook run parallel to the slide bar. In an operational configuration, the countertop support bar and the sink hook are perpendicular to the slide bar.
DESCRIPTION OF THE DRAWINGS
[0012] The invention may take form in certain parts and in the arrangement of parts, the preferred embodiment of which will be described in detail in the specification and illustrated in the accompanying drawing, which for a part hereof:
[0013] FIG. 1 shows a prospective side view illustrating a sink clamp positioned on a countertop with the sink clamp holding a sink in an installed position;
[0014] FIG. 2 shows a prospective side view of the sink clamp with the countertop support bar at a slight angle from the slide bar, illustrating the pivot point of the sink clamp;
[0015] FIG. 3 shows a prospective top view of the sink clamp positioned on a countertop, with the sink clamp holding a sink in an installation position to be installed;
[0016] FIG. 4 shows a side view of the sink clamp in the operational position, with the slide bar perpendicular to the countertop support bar and the sink clamp opened;
[0017] FIG. 5 shows a prospective side view of the sink clamp in the standby position;
[0018] FIG. 6 shows a cross-section of the sink clamp, sink, and countertop;
[0019] FIG. 7 shows a prospective side view of the sink clamp in the operational position, with the slide bar perpendicular to the countertop support bar and the sink clamp opened; and
[0020] FIG. 8 shows a prospective side view illustrating the sink clamp positioned on a countertop, with the sink clamp holding a sink in position to be installed, with a gap between the sink and the countertop. In this position, an installer can easily make adjustments to the location of the sink.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] The following discussion describes embodiments of the invention and several variations of these embodiments. This discussion should not be construed, however, as limiting the invention to these particular embodiments. Practitioners skilled in the art will recognize numerous other embodiments as well. It is not necessary that the device have all the features described below with regard to the specific embodiment of the invention shown in the figures.
[0022] In the following description of the invention, certain terminology is used for the purpose of reference only, and is not intended to be limiting. Terms such as “upper,” “lower,” “above,” and “below” refer to directions in the drawings to which reference is made. Terms such as “inward” and “outward” refer to directions toward and away from, respectively, the geometric center of the component described. Terms such as “side,” “top,” “bottom,” “horizontal,” and “vertical” describe the orientation of portions of the component within a consistent but arbitrary frame of reference, which is made clear by reference to the text and the associated drawings describing the component under discussion. Such terminology includes words specifically mentioned above, derivatives thereof, and words of similar import.
[0023] Referring generally to FIG. 1 and FIG. 8 is a clamp 2 , embodying features of the present invention comprising a slide bar 20 , a clamp arm 16 , a sink hook 10 , and a countertop support bar 8 . The clamp arm 16 is moveable and stationary, connected to the slide bar 20 . The countertop support bar 8 is pivotally attached to the clamp arm 16 , as described in more detail below. The sink hook 10 is attached to the slide bar 20 .
[0024] The slide bar 20 and the clamp arm 16 are a standard quick bar clamp. However, it is understood that the invention may be employed in any number of bar clamps without departing from the principles of the present invention. The slide bar 20 passes through the clamp arm 16 , such that a user may cause the clamp arm 16 to move along the longitudinal axis on the slide bar 20 . When not engaged by a user, the clamp arm 16 is stationary and connected to the slide bar 20 . The clamp arm 16 comprises a grip 24 , a drive handle 22 , and a clamp support 28 . When a force is applied to the drive handle 22 , the slide bar 20 moves along through the clamp arm 16 . Generally, the force is created by a user's hand. Standard quick bar clamps are known for having enormous force.
[0025] As shown in FIG. 2 and FIG. 4 , the clamp arm 16 is connected to the countertop support bar 8 . The clamp arm 16 and countertop support bar 8 are connected by a pivot 26 . The pivot 26 acts as a hinge connection, such that the clamp arm 16 and the countertop support bar 8 are allowed to rotate so that when the clamp 2 is in the operational position, the longitudinal axis of the clamp arm 16 is at an approximate ninety-degree angle from the longitudinal axis of the slide bar 20 . When the clamp 2 is in the storage position, the longitudinal axis of the clamp arm 16 and the longitudinal axis of the slide bar 20 are approximately parallel. When the clamp 2 is in the operational position and the clamp arm 16 exerts a force against the pivot 26 , this prevents the movement of the pivot 26 .
[0026] To provide additional support for the pivot 26 , a pivot block 32 is located between the clamp support 28 and the countertop support bar 8 . The pivot block 32 allows the force from the clamp arm 16 to be transferred to the countertop support bar 8 so that when the clamp arm 16 applies a force to the countertop support bar 8 , the pivot block 32 aids in transferring the force to the countertop support bar 8 .
[0027] The slide bar 20 has a first end 50 and a second end 52 . Located at the first end 50 is a bar stop 30 . The bar stop 30 prevents the clamp arm 16 from sliding off the slide bar 20 . The second end 52 is located on the opposite end of the longitudinal axis of the slide bar 20 . Located near the second end 52 is the sink hook 10 . However, the sink hook 10 may be located anywhere along the slide bar 20 . In order to reinforce the slide bar 20 , a slide bar support 38 is located at the same location as the sink hook 10 . The slide bar support 38 is made of a material that can withstand a considerable tension force. The slide bar support 38 allows for the diameter of the slide bar 20 to be reduced. As described in detail below, when the sink hook 10 is in the storage position, the sink hook 10 can fold into the slide bar support 38 . This configuration reduces the overall size of the second end 52 and sink hook 10 . It also provides the additional strength needed to support a sink 6 .
[0028] As shown in FIG. 2 , the length of the countertop support bar 8 is generally longer than a typical sink opening 54 . Generally, the overall length of the countertop support bar 8 is between one to five feet long. As illustrated in FIG. 2 , to reinforce the countertop support bar 8 , a flange 34 runs along the longitudinal axis of the countertop support bar 8 . In practice, there are two flanges 34 on each side of the countertop support bar 8 . To reduce the weight of the countertop support bar 8 and to allow the clamp arm 16 to travel through the countertop support bar 8 , there is at least one slot 14 . The length and size of the slot 14 may vary. As shown in FIG. 2 , the width and the length of the slot 14 must be large enough to allow for the clamp arm 16 to travel through the countertop support bar 8 . The countertop support bar 8 is made from any ridged material that can support the weight of a sink and withstand the forces applied by the clamp arm 16 . In practice, the clamp arm 16 is manufactured from steel or aluminum. To prevent scratching a countertop 4 or cabinet, a rubber pad (not shown) may be placed between the countertop support bar 8 and the countertop 4 .
[0029] As shown in FIGS. 4 and 7 , the sink hook 10 is located along the slide bar 20 . Generally, the sink hook 10 would be located at the second end 52 . The sink hook 10 is attached to the slide bar 20 with a sink hook hinge 36 connection. The sink hook hinge 36 allows the sink hook 10 to rotate to be either perpendicular or parallel to the slide bar 20 . When the sink hook 10 and the slide bar 20 are inserted into a drain opening 37 (generally located at the base of the sink 6 ), the sink hook 10 is parallel to the slide bar 20 . Once the sink hook 10 and the slide bar 20 are inserted into the drain opening 37 , the sink hook 10 is rotated such that the sink hook 10 is perpendicular to the slide bar 20 . This configuration allows the clamp 2 to hold the sink 6 . A detent device (not shown) may be located to prevent the sink hook 10 from rotating freely.
[0030] To prevent damage to the sink 6 and to prevent the users from inserting the slide bar 20 too far into the drain opening 37 , a guild block 12 is located near the second end 52 above the sink hook 10 . In practice, the guild block 12 would be located approximately one to eight inches above the sink hook 10 .
[0031] As shown in FIG. 2 and FIG. 7 , the sink hook 10 has a U-shape. As shown in FIG. 5 , the U-shape configuration allows the sink hook 10 to fold around the slide bar 20 and the slide bar support 38 . This reduces the overall bulk of the clamp 2 . As described above, the configuration allows the user to easily insert the sink hook 10 and slide bar 20 into the drain opening 37 . When the sink hook 10 is through the drain opening 37 and in the operational position, the sink hook 10 has a cantilever configuration. However, one skilled in the art will recognize that the sink hook 10 may have several different shapes and configurations to those shown such as a hook. The length of the sink hook 10 must be at least long enough to span the length of a drain opening 37 . In practice, the sink hook 10 length would be between one to six inches. The sink hook 10 may be made of any ridge material that would support a sink; generally, the sink hook 10 would be made of steel or aluminum.
[0032] To operate the clamp 2 , the sink 6 is placed under the countertop 4 . While the sink hook 10 is in the storage position and the countertop support bar 8 is at a slight angle to the slide bar 20 as shown in FIG. 2 , the sink hook 10 and the second end 52 of the slide bar 20 are inserted into the drain opening 37 . The installer rotates the sink hook 10 from the closed position to the open position as shown in FIG. 7 .
[0033] The installer lifts the sink 6 and the clamp 2 such that the countertop support bar 8 is located above the countertop 4 . The countertop support bar 8 is then rotated to the operational position as shown in FIG. 7 . Next, the installer rotates the countertop support bar 8 , such that the countertop support bar 8 is perpendicular to the slide bar 20 and parallel to the countertop 4 . The countertop support bar 8 is then positioned on top of the countertop 4 as shown in FIG. 8 .
[0034] When the installer applies pressure to the drive handle 22 , the clamp arm 16 is activated thus moving the slide bar 20 . The movement of the slide bar 20 causes the sink 6 to rise closer to the underside of the countertop 4 .
[0035] Once the sink 6 is near the countertop 4 , a gap 40 is created between the sink 6 and the countertop 4 . The installer may make any necessary adjustments to ensure that the sink 6 is located properly in the sink opening 54 . The installer then places adhesive on a sink rim 42 . Next, the installer applies pressure to the drive handle 22 , again causing the sink 6 to move toward the countertop 4 . Once the sink rim 42 comes into contact with the countertop 4 , the user can apply additional force to ensure a tight fit between the sink rim 42 and the countertop 4 .
[0036] A variety of different permutations of the invention is contemplated and not meant to be limited by this disclosure. The present invention is not limited to the preferred embodiments described in this section. The embodiments are merely exemplary, and one skilled in the art will recognize that many others are possible in accordance with this invention. Having now generally described the invention, the same will be more readily understood through references to the above descriptions and drawings, which are provided by way of illustration, and are not intended to be limiting of the present invention, unless so specified. Any element in a claim that does not explicitly state “means” for performing a specified function, or “steps” for performing a specified function, should not be interpreted as a “means” or “steps” clause as specified in 35 U.S.C. §112.
[0037] All features disclosed in the specification—including the claims, abstracts, and drawings, and all the steps in any method or process 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 the specification—including the claims, abstracts, and drawings—can 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 only one example of a generic series of equivalent or similar features.
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This disclosure describes a sink clamp and a method of installing a sink that utilizes a quick bar clamp, a sink hook, and a countertop support bar. The quick bar clamp is comprised of a slide bar, a clamp arm, and a bar clamp. The clamp arm is attached to the countertop support bar. The sink hook is attached to the end of the slide bar. In operation, the sink hook is located on the underside of a sink. The slide bar is slotted through the drain opening. The countertop support bar rests on top of a countertop. When an installer utilizes the bar clamp, the sink is raised to the underside of the countertop.
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The present application is a continuation-in-part of my previous application Ser. No. 144,516, filed Jan. 15, 1988.
BACKGROUND OF THE INVENTION
Underground bores such as oil wells, pipelines, gas mains and the like are susceptible to cracking or rupturing due to corrosion of the existing casings, shifts in the ground and external pressures which can crush or rupture the bores. These losses of integrity can cause the fluids passing through them to seep into the environment which can cause contamination to water tables as well as presenting fire hazards in the cases of gas mains and the like.
Likewise, certain situations require the closure of previous perforations or other man-made openings in casings, tubings or the like. In some cases repairs are required to bores that have been damaged by wear or abrasion by moving components. Also, the relining of a bore to present a different material interface within the bore can be extremely advantageous.
To repair these bores various elaborate methods have been developed which generally involve inserting a new section of pipe or liner into the bore to be repaired and placing the new lining in the appropriate section and then expanding the lining so that it then fills or covers the gap. These methods for repairing the casings generally have been limited to fairly small areas because of the difficulties encountered in handling long liners, and have largely been unsuccessful due to the problem of "springback" of metallic tubular materials when expanded internally. Springback prevents establishment of a good seal against the well casing.
SUMMARY OF THE INVENTION
The method for relining downhole casings and the like which is provided for by this invention involves spiral wrapping of a resilient flexible strip lining material about a special downhole tool to the length of the patch or repair to be made. The tool with wrapping attached is inserted into a bore of slightly larger internal diameter than the overall diameter of the wrapped tool to the location of the patch or repair to be made. One end of the wrapping material is then expanded from the tool tightly against the internal wall of the bore to be relined and the wrapping is then unwound progressively off the tool until, by its resiliency, it tightly engages the walls of the bore to be lined to the full length of the wrapping. The other end of the wrapping material is then expanded from the tool and against the bore wall.
It is desirable for one of the alternating layers of material to be comprised of a settable resinous material such as an epoxy to ensure adhesion and a complete seal between the various layers of lining materials.
Once the lining material is in place, the mandrel is then withdrawn and the bore is returned to use.
By the term "bore" it is meant any cylindrical opening or the like within a surface to include oil wells, water mains, gas mains, pipelines, electrical conduits or the like.
By "lining material" it is meant any form of flexible material having sufficient resiliency or elasticity to uncoil in the manner described. This material can be various sheet metal such as steel having a thickness of between 0.004 inches and 0.030 inches with a preferable thickness of 0.010 inches or dictated by the bore to be repaired. For example, for oil wells the use of beryllium copper is preferred because of its corrosion resistance and high strength. In other cases, various plastics reinforced with glass fiber or carbon fiber, etc. may be employed. Special stainless steels and nickel-base alloys may be of use. It is to be borne in mind that the interior of an oil well is a hostile environment containing chlorides, hydrocarbons, sometimes sulfides, etc. Many metallic materials simply disintegrate in such an environment. Beryllium copper, such as Alloy 190, having a yield strength of about 100,000 to about 125,000 psi and a modulus of 18.5×10 6 is particularly well suited to the service.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a machine for wrapping lining material about the downhole tool at the well head.
FIG. 2 shows the tool when it is first placed into the bore.
FIG. 3 shows the lower packer assembly in its inflated position with the lining material unwrapped up to the upper packer.
FIGS. 4 and 5 show, in cross section, the lower packer assembly.
FIGS. 6 and 7 show, in cross section, of the upper packer assembly.
FIG. 8 depicts the arrangement of the wrapping material strip at the initiation of the wrapping operation.
FIG. 9 depicts the thin sheet material which may be formed into a collar about the downhole tool to fasten the wrapping material thereto, and FIGS. 10 and 11 depict the sheet of FIG. 9 after it has been wrapped into a collar.
FIGS. 12A through 12E depict a supplemental safety device for preventing undesired loss of the tool down the well.
DETAILED DESCRIPTION OF THE INVENTION
In carrying the invention into practice, the downhole tool is first prepared. The tool comprises an upper packer assembly, a lower packer assembly, which incorporates a release device such as a shear pin operable from the surface to permit rotation of the upper packer with respect to the lower packer upon demand, with the two packer assemblies being spaced apart by a mandrel section of desired length having in mind the length of patch to be effected in the well to be repaired. The mandrel section itself may be made of sections of hollow steel such as tubing steel screwed together to form the requisite length. Each of the packer assemblies has a hollow core, with a check valve being provided at the lower end of the lower packer assembly. The downhole tool is suspended in the well on hollow tubing string steel, permitting transmission of hydraulic commands to the tool from the surface.
The completed downhole tool with spirally wrapped strip material therearound is depicted in FIG. 2 of the drawing as being suspended in a well adjacent a failed place in the well casing to be patched. As shown in FIG. 2, the tool comprises a mandrel 4 having a lower packer assembly 2 and an upper packer assembly 5. Lining material 21 is shown wrapped about the mandrel in FIG. 2. A centralizer 56 may be employed at the bottom end of the tool. The tool is shown suspended from tubing string 3. Other essential features of the downhole tool include circulating means for fluids which are controlled by commands from the surface. These will be described in connection with FIGS. 4 through 7.
Turning now to FIG. 1, which depicts a machine 11 mounted on the well head of a well to be patched in accordance with the invention, it will be seen that the machine consists of a frame 12 bearing a fixed crosshead 13 and a movable crosshead 14. The movable crosshead is raised and lowered by lead screw 23 which is powered by reversible power head 16 through pins 26. Upper and lower collets, designated 28 and 24 respectively, are mounted on the frame about upper port 17 and on movable crosshead 14. Collets 24 and 28 are preferably of the type which are normally closed and require actuation to be opened. Material payoff assembly 27 is preferably mounted concentrically about lead screw 23 and is powered by the same power head 16 which powers lead screw 23. Material payoff means 27 bears a plurality of axles 15 adapted to hold spools of strip 30. Brake means 19 prevents rotation of material payoff means 27 when the movable crosshead 14 is being raised. For this purpose also, drive means 16 is connected to material payoff means 27 by ratchet means so that material payoff means 27 is powered only when lead screw 23 is descending. Upper and lower ports 17 and 18 in the frame are aligned so that tool 22 can be passed completely therethrough. The collets 24 and 28 are controlled such that at least one of them is always closed to grip the tool while the wrapping operation is in progress.
To initiate the wrapping operation, tool 22 is passed downwardly through machine 11 to the point at which the lower packer assembly 2 reaches the wrapping area, i.e., the area at which the strip material 21 wound on spools 30 can reach tool 22 at the angle preset by the axles 15 on which spools 30 are mounted. The strip material is fastened to tool 22 over the lower packer assembly 2, preferably in the pattern depicted in FIG. 8 and preferably using the collar device 34 shown on FIG. 10 to fasten the strip material to tool 22. At this point, the movable crosshead 14 is in the fully raised position with collet 28 closed. Collet 24 is then closed and collet 28 is opened. Power head 16 then moves tool 22 downward while wrapping strip material 21 thereabout. Movement of the tool downward and the rate of rotation of the material payoff assembly 27 are fixed and coordinated by the pitch of lead screw 23. When the movable crosshead 14 reaches the lower end of its travel, collet 24 is closed, upper collet 28 is opened and brake 19 is set so that the wrapped-on strip material 21 will not become unwrapped during the elevation of crosshead 14. Crosshead 14 is then elevated by reversing power head 16, while no power is transmitted to material payoff means 27 due to the fact that the drive thereto is ratcheted. The process of alternately raising and lowering crosshead 14 to feed and wrap portions of tool 22 is continued until the upper packer assembly 5 is reached and wrapped. A collar similar to that shown in FIG. 10 is then wrapped about the upper packer assembly 5 to lock the wrapped strip thereto. The strip material is then cut off and the tool 22 is ready for use. Since there is no longer any need for the machine to remain at the wellhead, and in fact, it can be transported to the next job, tool 22 can be lowered completely through the wrapping area, fitted with a split collar as a stop on the wellhead to permit removal of the machine, and the process of patching the well can proceed.
Before proceeding with a discussion of the well patching procedure, the construction of the upper and lower packer assemblies will be described with reference to FIGS. 4 and 5 (Lower) and FIGS. 6 and 7 (Upper) packer assemblies, respectively. These Figures illustrate that the essential features of the respective packer assemblies are: (1) Expandable means (the packers) at the upper and lower ends of the tool permitting expansion from the tool diameter to fit forcibly against the well casing, (2) Spindle means preferably located adjacent the lower packer assembly which on command can permit rotation of the mandrel and upper packer assembly with respect to the lower packer assembly, and (3) Valve means permitting controlled circulation of fluid under pressure along the inside face of the newly formed well liner.
FIGS. 4 and 5 illustrate the upper and lower portions of the lower packer assembly, with reference character 64 representing the steel body of the assembly, 51 representing the packer itself, and being an inflatable rubber sleeve fastened at the ends to the assembly body 64, reference character 50 representing the spindle held together from rotation by shear pin 53, rollers 54 which rotate in race 65 after the shear pin is broken and the upper portion of the tool is rotated from the surface, valves 10 are circulating valves operated by interior tool hydraulic pressure in the hollow core 6, holes 71 communicate between the tool core 6 to the inner face of the packer 51 to inflate packer 51 in response to hydraulic pressure PI in core 6, check valve 58 of the ball-check type admits fluid contents of the well to the interior of the tool as the tool is lowered into the well so that interior pressure in the tool is equalized to the exterior pressure, screen 72 prevents entry of well solids into the interior of the tool, and 55 represents pressure discs to be blown after the well patch is completed and the upper and lower packers are to be deflated for withdrawal of the tool from the well. It will be appreciated that additional ball-check valves may be employed in patching wells which have excessive amounts of suspended solid material and that the area of the screen can be varied depending upon the conditions encountered in the well.
In FIGS. 6 and 7 reference character 60 represents the upper packer, which is fastened at the ends to the steel body of the upper packer assembly, 61 are rupture discs which rupture at pressure P2 to inflate the upper packer (pressure P2 being higher than pressure P1, the pressure at which the lower packer is (inflated), valves 62 are check valves that equalize the head pressure in the well with the pressure on each side of rupture discs 61 to prevent premature bursting of said discs 61, passages 63 lead to the interior face of packer 60 to inflate it. Both packers are shown in the deflated and in the inflated condition on opposite sides of the tool.
The tool is intended to be operable to patch holes in well casing or tubing without removing the liquid contents of the well. This is not only for convenience in the field but also due to the fact that disposal of the well contents could pose an environmental problem.
With the tool prepared as described in accordance with FIG. 1 hereinbefore, it is lowered into the well from tubing string 3 to the location of the leaking area in the well which must be patched. It is to be emphasized that the patch can be of considerable length, e.g., 30 feet, 50 feet or even 100 feet or more. As the tool descends, ball-check valve 58 opens to equalize interior pressure in the hollow core of the tool 6 with the pressure in the well. The hydraulic signals transmitted to the tool from the surface depend upon the differential in pressure within the tool, not the absolute pressure. When the tool has reached the area to be patched, as indicated in FIG. 2, pressure in the interior of the tool is increased to P1 and the lower packer is inflated against the casing 32 of the well. This act locks the lower packer assembly against the casing so as to prevent movement and breaks the collar 34, pushing the collar 34 and the first wraps of the lining strip 21 firmly against the inner face of the well casing 32. The tubing string is then rotated from the surface in the direction opposite the wrapping direction of the liner strip to break the shear pin 53. The upper portions of the tool are then rotated to unwrap the liner strip 21 against the inner face of the casing 32 all the way to the upper packer so as to arrive at the position shown in FIG. 3. The resilient nature of the strip material causes it to move against the casing as the strip is unwrapped in a manner akin to the uncoiling of a coiled spring. Internal pressure in the tool is then increased to pressure P2 to rupture the discs 61 and inflate the upper packer. The inflated upper packer 60 breaks the join of the upper collar 34 and presses it firmly against the casing along with the upper wraps of the liner strip 21. Internal pressure is then raised to P3 to open circulating valves 10 and hot water is circulated along the inner face of the liner to set the heat settable resin positioned between the overlapping metal strips 21. When sufficient time at temperature to set the resin has passed, the internal pressure is raised to P4 to blow rupture discs 55. This equalizes the internal and external pressures and deflates the packers, whereupon the tool may be removed from the repaired well. Bypass passages 67 permit the circulating liquid to move past the upper packer without deflating it. Alternatively, longitudinal grooves may be provided in the periphery of the upper packer.
FIG. 8 depicts a preferred pattern for starting the wraps of liner strip about the tool. Collar 34 is provided with a longitudinal set of slots 35 into which the ends of metal strip 21 may be inserted. Between metal strips 21, strips of plastic screen, such as fly screen, impregnated with liquid epoxy are placed (reference character 36) until four strips of each description have been located. Conveniently, the end of each strip is cut at an angle as shown in the drawing. The flap 37, shown more advantageously in FIGS. 9 and 10 overlaps the located ends of the liner strips 21 and 36 to provide a more secure anchor for the strip, and prevent it from becoming unraveled from the tool. The screen material can be fastened to collar 34 using a hot glue gun. It is very important that the strip be securely fastened to the tool and remain so during descent of the tool into the well, becoming detached from the tool only upon commands from the surface.
FIG. 9 depicts the pattern of the thin strong sheet material from which the collar is made. The pattern is rectangular and bears an aligned row of slots 38 punched adjacent an edge thereof. A corresponding set of ears 39 parallel to slots 38 is placed at a distance corresponding to the diameter of the collar 34 made when the pattern 40 is rolled into a cylinder. Slots 35, also shown in FIG. 8, are punched adjacent the opposite edge of the pattern 40 to hold the lining strip. It will be seen that a flap 37 is formed when pattern 40 is rolled into a cylinder. Ears 39 may be fastened to pattern 40 in breakaway fashion as by spot welding, or may be die-formed into the pattern. The ear-and-slot system holds together firmly during wrapping of the lining strip and descent of the wrapped tool into the well. The force of the expanded packers exerted internally upon the collar easily ruptures the collar joins when the proper command is given from the surface and the collar material, being springy, presses firmly against the well casing. The collar material can be 0.010 inch thick, aged beryllium copper sheet or strip of high strength.
FIG. 10 depicts the pattern 40 of FIG. 8 after it has been rolled into the collar. Slots 38, ears 39, flap 37 and strip-holding slots 35 are shown. Dimples 43 keep collar 34 from slipping on the packer during the wrapping process. A supplemental set of slots 42 and catches 43 cut into pattern 40 may be provided to hold tab 37 tightly to collar 34 as shown in FIG. 11 to facilitate passages of the collar-wrapped packer through machine 11. Catches 43 are released from the lower collar to permit attachment of the liner strip material to tab 37.
FIGS. 12A through 12E depict an additional safety feature to prevent loss of the tool down the hole during the wrapping process. Each mandrel section can be provided with an annular recess 4a near the top end thereof. A shoulder 92 surrounds the tool at a location above upper collet 28. Shoulder 92 is activated by valve 93 and prevents mandrel section from moving down even if upper collet 28 is open, as shown in FIG. 12B. Shoulder 92 is driven by shaft 94 and spring 95.
It is to be appreciated that the well liner provided in accordance with the invention must pass a "gage" test and a pressure test after it is formed to demonstrate that it presents no impediment to passage of well tools and that it will prevent seepage of undesireable materials from the interior of the well into the environment. This represents a stringent set of criteria which must be passed. Use of 0.010 inch thick strip of beryllium copper alloy; with interspersed epoxy provides in four layers essentially the strength of the original steel casing material and provides far greater corrosion resistance especially to chlorides.
Preferably, the heat settable liquid epoxy is applied to the screen strip material at a point very close to mandrel. A device comprising a tube having a thin slot cut longitudinally therein and having a length of about the width of the screen strip is used as a spreader. Liquid epoxy is stored under pressure in a discardable container and is led to the spreader by a plastic tube provided with a positive displacement meter such as a peristaltic pump, the meter being connected to the screen strip supply such that the meter turns only when screen strip is actually being wrapped. This positive control prevents spillage of liquid epoxy when no wrapping is being conducted. Upon completion of the wrapping operation, only the spreader needs to be cleaned. The container and plastic tube can be discarded, a feature of practical advantage in the field. The device is a joint invention of the present inventor and A.C. Hill and will be covered in a separate application.
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The invention relates to a method and apparatus for relining bores such as oil wells, using multiple layers of spiral wrapped, resilient lining material which expands to form a continuous liner for the bore.
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FIELD OF THE INVENTION
The present invention is in the area of routing data packets in data packet networks such as the well-known Internet, and pertains more particularly to methods and apparatus for implementing a single higher-capacity port from a plurality of lower-capacity ports.
BACKGROUND OF THE INVENTION
At the time of the present patent application demand for increased data capacity and efficiency in Internet traffic continues to increase dramatically as more individuals and businesses increase their use of the Internet. The ever-increasing demand also drives development of equipment for the Internet such as data packet routers. A number of enterprises are developing routers that are capable elf faster and higher capacity handling of data packets.
The Internet, operating globally, comprises components from a wide variety of companies and organizations. It is, of course, necessary that such equipment conform to certain hardware and connection standards and operate by certain data transfer standards and protocols. These standards are all well known the skilled artisan.
In the Internet art at the time of this application a common standard for links between routers is the SONET OC-48c standard, which provides a data capacity of 2.5 gigabits per second (Gb/s). The increasing demand for faster routing has led to a higher-capacity interconnection OC-192c standard with a data capacity four times higher, or 10 Gb/s. Those purveyors of router equipment conforming to the OC-48c standard have an incentive to upgrade to the higher-capacity standard. One way to upgrade a router having OC-48c ports to interface to OC-192c links, is to develop new line cards with OC-192c compatible ports, and interface circuitry to handle the higher-speed interconnecting links. Developing the new equipment is far from trivial, and requires considerable time and expense.
The present inventors have developed a new and unique method and apparatus for interfacing router equipment originally developed and devoted to the OC-48c standard to the newer, higher-speed OC-192c links.
SUMMARY OF THE INVENTION
In a preferred embodiment of the present invention, in a data packet router, a line card for interfacing to a standard data link having a first transmission capacity is provided; comprising a first portion interfacing to the router and having a plurality of ports or packet processing engines each with a transmission capacity less than that of the standard data link; and a second portion having a framer compatible with the standard data link coupled to the standard data link, an ingress and an egress data path between the framer and the slower ports or engines, each with separate ingress buffers and egress buffers for each slower port, and an interface control circuit controlling data packet transfers between the slower ports and the framer in both directions. The standard data link may be one of OC-192c-compatible or 10 Gigabit Ethernet compatible, and the slower ports may be OC-48c ports.
In a preferred embodiment the interface control circuit extracts a key from incoming packets from the standard data link, processes the extracted key for each packet, and uses selected bits of the result for the packet to map the packet to an individual one of the slower ports. The processing may be by such as a hashing function. The key for an incoming Internet Protocol (IP) packet in one embodiment is the source address, destination address (SA/DA) pair, producing a unique processed result, such that all packets having a common SA/DA pair are routed by the same slower port, using a selected pair of bits from the result. Labels of multi-protocol label-switching (MPLS) packets may be processed to map MPLS packets to the slower ports, and packets other than Internet Protocol (IP) and multi-protocol label-switching (MPLS) packets may be processed by point-to-point protocol (PPP) code.
In some embodiments of the line card the control circuit monitors buffer content for the ingress buffers, and reroutes packets from a first buffer to a second buffer, based on the first buffer content being above a pre-set threshold. The egress buffers may be provided in a capacity to hold at least two maximum-size packets, and the control circuit pulls a packet from a buffer for the framer only if the buffer contains a complete packet. In another aspect of the invention, on a line card for a data packet router, a, method for routing data packets from a standard data link having a first transmission capacity to a plurality of slower ports or packet processing engines is provided, the method comprising the steps of (a) extracting a key from each incoming packet; (b) producing a unique data string from the key, (c) selecting bits from the data string; and (d) mapping the packets to the slower ports according to the binary value of the selected bits.
In some embodiments of the method the standard link is compatible with SONET OC 192c protocol, and the slower ports are compatible with SONET OC 48c protocol. Further, the unique data string may produced by a hashing function. Also in some embodiments, in step (a), the key for an incoming Internet Protocol (IP) packet is the source address, destination address (SA/DA) pair, producing a unique result, such that all packets having a common SA/DA pair are routed by the same slower port, using selected bits from the unique result. The unique result may be produced from the SA/DA pair by a hashing function.
In some embodiments, in step (a), labels of multi-protocol label-switching (MPLS) packets are selected as the key. Also in some embodiments, in step (a), the key for packets other than Internet Protocol (IP) and multi-protocol label-switching (MPLS) packets may be point-to-point protocol (PPP) code. Packets may be routed to the slower ports through ingress buffers dedicated to the ports.
In some embodiments buffer content for the ingress buffers is monitored, and packets are rerouted from a first buffer to a second buffer, based on the first buffer content being above a pre-set threshold. An egress buffer may be provided for each slower port in a capacity to hold at least two maximum-size packets, and a packet is pulled from an egress buffer for the framer only if the buffer contains a complete packet.
In yet another aspect of the invention a method for enabling a data packet router line card having a plurality of ports or packet-processing engines to receive on a data link having a capacity greater than the capacity of any one of the ports is provided, comprising the steps of (a) adding a framer to the card for coupling to the data link; (b) coupling the framer to slower ports through an interface control circuit and buffers dedicated one-to-one to each port; (c) extracting a key from each incoming data packet; and (d) using the key with a mapping function to map each packet to an individual ingress buffer, and hence to an individual port.
In this method in some embodiments the plurality of ports are each SONET OC-48c compatible, and the data link is OC-192c compatible or 10 Gigabit Ethernet compatible. In step (d), the mapping function may be a hashing function producing a unique bit map for each extracted key, and specific bits of the bitmap are selected and used to map the packet to individual ones of the ports. The key for an incoming Internet Protocol (IP) packet is, in a preferred embodiment, the source address, destination address (SA/DA) pair, producing a unique result, such that all packets having a common SA/DA pair are routed by the same port, using selected bits from the hash result.
In some embodiments labels of multi-protocol label-switching (MPLS) packets are hashed to map MPLS packets to the ports, and packets other than Internet Protocol (IP) and multi-protocol label-switching (MPLS) packets are hashed by point-to-point protocol (PPP) code. Also in some embodiments the control circuit monitors buffer content for the ingress buffers, and reroutes packets from a first buffer to a second buffer, based on the first buffer content being above a pre-set threshold. Further, there may be a step for coupling the framer to the ports also through individual egress buffers each having a capacity to hold at least two maximum-size packets, and wherein the control circuit pulls a packet from an egress buffer for the framer only if the buffer contains a complete packet.
In embodiments of the present invention taught in enabling detail below, for the first time apparatus and methods are contributed for mapping a fast link to slower ports or engines, and for ensuring as well that IP packets all travel by the same path.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of an exemplary router with conventional data interfaces in the prior art.
FIG. 2 is a diagram illustrating a prior art approach to interfacing an OC-192 link to, OC-48c ports.
FIG. 3 is a diagram illustrating the problem of connecting an OC-192c link to 0 C-48c ports.
FIG. 4 is a diagram illustrating an interface according to an embodiment of the present invention.
FIG. 5 is a more detailed block diagram encompassing block 43 of FIG. 4 interfacing to OC-48c ports.
FIG. 6 is a diagram of elements in the Ingress Data Path of FIG. 5 .
FIG. 7 is a diagram of an IP data packet indicating a unique method for routing such packets.
FIG. 8 is a diagram of elements in the Egress data path of FIG. 5 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a block diagram of an exemplary router 11 with conventional data interfaces 13 and 15 as used in the prior-art. Interfaces 13 and 15 in this example are line cards each having four OC-48c standard ports capable a data rate of 2.5 Gb/s each. Line card 13 is labeled i l and line card 15 is labeled I n ) illustrating that there may multiple line cards in a router
FIG. 2 is a diagram illustrating a prior art approach to interfacing an OC-192 link to OC-48c ports. In this approach there are two end-blocks 17 and 19 , each interfacing to four OC-48c ports. A single line 21 joins the two end-blocks, labeled OC-192. In this solution data packets in one direction, for example arriving at block 17 from OC-48 ports 1 through 4 , are multiplexed onto line 21 to be transmitted to block 19 . Similarly, data packets arriving from ports OC-48 A through D at block 19 are multiplexed onto line 21 to be transmitted to block 17 and hence onto to ports OC48 1 through 4 . In this scheme line 21 is operated, for example, as a time division multiple access link, wherein each port pair has a transmit and receive time slice. Port 1 may be paired with port A for example, and receive one-forth of a time cycle for transmitting and receiving.
Note that the data on line 21 is strictly controlled and constrained, so this solution does not solve the problem of how to interface OC-48c ports efficiently to an unstructured OC-192c line, which is the problem illustrated in general terms in FIG. 3 . FIG. 3 shows an unstructured OC-192c source/receiver 23 connected to four OC-48c ports 25 -- 31 , labeled also as ports 0 , 1 , 2 , and 3 . In this example each of the OC-48c ports is a packet-processing application-specific integrate circuit (ASIC), referred to by the inventors as a packet processing ASIC, or PPA. The simple point-to-point connection is, of course, impractical, because there is no way to manage apportioning data packets among the four PPAs.
There are really two problems, or desirable results, illustrated by FIG. 3 . One is that it would be desirable to balance traffic among the four PPAs. The other is that it would also be highly desirable if IP packets having the same source and destination could be routed by the same physical path. This is because in IP, packets may typically be for real-time communication, such as telephone conversations and the like, and if such packets take different routes from source to destination there will likely be problems with latency and dropping of data packets. Packets will not typically arrive in order if traveling by different routes, and therefore may not be properly reassembled at the destination. Also, packets arriving out of order are commonly dropped, and the dropped packets must be resent. This wastes bandwidth, lowers throughput, and delays delivery.
FIG. 4 is a diagram illustrating an interface according to an embodiment of the present invention. In this schematic OC-192c line 33 , operating at up to 10 Gb/s, interfaces to four OC-48c PPAs 35 - 41 through a unique hardware interface 43 . In a preferred embodiment of the present invention block 43 is implemented as a single ASIC. In other embodiments block 43 may be a chip set, and in still other embodiments there may be a microprocessor and firmware employed to accomplish the functionality of block 43 as described in further detail below.
FIG. 5 is a block diagram illustrating additional elements and interconnectivity for interface circuitry 43 of FIG. 4 . In FIG. 5 packets coming into interface circuitry 43 arrive and leave an OC-192c transponder 45 . Packets are exchanged between the transponder and an OC-192c. framer 47 . Both transponders and framers are circuit elements well-known in the art. In the case of packets coming into a line card and transferred from the OC-192c framer 47 into and through an Ingress data path 51 and then to PPAs 0 through 3 . Packets from the line card exiting to an OC-192c line go from PPAs 0 through 3 through an Egress data path 49 , and then to the OC-192c framer 47 , then to the line. The handling of ingress and egress packets is necessarily somewhat different, which is the motivation for the different Egress and Ingress data paths.
FIG. 6 is a block diagram of ingress data path 51 from FIG. 5 . Ingress packets received from OC-192c framer 47 arrive at a rate that is four times faster than a single PPA can handle. Ingress logic needs to evenly disperse the incoming packets over the four PPAs 59 , 65 , 71 and 77 on the line card to keep up with the incoming traffic. Dispersion of the packets also needs to be balanced in order to keep any one PPA from being overloaded with packets, and to maximize the overall through put. Since no dispersion scheme: round robin, linear, or any other, is perfect, buffering memory is required in each separate path to a PPA, and there are therefore four synchronous first-in first-out buffers; one in each path, these being buffers 55 associated with PPA 59 , buffer 61 , associated with PPA 1 , buffer 67 , associated with PPA 71 , and buffer 73 , associated with PPA 77 . The purpose of the buffering memory in each path to a PPA is to even out any temporary unevenness encountered in the dispersion technique, described in more detail below.
Referring again to FIG. 6, there are two new and unique elements in the data path, an Ingress Packet Demultiplexor (EPD) 53 , and four separate Utopia Interface Converters (UIC). The function of the IPD will be first explained. As seen in the exemplary block diagram there are data bus and control connections between the elements of the Ingress Data Path.
One important function of the IPD is to map incoming packets into the four separate FIFO buffers 55 - 73 . It is desirable, as before stated, that TP packets having the same source/destination pair be all routed by the same physical path, and it is further desirable that a creditable job of load-balancing be done as well.
FIG. 7 is a generalized diagram of an IP data packet 79 in the art. In IPv4 protocol there is a data portion 81 and a header portion 82 comprising five header fields 83 through 91 . Amongst the five fields are a source,address (SA) and a destination address (DA). Given an SA/DA pair, the IDP applies a hash function to determine a unique bitmap for each SA/DA pair, so that all packets with a common SA/DA pair will result in the same bitmap. As there are but four destinations, FIFOs 55 , 61 , 67 , and 73 , the IDP need only consider any two bits of the result of the hash. In a preferred embodiment the two bits considered are the two least significant bits. Packets are then routed to buffers 55 , 61 , 67 and 73 according to these two selected bits, unique and common for each unique SA/DA pair. Thus, IP packets with the same SA/DA are always routed by a common physical path.
MPLS packets are hashed using up to three labels on the label stack for the packets. All other packets (not IP or MPLS) are hashed according to point-to-point protocol (PPP) code. This keeps common PPP types together by path, and disperses various other PPP types over the four PPAs.
Each UIC in the four separate data paths to PPAs reads packets from the coupled FIFO and passes packets to the associated PPA, in this example, by a UTOPIA III+interface. The UIC design mimics framer handshaking to PPA interfaces, so there needs be no alteration of the PPAs to accommodate the data transfer.
In most cases, because the input to a line card such as described herein will be from a large number and wide variety of sources communicating with a similarly wide variety of destinations, the load-balancing provided by the IDP will be quite good. In some cases, however, for any of a number of reasons, there will be data surges and bursts that will tend to overload a particular FIFO.
In another aspect of the invention the IDP has a further function in load-balancing. This further function is provided for the unusual circumstance of sudden or sustained overload as described immediately above. The IDP has reference to, in a preferred embodiment, a programmable threshold relative to the momentary load content of each FIFO. During those periods when all FIFOs are functioning below threshold, the load balancing by hashing will be considered adequate. If a threshold is exceeded, however, and preferably before packets are ignored or dropped, the IPD will spill packets from the threatened FIFO to a FIFO less loaded. This is done in one embodiment on a round-robin basis so redirected packets will go by the next path in order for which it is found that the threshold is not exceeded.
FIG. 8 is a block diagram of Egress data path 49 of FIG. 5 . The elements in this example are a framer interface 93 , and four FIFO buffers 95 , 97 , 99 and 101 . In a preferred embodiment there are four FIFOs 95 , 97 , 99 and 101 , each interfaced to a PPA from 0 to 3. The FIFOs are for temporary storage to have an entire packet before being read by a frame interface 93 to be sent to framer 47 . Interface 93 reads the FIFOs in a round-robin scheme in this embodiment, skipping any FIFO not having a complete packet. Since the frame interface is four times as fast as the PPA interface, each FIFO needs only enough capacity to store only two maximum size packets.
A major advantage of the unique circuitry and connectivity described in embodiments above is that relatively uncomplicated additions, being the egress and ingress circuitry and:the control blocks described above (IPD, UIC and framer interface) can be added to a line card developed for OC-48c handling, providing a card for interfacing to an OC-192c line, while also balancing data flow and ensuring that IP packets having the same SA/DA pair are routed by a constant path.
It will be apparent to the skilled artisan that the embodiments described are exemplary, and that there may be considerable alterations in the embodiments described while not deviating from the spirit and scope of the present invention. It is desirable that functionality in a preferred embodiment of the invention be implemented as hardware, with a minimum of software-based functionality. This is not, however, limiting to the application and practice of the invention, and software functionality may be used more extensively in many embodiments. The invention should be accorded the breadth of the claims that follow:
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A line card for a data packet router interfaces to a high-speed standard data link, and has a first portion interfacing to the router and having a plurality of slower ports, and a second portion having a framer compatible with and coupled to the data link. The framer is coupled through an ingress and an egress data path between the framer and the slower ports, each with separate ingress buffers and egress buffers for each port. An interface control circuit controls data packet transfers between the slower ports and the framer in both directions. In a preferred embodiment a function is used by the control circuit to map packets from the link to the ports, using keys extracted from the incoming packets. For an IP packet the key is the source address, destination address (SA/DA) pair, which constrains packets for same IP conversations to be routed by the same path.
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CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
[0001] This application claims priority to provisional patent application number 60/435,890, filed on Dec. 20, 2002.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a fluid coupling union such as a fluid coolant rotating union having a secondary sealing assembly which provides a depressurized condition displacement of the floating seal members from one another to provide a pop-off or gap between the seal members when the cooling union is depressurized.
[0003] Fluid coolant unions are used extensively in conjunction with machine tools in various high speed drilling and boring transfer operations, high speed machine tool spindles, and in various applications such as machining centers and flexible transfer lines. In such applications, the rotating union is structurally arranged to conduct various types of coolants, such as water-based, oil-based, and air-based fluids into the machine tool spindle. Preferably, such coolants may be used without prolonged dry-run periods of operation of the coolant union. Coolant unions generally include conventional seal assemblies having a rotating seal member mounted to the end of the rotating rotor member, which seal member is axially aligned to engage a non-rotating complementary seal member which is mounted to an axially movable carrier member mounted within the housing.
[0004] In existing prior art coolant union assemblies, when the union is operating in the pressurized condition the sealing surface of the non-rotating seal member is biased into engagement with the sealing surface of the rotating seal member by overcoming some type of spring or baffle diaphragm bias means which is designed to axially separate the seal members when in the non-pressurized dry-running condition. As the liquid or fluid coolant is passed through the coolant union, the coolant lubricates the contacting seal members to minimize wear between the members. When the condition is reached where the union is unpressurized and fluid coolant is not passing through the union, a “dry running” condition is achieved and the facing surfaces of the rotating and non-rotating seal members do not receive any lubrication. During this dry-running condition, the increased wear on the seal facings results in leakage about the seal facings which ultimately require replacement of one or both of the seal members. Such replacement of the seal facing and the rotor assembly are expensive and time consuming.
[0005] To overcome the problems associated with dry-running, coolant unions have been developed to include structure which separates the rotating and non-rotating seal facings from one another when fluid coolant is not passing through the union. Such “pop-off” type unions may be biased by spring or diaphragm members. Such biasing members position the seal members apart from one another in the absence of the passage of fluid coolant passing through the union. However, such coolant unions are complex and expensive to manufacture. Also, during start-up of such coolant unions, excessive amounts of the fluid coolant are permitted to pass through the enlarged gap separating the rotating and non-rotating seal facings.
SUMMARY OF THE INVENTION
[0006] The present invention provides a novel fluid coolant union which utilizes chamfered seal faces on at least one of the non-rotating and rotating portion floating seal assembly facings of the coolant union. Such coolant unions permit the handling of multiple cooling media, such as water-based, oil-based, air-oil mist based and air-based coolants to be directed through the coolant union. Additionally, it has been determined that by chamfering the seal faces in accordance with the present invention, the handling of the multiple media with a single seal balance is permitted while controlling leakage for the water-based, the oil-based, the air-oil mist and the air-based media to minimum levels. The chamfered seal face of at least one of the floating seal assembly facings additionally permits the use in the seal faces of special silicon carbide based materials containing specific and various porous type structures that may contain known lubricants such as graphite to provide a self-lubricating property to the seal faces. By utilizing chamfered seal faces, the seal faces may contain a specific combination of silicon carbide based materials which provide different porous structures with respect to the coolant media when operating in a dry run condition. Thus, by utilizing chamfered seal faces, it has been found that the PV (pressure×sliding velocity) limit of such specialized seal facing provides an increase in operating life for such seal facings as compared to the situation when the seal facings are not chamfered.
[0007] In accordance with a further embodiment of the present invention, the coolant union includes a secondary sealing assembly. The secondary sealing assembly provides a sealing arrangement for the union to prevent leakage forward between the floating seal assembly of the coolant union and the carrier member that are adapted for axial sliding movement within the passageway in the housing. This secondary sealing arrangement or assembly includes an annular groove radially extending around the inside surface of the union housing, with the annular groove containing an annular seal member. Preferably, the annular seal member is a U-shaped seal member. This U-shaped seal member is positioned within the annular groove and includes an inside corner thereof chamfered. The U-shaped seal member is then chamfered and sized to structurally cooperate with a triangular shaped back-up ring configured and sized to provide the unfilled volume within the annular groove which, when pressurized, stores sufficient relative displacement of the floating seal faces from one another to create a micro pop-off or a minute separation of the seal faces when depressurization occurs.
[0008] The radial interference fit between the chamfered U-shaped annular seal member, the enclosing housing and the floating seal is less that standard to provide for the necessary interaction of the U-shaped seal member and the floating seal to create a micro pop-off between the rotating and the floating seal facings. This is accomplished by chamfering the inside corner of the U-shaped seal member to a size in relation to the dimension of the triangular plastic back-up ring to provide an unfilled volume and permit freedom of movement of the U-shaped secondary seal member. The unfilled volume, when pressurized, stores sufficient relative displacement of the floating seal members with respect to one another to create the pop-off or separation of the seal faces. This separation or gap between the seal faces is very small.
[0009] The triangular back-up ring is comprised of a selected plastic material which provides a necessary combination with the chamfered U-shaped seal member. By sizing the back-up ring to the unfilled volume of the chamfered U-shaped seal member, the chamfered U-shaped seal member and back-up ring provides the freedom of movement for the long term functioning of the secondary seal assembly without hang-up while permitting the adjustability of the position of the floating seal for variable axial locations of the rotor. The resultant fluid coupling union is simpler in construction because it does not require a spring-biased member or baffle member to provide separation of the floating seal faces and to provide contact of the seal faces during pressurization.
[0010] The present invention consists of certain novel features and structural details hereinafter fully described, illustrated in the accompanying drawings, and particularly pointed out in the appended claims, it being understood that various changes in the details may be made without departing from the spirit or sacrificing any of the advantages of the present invention.
DESCRIPTION OF THE DRAWINGS
[0011] For the purpose of facilitating and understanding the present invention, there is illustrated in the accompanying drawings a preferred embodiment thereof, from an inspection of which, when considered in connection with the following description, the invention and its construction and operation and many of its advantages will be readily understood and appreciated.
[0012] FIG. 1 is a vertical section view of the fluid coolant union provided in accordance with the present invention, with the coolant union shown in its unoperated, unpressurized condition;
[0013] FIG. 2 is a view similar to FIG. 1 showing the fluid coolant union in its operated, pressurized condition in accordance with the present invention;
[0014] FIG. 3 is an enlarged view of the portion of the secondary seal assembly in accordance with the present invention when the coolant union is in the unoperated, unpressurized condition;
[0015] FIG. 4 is an enlarged view of the portion of the secondary seal assembly in accordance with the present invention with the coolant union shown in the operated, pressurized condition;
[0016] FIG. 5 is a schematic cross-sectional view illustrating the chamfered U-shaped secondary annular seal member in accordance with the present invention; and
[0017] FIG. 6 is a schematic cross-sectional view of the triangular back-up ring member of the secondary seal assembly in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] Referring now to the drawings wherein like numerals have been used throughout the several views to designate the same or similar parts, there is illustrated in the drawings a rotating fluid coolant union 10 incorporating the novel sealing arrangement in accordance with the present invention. The fluid coolant union 10 , as shown in FIGS. 1 and 2 , is utilized to conduct a fluid coolant either in a liquid or gaseous state from a source of coolant (not shown) to a spindle of a machine tool and the like. The spindle could be a machine tool used in the various applications such as machining centers, flexible transfer lines or any environment where fluid coolants such as water-based, oil-based, air-oil mist based and air-based coolants may be used in conjunction with the fluid coolant union 10 .
[0019] The fluid coolant union 10 is comprised of a rotor or shaft member 12 , coupled to an end cap or housing member 14 . The end cap or housing 14 provides a cylindrical housing for the fluid coolant union with the housing identified as reference numeral 14 . The cylindrical bore 16 of the housing 14 defines a seal chamber 15 which locates the seal assembly 18 within the coolant union 10 .
[0020] As shown in FIGS. 1 and 2 , the seal assembly 18 is comprised of a rotating seal member 20 which is mounted to the end 12 a of the stub rotor member 12 and a non-rotating seal member 22 mounted to the end of a carrier member 24 . The rotating seal member 20 is, preferably, a disc-shaped, one-piece silicon carbide member which provides a generally flat-shaped annular seal surface 20 a about an opening 21 through the center thereof. The non-rotating seal member 22 of the seal assembly 18 is also a generally flat disc-shaped member that is also, preferably, comprised of silicon carbide. The seal members 20 and 22 of seal assembly 18 may be comprised of various silicon carbide grades. The non-rotating seal member 22 includes an opening 23 therethrough and includes an annular seal surface 22 a . The non-rotating seal member 22 is mounted to an end 24 a of a carrier member 24 which is axially movable within the cylindrical bore 16 of housing member 14 .
[0021] Importantly, one of the annular seal surfaces 20 a and 22 a is chamfered to present a narrowed and reduced annular contact seal facing between the floating seal assemblies. It is preferred that the non-rotating seal face surface 22 a is the seal surface that is chamfered. The chamfered portion is shown as beveled portions 25 and 29 in FIGS. 1 and 2 . The mating between seal surfaces 20 a and 22 a permits the handling of multiple media, such as water-based, oil-based, air-oil mist based and air-based fluid materials to be used without prolonged dry run conditions. As shown in FIGS. 1 and 2 , it has been found that when the width of the annular seal surface 22 a of the seal assembly 18 is narrower than the width of the rotating annular seal surface 20 a then the seal assembly 18 is more capable of operating in an unpressurized running dry run condition without significant damage to the seal members 20 and 22 .
[0022] The fluid coolant union 10 in accordance with the present invention further includes a secondary seal assembly 26 to prevent leakage of the fluid coolant forwardly of the carrier 24 through the gap 27 between the outer surface of the carrier side wall 35 and the inner surface 17 of the cylindrical bore 16 of the housing member 14 . The secondary seal assembly 26 is comprised of a U-shaped annular sealing member 30 positioned within an annular groove 28 positioned within the inner surface 17 of the housing member 14 that engages the inner surface 17 of the housing member 14 and the outer surface 35 of the carrier member 24 . The U-shaped annular sealing member 30 of the secondary seal assembly 26 , as shown in FIGS. 3, 4 and 5 is a modified U-shaped type annular seal. As shown in FIG. 3 , the U-shaped annular seal member 30 is positioned within the annular groove 28 within the housing member 14 . When the U-shaped seal member 30 is positioned within the annular groove, the lip members 31 and 32 and the foot connection member 33 ( FIG. 5 ) of the annular seal substantially contact the inner and outer surfaces of the annular groove as well as the front surface or the side of the groove opposite the high pressure area, as shown in FIGS. 1 and 3 . As shown in FIG. 5 , the U-shaped seal member is comprised of an elastomer type material and includes a chamfered diagonal cut 34 on the foot portion of the seal assembly 30 that is positioned toward the outer surface 35 between the carrier 24 and the cylindrical bore 16 of the housing member 14 . This chamfered cut is sized in relation to a triangular back-up ring 36 to structurally cooperate with the triangular back-up ring 36 ( FIG. 6 ) to provide an unfilled volume which, when pressurized, stores sufficient relative displacement energy ( FIG. 4 ) to the floating seal assembly to create a micro pop-off or separation of the seal faces 20 a and 22 a when the coolant union is depressurized, the condition as shown in FIG. 1 .
[0023] FIG. 6 represents a cross-section of the annular back-up ring 36 which is comprised of polymer material. This particular specialized plastic material provides a back-up ring that controls the absorption of moisture and controls the hardness of the material as well as controls the machineability of the back-up ring to permit the back-up ring 36 to be structurally arranged to occupy the space and volume within the chamfer cut in the inner wall of the U-shaped annular seal.
[0024] During the operation of the coolant union 10 in the pressurized operating condition, the U-shaped secondary seal member 30 engages the annular back-up ring 36 to prevent the extrusion of the secondary seal into the gap. Because of the precise control of the gap distance between the floating seal assembly and the rotor assembly, a reduced amount of fluid coolant is permitted to pass between the annular seal surfaces 20 a and 22 a of the rotating and non-rotating seal members. The gap between the seal members when the coolant union 10 is in the unpressurized, unoperable condition is minimized and substantially limited because of the pull-back action on the non-rotating seal member during depressurization of the union. Thus, the secondary seal assembly provides a sealing function as well as a separation function of the floating seal assembly. Because the gap is minimized in the unpressurized condition, a minimum amount of coolant is permitted to pass between this reduced gap during start up of the coolant union. The reduced amount of fluid coolant to pass between the annular seal surfaces 20 a and 22 a results in a cleaner operating and more efficient fluid coolant union.
[0025] Additionally, the radial interference fit between the chamfered U-shaped annular seal 30 and the annular groove 28 within the housing member 14 permits the adjustable setting of the gap between the annular seal faces 20 a and 22 a . This is because the interference fit is less than standard such that upon pressurization of the union, the chamfer on the annular seal 30 and the back-up ring provide a sufficient interaction or displacement energy to create the micro pop-off of separation when the union is depressurized. This permits the adjustment of the floating seal assembly 24 for variable axial locations of the stub rotor member 12 and permits the predetermined relocation and adjustment of the floating seal assembly 24 .
[0026] While the invention is described with reference to a preferred embodiment, various modifications may be made without departing from the spirit and scope of invention as defined in the appended claims. For example, although the sealing arrangement is described with reference to a stub rotor member 12 , the stub rotor assembly may be contemplated to be a bearingless stub rotor member or may be a rotor assembly that is confined within fixed bearing structures. This permits the present invention to provide a wide range of operation through a coolant union from hundreds of RPMs to in excess of 40,000 RPMs.
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A coolant union includes a seal assembly having a first seal member and a non-rotating second seal member. At least one of the annular sealing surfaces presented by the rotating seal member and the non-rotating seal member is chamfered such that the chamfered sealing surface presents a sealing surface width less than the width of the dimension of the other sealing surface. The fluid coolant union further includes a U-shaped annular secondary seal member having a chamfered portion structurally arranged to receive a triangular back-up ring which stores sufficient relative displacement of the floating seal assembly to create a separation between the first rotating seal and the second non-rotating seal members during the unpressurized condition.
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BACKGROUND OF THE INVENTION
The present invention relates to a hydraulic control device for a primary hydraulic consumer and a secondary hydraulic consumer.
A hydraulic control circuit of this type is known, e.g., from DE 197 03 997 A1. The pressure medium flows to the two hydraulic consumers via metering orifices. A pressure scale is located upstream of the first metering orifice, which is assigned to the primary, first hydraulic consumer, and a pressure scale is located downstream of the second metering orifice, which is assigned to the secondary, second hydraulic consumer. The pressure scales serve to maintain constant pressure differences via the metering orifices when the quantity of pressure medium delivered is sufficient, independently of the load pressures. As a result, the quantity of pressure medium flowing to a hydraulic consumer depends only on the opening area of the particular metering orifice. The pressure medium source is typically an adjustable hydropump that is controllable as a function of the highest load pressure such that the pressure in a supply line is greater than the highest load pressure, by a certain pressure difference.
With regard for the first consumer, the control circuit corresponds to a load-sensing control (LS control). LS control or LS consumers are typically referred to when hydraulic consumers are controlled to which pressure medium flows via a meter orifice and an upstream pressure scale, and when the pressure scale registers the falling pressure via the particular metering orifice and holds it constant. The pressure scale is acted upon in the closing direction only by the pressure in front of the metering orifice, and it is acted upon in the opening direction only by the load pressure of the particular hydraulic consumer and by a compression spring.
With regard for the second consumer, the control circuit corresponds to an LUDV control. In this case, the pressure scale located downstream of the second metering orifice is acted upon in the opening direction by the pressure after the second metering orifice, and it is acted upon in the closing direction by a control pressure that is present in a rear control space, the control pressure typically corresponding to the highest load pressure of all hydraulic consumers supplied by the same hydropump. If several hydraulic consumers controlled in this manner are actuated simultaneously, the quantities of pressure medium flowing to them are reduced by the same ratio when the quantity of pressure medium delivered by the hydropump is less than the partial quantities of pressure medium demanded. This case is referred to as a control with load-independent flow distribution (LUDV control). The hydraulic consumers controlled in this manner are referred to as LUDV consumers. LUDV control is a special case of load-sensing control (LS control). In that case as well, the highest load pressure is also sensed, and the pressure medium source generates an inlet pressure that is greater than the highest load pressure by a certain amount Δp.
Publication DE 197 03 997 A1 mentioned above discloses a priority-based switching between the LS consumer and one or more LUDV consumers, in which priority is given to supplying the LS consumers with pressure medium. In addition to the pressure scale of the LS consumer, a priority valve is provided that includes a first connection, which is connected with a line section upstream of the first metering orifice and a second connection connected with the load-sensing line, and the valve element of which is capable of being acted upon—in the direction in which the connection between the first connection and the second connection is opened—by the load pressure of the primary hydraulic consumer, i.e., the LS consumer, and by an additional force. In the closing direction, the valve element is acted upon by pressure upstream of the metering orifice of the LS consumer—in a supply line or between the pressure scale and the first metering orifice. In this manner, it is ensured that priority is given to supplying the LS consumer with pressure medium. In particular, the pressure upstream of the first metering orifice is regulated to a value that is higher than the load pressure of the primary consumer at least by an amount that corresponds to the additional force that acts on the valve element of the primary valve.
SUMMARY OF THE INVENTION
The object of the present invention is to provide—based on the described state of the art—a hydraulic control device that is simpler and more cost-effective to manufacture.
This object is attained by a hydraulic control device according to the present invention.
The present invention relates to a hydraulic control device for a primary hydraulic consumer and one more secondary hydraulic consumers. The primary consumer is controlled by a first metering orifice, upstream of which a (LS) pressure scale is located. The secondary consumer is supplied by a second metering orifice, which is located downstream a pressure scale, in the manner of LUDV control.
The present invention is characterized by the fact that a further control edge is provided on the valve piston of the pressure scale of the primary consumer, which controls the supply of pressure medium from a supply line into a load-sending line. Two control edges are therefore provided on the valve piston of this pressure scale. The first control edge controls the flow of pressure medium supplied to the first metering orifice in the sense of an individual pressure scale for the primary consumer. The second control edge controls a flow area between the inlet and the load-sensing line. As a result, the pressure in the load-sensing line can be increased if the falling pressure difference at the metering orifice of the primary consumer falls below a certain value. This results in an increase in the pressure level upstream of the second metering orifice and, therefore, a reduction in the flow of pressure medium supplied to the secondary consumers. As a result, a sufficient quantity of pressure medium is available to the primary consumer.
The present invention makes clever use of the knowledge that the pressure scale of the primary consumer and the control mechanism of a pressure increase in the load-sending line are controllable using the same pressure signals, in order to realize these two functionalities in a single valve having a simple design. Compared with the conventional means of attaining the object of the present invention, a separate primary valve is not needed, thereby saving material, installation space, and costs. In addition, the inventive control device requires little maintenance, given the smaller number of movable components.
The pressure difference that results at the metering orifice of the primary consumer may be held nearly constant, independently of the operating state, since this pressure difference is determined by the control spring of the pressure scale in every operating state. When the quantity delivered by the pump is adequate and the secondary consumers are load-guiding, the pressure scale of the primary consumer behaves in the manner of an individual pressure scale and throttles the supply of pressure medium in such a manner that a pressure difference determined by the control spring is produced via the metering orifice of the primary consumer. If undersaturation exists, the pressure in the load-sensing line is regulated by the second control edge such that, in turn, the pressure difference at the metering orifice of the primary consumer corresponds to the pressure equivalence of this control spring. In comparison, with traditional control, various springs are provided in the pressure scale and in a primary valve that controls the load-sensing line. To ensure system behavior that may be unambiguously determined, considering the production tolerances, these springs are adjusted to different pressure equivalence values. Under certain circumstances with the conventional system, therefore, a noticeable reduction in pressure occurs at the metering orifice of the primary consumer, e.g., during the transition to undersaturation.
For example, the control edges are located such that a moving direction to open the first flow area corresponds to the moving direction to open the second flow area. This means that the control edges are formed on surfaces of the valve piston that are oriented in the same axial direction. The fact that the two control mechanisms of the pressure scale are actuated in the same direction makes it easier to realize them using a single valve piston.
According to a particularly preferred embodiment, the second flow area is not opened—i.e., pressure medium is not supplied to the load-sensing line—until the hydraulic resistance at the first flow area is nearly minimal. This means that the control mechanism of a pressure increase in the load-sensing line does not engage until the regulation of the flow rate across the pressure scale—that is, through the first area—has reached the upper flow limit of its control range. As a result, an unnecessary increase in the pressure level of the variable-displacement pump and a throttling of the secondary LUDV consumers is prevented for as long as the variable-displacement pump continues to deliver a sufficient quantity of pressure medium. When the control regions of these two control mechanisms adjoin each other in this manner and do not overlap—or they overlap only slightly—it is also possible to always ensure a stable operating state of the inventive hydraulic control device that may be unambiguously assigned to the particular load conditions.
A simple design of the pressure scale of the primary consumer results when it is designed as a gate valve with a valve bore and includes an inlet chamber and two outlet chambers—a first outlet chamber connected with the metering orifice, and a second outlet chamber connected with the load-sensing line.
The complexity of the pressure scale of the primary consumer may be reduced when an end face of the valve piston abuts the first outlet chamber, which is connected with the metering orifice. As a result, the pressure in the outlet chamber acts simultaneously as control pressure on the valve piston, in order to act upon it in the closing direction of the two flow areas.
According to a second, preferred embodiment, a fluid path is formed in the valve piston, which connects a control pressure space formed on an end face of the valve piston with the first outlet chamber. A fluid path of this type is easy to manufacture and is a space-saving way to apply pressure to a control pressure space of the pressure scale upstream of the metering orifice.
The fluid path preferably includes a bore that leads into the circumferential surface of the valve piston and is capable of being moved to overlap with the second outlet chamber. A particularly advantageous design of the pressure scale is obtained, since the fluid path serves simultaneously as a pressure line to the control pressure space and as a flow-through path into the second outlet chamber. Only a small flow area is still required between the inlet line and the load-sensing line, and a quantity of pressure medium supplied to and removed from the control pressure chamber is also small. A fluid path with a small diameter may therefore be used. Since fluid may not be supplied to the load-sensing line until the flow area between the inlet chamber and the first outlet chamber of the pressure scale is already largely open, the fluid pressure in the first outlet chamber largely corresponds to the fluid pressure in the inlet chamber. Fluid may therefore be easily supplied to the second outlet chamber from a region in the first outlet chamber, instead of directly from the inlet chamber, and the simple valve design described may be attained.
As an alternative, a recess is provided in the valve piston that may be moved to overlap simultaneously with the inlet chamber and the second outlet chamber. As a result, the first flow area and the second flow area may be designed independently of each other, if necessary.
The present invention and its advantages are described in greater detail below with reference to the exemplary embodiment presented in the figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a circuit diagram of a hydraulic control device with a primary consumer and a control valve that controls the flow of pressure medium to the primary consumer and the supply of pressure medium to a load-sensing line.
FIG. 2 is a sectional image of the control valve shown in FIG. 1 ,
FIG. 3A is a sectional image of the control valve shown in FIG. 1 , in an alternative design,
FIG. 3B is a symbolic depiction of the control valve shown in FIG. 3A ,
FIG. 4 is a schematic diagram of a further design of the control valve shown in FIG. 1 , and
FIG. 5 is a circuit diagram of a hydraulic control device, comparable to FIG. 1 , with a by-pass line for indicating a load pressure of the primary consumer to the load-sensing line.
DESCRIPTION OF THE PREFERRED EMBODIMENT
According to FIG. 1 , a variable-displacement pump 10 with a displacement control 11 suctions pressure medium out of a tank 12 and supplies it to a system of supply lines. Via the supply lines, a first hydraulic consumer 14 , which is designed as a synchronous cylinder, and at least one second hydraulic consumer 15 , which is a differential cylinder, are supplied with pressure medium. The direction and speed of the synchronous cylinder 14 are determined via actuation of a 4/3-proportional directional control valve 16 , the valve spool of which is centered via a spring in a central position, in which the four working connections and one control connection 18 of directional control valve 16 are blocked. When the valve spool is displaced from its central position in one direction or the other, a metering orifice 17 is opened to an extent that depends on the displacement of the valve spool. Downstream of the metering orifice, control connection 18 is connected with the approach to synchronous cylinder 14 .
A control valve 45 with the function of a 2-way pressure scale is installed between a supply line 13 and a supply connection 19 of directional control valve 16 . Accordingly, control valve 45 controls the flow area of a fluid connection 20 between its inlet 46 and one of its outlets 23 , i.e., between supply line 13 and supply connection 19 of directional control valve 16 . Valve piston 48 of control valve 45 is acted upon, in the direction of closing connection 20 , by pressure upstream of a metering orifice 17 and, in the direction of closing, via a control line 61 by pressure in control connection 18 of directional control valve 16 , i.e, by the load pressure of synchronous cylinder 14 , and by a control spring 21 . The force of control spring 21 is designed such that it is equivalent to a pressure difference of, e.g., 15 bar above metering orifice 17 .
While control valve 45 assigned to first hydraulic consumer 14 is therefore located upstream of first metering orifice 17 , second pressure scale 30 assigned to second hydraulic consumer 15 is located downstream of a second metering orifice 31 . To control the direction of differential cylinder 15 , a directional control valve 32 is located between second pressure scale 30 and the differential cylinder, via which pressure does not drop noticeably when differential cylinder 15 is actuated, compared with the drop in pressure at metering orifice 31 . Metering orifice 31 and the control grooves required to control direction are designed on the same valve spool in a known manner, so that direction and speed are automatically controlled jointly. Control piston 33 of pressure scale 30 is acted upon—in the direction of opening the connection between metering orifice 31 and directional control valve 32 —by the pressure after metering orifice, and, in the direction of closing the connection, by a control pressure that exists in a rear control pressure space 34 , and by a weak compression spring 35 , which is equivalent to a pressure of, e.g., only 0.5 bar. The front side of control piston 33 is connected via a channel 36 extending in the control piston with control pressure space 34 . A non-return valve 37 that is open toward the control pressure space is located in channel 36 .
In parallel with metering orifice 31 , pressure scale 30 , and directional control valve 32 for second hydraulic consumer 15 , further metering orifices, pressure scales, and directional control valves for further hydraulic consumers may be connected to the system of supply lines 13 . Control pressure spaces 34 of all pressure scales 30 are connected with each other, so that the same pressure forms in these control pressure spaces. When a second hydraulic consumer is actuated, control pistons 33 of the pressure scales attempt to move into a position in which a pressure occurs on their front side that is higher than the pressure in control pressure spaces 34 only by the pressure difference equivalent to the force of compression spring 35 .
Disregarding first hydraulic consumer 14 entirely, the highest load pressure of all actuated, second hydraulic consumers 15 is transferred to control pressure spaces 34 via channels 36 and non-return valves 37 . Control pressure spaces 34 are connected to a load-sensing line 38 that leads to displacement control 11 of pump 10 . Load-sensing line 38 is also connected with tank 12 , via a current control 55 . These current controls relieve the pressure on load-sensing line 38 when none of the hydraulic consumers is actuated.
Variable displacement pumps and related controllers are known in general and are readily available on the market. It is therefore not necessary to discuss them in greater detail. It should merely be noted that the pump control serves to adjust a pressure in supply line 13 that is higher than the pressure in load-sensing line 38 by a pressure difference Δp equivalent to the force of a control spring. Pressure difference Δp is, e.g., 20 bar, and is therefore higher than pressure difference of 15 bar, which is equivalent to the force of control spring 21 of control valve 45 .
First hydraulic consumer 14 should be supplied with pressure medium with priority over second hydraulic consumer 15 . A second controllable connection 22 is provided in control valve 45 for this purpose. Connection 22 is designed as an orifice with a proportionally controllable flow area between inlet 46 and an outlet 47 . Outlet 47 is connected with load-sensing line 38 .
For the second fluid connection 22 controlled by it, valve piston 48 of control valve 45 is acted upon, in the direction of closing, by a pressure upstream of metering orifice 17 and, in the direction of opening, by the load pressure of primary consumer 14 applied via control line 61 , and by control spring 21 .
Control valve 45 is shown in greater detail in FIG. 2 . A valve bore 71 is provided in valve housing 70 . Valve piston 48 is displaceably supported in this bore. The valve bore is abutted by an inlet chamber 72 and two outlet chambers 73 and 74 . The inlet chamber is connected with connection 46 , which is designed as a bore, and, therefore, with supply line 13 . Outlet chamber 73 is connected with outlet 23 , i.e., with metering orifice 17 . Outlet chamber 74 leads into load-sensing line 38 , via connection 47 .
Controllable fluid connection 20 is established via a radially recessed section 76 of valve piston 48 . Control edge 77 is formed on valve piston 48 , on a step located in the direction of inlet chamber 72 . Control edge 77 bounds a first flow section between itself and a housing segment 78 , which is formed between inlet chamber 72 and outlet chamber 73 .
Fluid connection 22 is formed by a recess 78 in the circumferential surface of valve piston 48 . Recess 78 may be, e.g., an axial groove or a radial step of the valve piston. A control edge 79 , which bounds recess 78 in the direction of outlet chamber 74 , forms a second controllable and closable flow area with outlet chamber 74 .
A control pressure space 50 is connected to control line 61 , which directs the load pressure of primary consumer 14 . The pressure in control pressure space 50 acts on valve piston 48 in the direction of opening of fluid connections 20 and 22 . In addition, the force of control spring 21 on valve piston 48 acts in the direction of opening. The pressure present in control pressure space 49 acts in the closing direction. Control pressure space 49 is fluidly connected via a fluid channel 75 formed in valve piston 48 with radially recessed section 76 and, therefore, with outlet chamber 73 .
The mode of operation of the inventive control device will now be explained with reference to FIGS. 1 and 2 . An equilibrium of forces involving the following force and pressure components sets in at valve piston 48 of control valve 45 :
p LS +p 21 =p 38 +Δp Δp DW (Equation 1),
in which p LS is the load pressure of primary consumer 14 , p 21 is the pressure equivalent of the force of control spring 21 , p 38 is the load pressure in load-sensing line 38 , Δp is the control pressure difference of pump displacement control 11 , and Δp DW is the pressure that is falling at control edge 77 of connection 22 .
Control edge 79 is positioned such that connection 22 does not open until the flow area at control edge 77 is nearly at a maximum, i.e., when pressure drop Δp DW at control edge 77 has reached a value Δp DW* that is nearly a minimum. Value Δp DW* depends on the flow rate at control edge 77 , however.
If the flow of pressure medium conveyed by the pump is sufficient to supply all of the consumers, control pressure difference Δp remains constant at the value set by the control spring of pump displacement control 11 , e.g, 20 bar.
As long as the secondary consumers are load-guiding, that is, as long as the pressure in supply line 13 is greater than the sum of the load pressure of primary consumer 14 and the pressure equivalence of control spring 21 , a pressure drop Δp DW is generated via control edge 77 to regulate the supply to the primary consumer. The pressure drop Δp DW results in a throttling of excess pressure present in supply line 13 with respect to primary consumer 14 . Pressure P 38 in the load-sensing line corresponds to the highest load pressure of the secondary consumer, which is referred to below as p LUDV .
With a load pressure of the primary consumer of
p LS >( p LUDV +Δp )− p 21 −−Δp DW* (Equation 2),
in which (p LUDV +Δp ) is the supply pressure that may be generated by secondary consumer 15 , the control mechanism of a throttling at first control edge 77 is exhausted, and the associated flow area is completely open.
Therefore, when the supply pressure (p 38 +Δp ) falls above or below the value p LS +P 21 +Δp DW* , second control edge 79 opens the flow area of connection 22 . As a result, pressure p 38 in load-sensing line 38 increases to values greater than P LUDV . If the pressure (p 38 +Δp ) present in supply line 13 was previously dependent only on load pressure P LUDV of the secondary consumers, the supply line pressure (p 38 +Δp ) is now determined by load pressure p LS of primary consumer 14 . Supply line pressure (P 38 +Δp ) is controlled using control edge 79 and the feedback via displacement control 11 . Equation 1 directly results in the dependency
( p 38 +Δp )= p LS +p 21 ′+Δp DW* (Equation 3),
when one considers that control spring 21 is loaded less when regulation is carried out at control edge 79 than when regulation is carried out at control edge 77 , i.e., it has a slightly less pressure equivalence p 21 ′ than p 21 , and when Δp DW* is assumed to be a slight pressure drop at the flow area, which is nearly completely open and is bounded by control edge 77 . Essentially, the pressure in supply line 13 is regulated to a value that is higher than the load pressure of the primary consumer 14 by pressure equivalence p 21 ′ of control spring 21 .
When the flow of pressure medium conveyed by pump 10 does not suffice to supply all consumers, Δp may no longer be regarded as constant. The control capacity of pump 10 and its displacement control 11 are exhausted, and the pressure in supply line 13 drops. As before, connection 22 opens when the supply line pressure (p 38 +Δp ) drops to p LS +p 21 +Δp DW* . This results in an increase of the pressure present in load-sensing line 38 . As a result, the pressure between metering orifice 31 and pressure scale 30 of secondary consumer also increases. The pressure difference that is present at metering orifice 31 is reduced and, therefore, the flow of pressure medium that may be supplied to the secondary consumer also decreases. If necessary, when control pressure difference Δp has dropped accordingly, the pressure in load-sensing line 38 may increase to the supply pressure (p 38 +Δp ) and completely halt the supply to secondary consumer 15 , via pressure scale 30 . It is also possible to limit several secondary consumers 15 in this manner. Via this mechanism of throttling secondary consumer 15 , the supply pressure (p 38 +Δp ) is regulated per equation 3, to a value that is essentially higher than the load pressure of the primary consumer 14 by pressure equivalence p 21 ′ of control spring 21 .
In every case, a reliable supply of primary consumer 14 is therefore ensured such that a pressure difference that corresponds to pressure equivalence p 21 or p 21 ′ of control spring 21 is present above metering orifice 17 .
FIG. 3A shows a control valve 85 , which is a modified design of control valve 45 . A symbolic depiction of control valve 85 is shown in FIG. 3B . The only difference between control valve 85 and control valve 45 is that control valve 85 has valve piston 88 . Similar to valve piston 48 , valve piston 88 includes a radially recessed piston section 76 . A fluid channel 75 extends out of this piston section and leads into control pressure space 49 located on an end face of valve piston 88 . In contrast to valve piston 48 , there is no recess in the circumferential surface of the piston with which inlet chamber 72 may be connected directly with outlet chamber 74 . Instead, a bore 86 is formed perpendicularly to the axis of valve piston 88 . Bore 86 leads into fluid channel 75 . Together with a fine control groove 87 , bore 86 forms a control edge 89 for controlling a flow area at outlet chamber 74 . It should be noted that this opening area formed between control edge 89 and valve housing 70 does not open until the hydraulic resistance or pressure drop Δp DW at control edge 77 has already reached a value Δp DW* close to the minimum value. The pressure of the pressure medium, which is supplied by radially recessed piston section 76 via fluid path 75 when control edge 89 is opened therefore approximately corresponds to the pressure in inlet connection 46 . As a result the pressure in load-sensing line 38 may be increased nearly to the supply fine pressure that is present at inlet connection 46 .
A further design of a control valve 95 that may be used in place of control valve 45 or 85 is shown in FIG. 4 . The symbolic depiction of control valve 95 corresponds to that shown in FIG. 3B . A valve bore 91 is provided in valve housing 90 of control valve 95 . An inlet chamber 92 and two outlet chambers 93 and 94 are located at valve bore 91 . Chambers 92 , 93 and 94 are fluidly connected with related connections 46 , 47 and 23 , as shown in FIG. 4 . A cylindrical valve piston 96 is movably guided in valve bore 91 . Valve piston 96 includes an axially extending blind hole 97 that is open in the direction of outlet chamber 93 . From circumferential surface of valve piston 96 , two radially extending bores 98 and 99 extend toward blind hole 97 .
Bore 98 may be moved to overlap with inlet chamber 92 . As a result, a fluid connection is created from inlet connection 46 via bore 98 , blind hole 97 , outlet chamber 93 , and outlet connection 23 . Control edge 100 , which plays a decisive role in the control of the flow area of this connection, is the edge of bore 98 on the circumferential side. A fluid connection from inlet connection 46 to outlet connection 47 is created via bore 98 , blind hole 97 , bore 99 , and outlet chamber 94 . Control edge 101 , which is decisive for this, is the edge of bore 99 on the circumferential side. Bore 99 is located such that it does not overlap with outlet chamber 94 until the flow area controlled at bore 99 results in a slight hydraulic resistance/pressure drop Δp DW* . As a result, the pressure in load-sensing line 38 may be increased nearly to the inlet pressure present at inlet connection 46 .
On an end face of valve piston 96 facing away from blind hole 97 , valve piston 96 bounds a control pressure space 50 formed in valve housing 90 . It is connected to control line 61 , which guides the load pressure of primary consumer 14 . The pressure in control pressure space 50 acts in the direction of opening of the connections controlled by bores 98 and 99 . In addition, control spring 21 located in control pressure space 50 acts in the opening direction. In the closing direction, valve piston 96 is acted upon directly by the pressure in outlet chamber 93 , since valve piston 96 abuts outlet chamber 93 with its end face that leads into blind hole 97 . With this embodiment of control valve 95 , a very low pressure drop Δp DW* at bore 98 may be attained, and by locating outlet chamber 93 on the end-face end of valve piston 96 , it is not necessary design a separate control chamber or a control line that leads thereto, internally or externally.
FIG. 5 shows a further embodiment of the inventive hydraulic control device. The embodiment shown in FIG. 5 is largely equivalent to the design shown in FIG. 1 . The difference from the embodiment shown in FIG. 1 is that control line 61 that leads from control connection 18 of directional control valve 16 to control valve 45 is also connected with load-sensing line 38 , via a non-return valve 63 located in a by-pass line 62 . Non-return valve 63 blocks from load-sensing line 38 toward channel 61 , i.e., toward control connection 18 of directional control valve 16 . In addition, a non-return valve 64 is also located between second connection 47 of control valve 45 and load-sensing line 38 . Non-return valve 64 blocks toward connection 47 .
With the embodiment shown in FIG. 1 , as described above, even when a sufficient quantity of pressure medium is conveyed, a change takes place in the control mechanism of control valve 45 when load pressure p LS of primary consumer 14 exceeds the supply pressure (P LUDV +Δp ) specified by the secondary consumers, minus pressure equivalent p 21 of control spring 21 (pressure drop Δp DW* at control edge 77 is negligibly small). When the primary consumer becomes load-guiding in this sense, the control valve loses its functionality as an LS pressure scale. This is replaced by the mechanism of controlling the pressure in load-sensing line 38 .
With the embodiment shown in FIG. 5 , when a sufficient quantity of pressure medium is pumped, and given a load-guiding, primary hydraulic consumer 14 , the load pressure of this hydraulic consumer is directed via non-return valve 63 into load-sensing line 38 . The pressure in supply line 13 is therefore higher than the load pressure of hydraulic consumer 14 by control pressure difference Δp of variable-displacement pump 10 . In this case, control valve 45 has the function of an LS pressure scale and throttles the flow of pressure medium directed to metering orifice via first control edge 77 . The pressure difference present above pressure scale 17 therefore corresponds to pressure equivalent p 21 of control spring 21 .
Pressure medium is not directed to load-sensing line 38 via connection 22 until—when undersaturation occurs—the pressure (p 38 +Δp) in supply line 13 has dropped to the sum of load pressure P LS of hydraulic consumer 14 , pressure equivalent P 21 of control spring 21 , and a slight pressure drop Δp DW* at control edge 77 . The pressure drop via metering orifice 17 is basically not reduced, because, as undersaturation continues, pressure p 38 in load-sensing line 38 via control valve 45 increases and, as a result, pressure scales 30 of LUDV consumers 15 are displaced in the closing direction.
Non-return valve 64 prevents pressure medium from flowing from hydraulic consumer 14 via non-return valve 63 into the system of supply lines, provided that the pressure in the supply lines is not yet above the load pressure, e.g., at the beginning of an actuation.
Non-return valve 64 may be eliminated when connection 47 of control valve 45 is connected with non-return valve 63 in such a manner that non-return valve 63 blocks toward connection 47 .
List of Reference Numerals
10 Variable-displacement pump
11 Displacement control
12 Tank
13 Supply line
14 Synchronous cylinder
15 Differential cylinder
16 4/3-way proportional directional control valve
17 Metering orifice
18 Control connection
19 Supply connection
20 Fluid connection
21 Control spring
20 Fluid connection
23 Outlet
30 Pressure scale
31 Metering orifice
32 Directional control valve
33 Regulating piston
34 Control pressure space
35 Compression spring
36 Channel
37 Non-return valve
38 Load-signalling line
45 Control valve
46 Inlet
47 Outlet
48 Valve piston
49 Control pressure space
50 Control pressure space
55 Current control
61 Control line
62 Bypass line
63 Non-return valve
64 Non-return valve
70 Valve housing
71 Valve bore
72 Inlet chamber
73 Outlet chamber
74 Outlet chamber
75 Fluid channel
76 Recessed piston section
77 Control edge
78 Recess
79 Control edge
85 Control valve
86 Bore
87 Fine-control groove
88 Valve piston
89 Control edge
90 Housing
91 Valve bore
92 Inlet chamber
93 Outlet chamber
94 Outlet chamber
95 Control valve
96 Valve piston
97 Blind hole
98 Radial bore
99 Radial bore
100 Control edge
101 Control edge
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The invention relates to a hydraulic control device for a priority, first hydraulic consumer and a subordinate, second hydraulic consumer, pressure medium being deliverable to the first or the second consumer via a first or a second metering diaphragm. A pressure scale which allows a constant pressure difference to be adjusted above the first metering diaphragm is mounted upstream from the first metering diaphragm. For this purpose, said pressure scale is provided with a valve piston encompassing a first control edge, by means of which a first flow area between a feeding duct and the first metering diaphragm can be controlled. A second control edge which allows a second flow area to be controlled between the feeding duct and a load signaling line is provided on the valve piston of the first pressure scale.
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BACKGROUND OF THE INVENTION
This invention relates to a method for detecting the presence of a body, such as a saucepan or the like, placed on the hob plate of a glass ceramic cooking hob associated with a heating element located below this hob plate. The present invention also relates to a device for detecting the body on the hob.
Various devices and corresponding methods are known for detecting a saucepan or other container on a hob plate in correspondence with the relative heating element. These devices and methods are generally complicated and sometimes do not provide reliable detection of the presence of the saucepan on the hob.
In addition, the known devices do not enable the presence of a container on the hob plate of the cooking hob to be detected using only means and methods of simple implementation, allowing consequent control of the operation of the heating element located below the hob plate on which the container is placed.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a method of the stated type which is of simple implementation and which allows reliable detection of the presence of a body or container placed on the hob plate of the glass ceramic cooking hob.
A further object is to provide a method of the stated type which enables the operation of the heating elements of a glass ceramic cooking hob to be controlled on the basis of the measured dimensions of the container or body placed on the hob.
A further object is to provide a method of the stated type which also enables the temperature of the glass ceramic cooking hob to be controlled, to hence control the food preparation on the basis thereof.
A further object of the invention is to provide a device of the stated type which is of simple construction and reliable use.
A further object is to provide a device of the stated type which enables the operation of the heating elements of the cooking hob to be controlled on the basis of the dimensions of the container or body placed on the hob.
A further object is to provide a device which costs less to make than analogous known devices and involves lower installation, maintenance and operating costs.
A further object is to provide a device having means for controlling the temperature of the hob plate of the glass ceramic cooking hob.
These and further objects which will be apparent to the one skilled in the art, are attained by a method of the aforestated type, consisting of measuring the variation in a physical characteristic of conductive means positioned between the electrically non-conductive hob plate and a corresponding heating element, the variation being caused by positioning a body or container on the hob plate associated with the heating element, the variation being measurable by way of a corresponding variation in an electrical signal passing through the conductive means, the latter electrical signal variation being evaluated by control means which control at least the heating element, the operating parameters of the latter being modified in relation to the variation in the electrical signal.
These objects are also attained by a device of the aforesaid type, having conductive means positioned between the hob plate and the corresponding heating element, the means being at least of open loop configuration and being connected to means for controlling the operation of at least the heating element, a physical characteristic of the conductive means varying following the positioning of a container on the hob plate associated with the heating element, the variation corresponding to the variation in a corresponding electrical signal passing through the means, this variation being measured by the control means, which consequently act on the heating element to modify its operating parameters.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of the device according to the invention;
FIG. 2 shows a first embodiment of the device of FIG. 1;
FIG. 3 shows a second embodiment of the device of FIG. 1;
FIG. 4 is a view from above of a usual heating element for a glass ceramic cooking hob with which a part of the device of the invention is associated;
FIG. 5 is a front view of the heating element of FIG. 4;
FIG. 6 is a detailed view of part of the element of FIG. 4;
FIG. 7 is a schematic view of a third embodiment of the device according to the invention;
FIG. 8 is a block diagram showing a fourth embodiment of the device according to the invention; and
FIG. 9 is a detailed representation of a particular arrangement of the device embodiment shown in FIG. 8.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 1, a glass ceramic cooking hob 1 comprises an electrically non-conductive hob plate 2 (of glass ceramic), on the top surface 4 of which there is a cooking zone 3. Below the hob plate 2, associated with the zone 3, there is a conductive element 5 connected to a usual electrical feed line 6. The conductive element 5 is connected to a control circuit 8 which also acts on at least one usual heating element 10 positioned below the conductive element (as can be seen from FIG. 1).
On using the glass ceramic cooking hob 1 by placing a container or saucepan P on the zone 3, the presence of the container disturbs the electrical field generated by the element 5 through which current flows. This gives rise to induced currents within the conductive element, to produce a variation in the voltage drop across it when no container P is placed on the hob plate 2.
This variation is measured by the circuit 8, which consequently acts on the element 10 to modify its heating power and hence proceed to the preparation of the food contained in the saucepan P.
More specifically, with reference to FIGS. 2 to 7 (in which parts corresponding to those of FIG. 1 are indicated by the same reference numerals) the conductive element 5 is a wire resistor 15 (see FIG. 4) arranged an open loop configuration in associated with the heating element 10. This resistor has two portions 15A and 15B placed at an angle between them above halogen lamps 16 defining the heating element 10 in the described example. The lamps 16 are of the linear type and are associated with a usual reflector element 17.
The resistor 15 (in the form for example of an open triangle) has an end 18, common to the portions 15A, 15B, associated with a support 20 formed preferably of ceramic material or other electrically insulating material. The support 20 is associated with a pin 21 carried by one end 22 of an elastic member 23, including in the preferred embodiment, at least one bracket 24 projecting from a shoulder 25 rising from a base 26 fixed (for example by screws 27 cooperating with holes 28 in the base) to the reflector element 17.
The free ends 29 and 30 of the portions 15A, 15B are associated with electrically insulating support pieces 31 removably positioned (for example by snap-fitting) in seats 33 in the element 17. The end 29 is electrically connected to the line 6, whereas the end 30 is connected to the circuit 8.
Finally, the element 17 has a connector block 35 for the electrical feed to the lamps 16.
The resistor 15 (or in general the conductive element 5) is connected into an electrical circuit 40 with which the control circuit 8, preferably of microprocessor type, is associated Specifically, in a first embodiment (see FIG. 2), the conductive element 5 is connected to a node 41 from which there extends an electrical branch 42 terminating in an usual oscillating circuit 43 (for example a usual Colpitts oscillator). The node 41 is connected to the collector 47 of a transistor 48, the base 49 of which is connected to a voltage divider 50, including resistors 50A and 50B. The emitter 51 of the transistor 48 is connected to the collector of a second transistor 54, the base 55 of which is connected to the oscillator or oscillating circuit 43.
The emitter 56 of the transistor 54 is connected to a node 57; this node is connected to a resistor 58 connected to earth at 59, and to the control circuit 8. The latter is connected to a element 60 for controlling the heating element 10 (for example a voltage regulator if the heating element is at least one halogen lamp, or a solenoid valve if the heating element is at least one gas burner).
In a second embodiment (see FIG. 3, in which the elements already described in FIG. 2 carry the same reference numerals), the circuit 40 includes a further transistor 63 connected between the circuit 8 and the node 57. Specifically, the base 64 of this transistor is connected directly to the node 57, the collector 65 is connected to a resistor 67 connected to the line 6, and the emitter 66 is connected to the circuit 8.
The first embodiment of the circuit 40 (FIG. 2) allows analog control of the circuit 8 whereas the second embodiment (FIG. 3) allows digital control of this circuit.
With both these embodiments the control is such that the circuit 8 is able to set only two states (on or off) of the heating element 10.
Specifically, if no saucepan is placed on the hob plate 2, the voltage V A across the ends of the resistor 58 and sensed by the base 64 of the transistor 63 of FIG. 3 has a constant value (for example between 0 and 2 V) such as to maintain this transistor in its inhibited state. In the latter case no signal is emitted by the emitter 66 and the circuit 8 detects the lack of the saucepan P on the hob plate 2. However in the case of FIG. 2, maintaining the signal V A fed to the circuit 8 within a suitable voltage value (for example 0-2) does not enable this circuit (operating with comparison algorithms) to detect the presence of the saucepan P on the hob plate 2.
It will now be assumed that the saucepan is placed on the hob plate.
In this case, the (generally metal) mass of such a container modifies the electrical field generated by the conductive element 5, with the result that current is induced in this element by virtue of known physical phenomena.
This causes a variation in a signal V B fed to the node 41. From the latter, corresponding signals reach the oscillator 43, and the transistor 48 via its collector 47. Respective signals V C and V D are fed from these latter to the transistor 54. As a result of the, from this latter transistor there emerges a signal V F , part of which flows from the node 57 to the resistor 58.
There is, therefore, an increase in the voltage drop across the resistor with the result that the voltage V A across its ends varies from that when the saucepan P is not present on the hob plate 2. Following this, with reference to FIG. 2, the voltage sensed by circuit 8 increases (for example to within a range of 2-5 V). Using suitable comparison algorithms, this causes the circuit 8 to detect the presence of the saucepan P and generate a signal V G directed towards the element 60 which controls the heating element 10. This signal modifies the state of the said element 60 (for example it opens the solenoid valve for the gas to the burner or increases the feed voltage to the halogen lamps 16) and therefore the state of the heating element. The latter, for example, passes from a state of inactivity to a state of maximum power to allow preparation of the food contained in the saucepan P. This happens if the operating knob or the heating element has been previously moved into the position for activating the element. In this respect, the knob is associated with a lighting member (for example a lamp, not shown) which is activated in known manner when a saucepan P is placed on that zone 3 whose element 10 is controlled the knob. The activation is preferably effected by the circuit 8.
Likewise, in FIG. 3 the variation in the voltage V A at the node 57 causes saturation of the transistor 63, which consequently generates a signal at the emitter 66, which reaches the circuit 8. This circuit is therefore activated and operates on the element 60 in the aforesaid manner.
FIG. 7 shows a third embodiment of the circuit 40. In this figure, parts corresponding to those of the previously cited figures are indicated by the same reference numerals.
In the figure under examination, the circuit 40 allows the power of the heating element to be regulated on the basis of the dimensions of the saucepan P. In this case, the heating element 10 includes at least two heat-generating members 76 and 77 (electrical resistors or halogen lamps) of substantially annular form arranged one within the other. By selectively activating these members the cooking zone can be limited (for example by activating only the inner member 77) or the heating power can be modified (by selectively activating the inner or outer member). In the circuit 40 of FIG. 7, the node 57 is connected to a transistor 80, the emitter 81 of which is connected to a resistor 82 connected to earth at 83. The transistor 80 and the resistor act as a current amplifier 84.
An electrical branch 85 is connected to the transistor, to terminate in a node 86 to which the inverting input 88 of an operational amplifier 89 is connected. The non-inverting input 87 of the latter is connected to a circuit part 90 comprising a resistor 91, a capacitor 92 and a zener diode 93, these being connected together in parallel. The part 90 includes a variable resistor 95 which can be adjusted to define the lower value of a range of voltage (or another analogous quantity), for example 0-15 V within which the circuit 8 does not detect the presence of any saucepan P on the hob plate 2.
The circuit part 90 is connected to the line 6 via a resistor 98. Finally, the circuit part 90 is connected to the branch 85 via an electrical branch 97. This circuit part removes any disturbances in the signal V N fed to the amplifier 89 by superimposing on this signal a more stable one.
The output 100 of the amplifier 89 is fed back along an electrical branch 101 including at least one variable resistor 102 which can be adjusted to define the upper value of the range of voltage (or other analogous quantity) within which the presence of the saucepan P on the hob plate 2 is detected.
Said output 100 of the amplifier 89 is connected to a resistor 105 and to an electrical branch 106 having a capacitor 107 connected to earth at 108. The branch 106 then terminates in the control circuit 8.
The operation of the circuit shown in FIG. 7 is identical to that shown in FIG. 2 as far as the generation of the signal V A . This signal varies as a function of the disturbance to the electrical field generated by the resistor 5 as a result of positioning saucepans or containers of different dimensions on the hob plate 2. For example, if the saucepan has a relatively small diameter, the variation in the signal V A (with respect to the value with the saucepan absent from the hob plate 2) is less than that of the same signal generated after positioning a large saucepan on the hob plate.
The signal V N which reaches the amplifier in the two stated cases (small and large saucepan) then either falls or does not fall within the band of voltage (or corresponding quantity) the lower limit of which is defined by adjusting the variable resistor 95 and the upper limit of which is defined by adjusting the variable resistor 102.
Depending on the relative position of the signal V N within the band, the amplifier 89 generates a signal V O the value of which varies on the basis of the size of the saucepan P placed on the hob plate 2. The signal V O is suitably integrated by the resistor 105 and capacitor 107 to make it "acceptable" to the circuit 8. The latter, using a comparison algorithm and depending on the value of the signal V O , selectively operates the members 76 and 77 to heat the saucepan P, possibly without activating that member above which the saucepan does not reach. As already stated, in the examples described heretofore, adjustment knobs located on a control panel (not shown) enable the user to adjust the heating power of the element 10. These knobs are preferably connected to the circuit 8.
Consequently, if with the knob positioned at any point corresponding to a precise requested heating power the circuit 8 does not detect any saucepan on the hob plate, the circuit interrupts or sets to a minimum the feed (electricity or gas) to the element 5. This is the case for all the described embodiments of the circuit 40. Preferably, the circuit takes this action a suitable predetermined time after the circuit 8 no longer detects the presence of the saucepan (in the manner heretofore described). A suitable timer 8A connected to the circuit 8 enables the latter to operate in the stated manner. The same conductive element 5 (or at least its "linear" portion 15A or 15B) enables the temperature of the heating element 10 and therefore the heating power fed to the saucepan or container P on the hob plate 2 to be controlled.
This application of the element 5 is shown in FIGS. 8 and 9. In these figures, parts corresponding to those of the already described figures are indicated by the same reference numerals.
In FIG. 8, the block diagram represents a circuit 200 with which the element 5 is associated for this temperature measuring function.
The 200 comprises an oscillator 201, for example including a Schmidt trigger and a current generator 202 connected to a resistance bridge 203, one arm of which comprises the resistor 5. The bridge 203 is connected to a comparator 206 in which a signal V K from the bridge is compared with a reference signal V L . The output 207 of the comparator 206 is connected to the oscillator 201; therefore on the basis of the comparison between V K and V L , this comparator generates a signal V P which controls the operation of the oscillator 201 by adjusting it as required.
The branch 204 (or diagonal) and the branch 210 of the bridge 203 are connected to electrical branches 211 and 212 terminating in a differential amplifier 213, the output of which is connected to a synchronous modulator 214 connected to an exit amplifier 215. The latter is connected to the circuit 8.
FIG. 9 shows in greater detail a preferred embodiment of the circuit 200 of FIG. 8. In this figure, parts corresponding to those described in FIG. 8 are indicated by the same reference numerals.
This embodiment of the invention comprises a bandwidth limiting filter 220 connected to the oscillator 20 and defined by resistors and capacitors, not shown. The filter 220 is connected to a transistor 221 acting as a current amplifier and connected to resistors 222 and 223. The latter and transistor 221 define the current generator 202.
Downstream of the latter there is a further filter 225 to filter, signals of different frequency. This filter (including electrical components such as inductors and capacitors) separates electrical signals of different frequencies (for example of 10 MHz and 1 KHz) used respectively for detecting containers on the hob plate 2 of the cooking hob 1 and for measuring the temperature of the heating elements 10 (and therefore of hob plate 2).
The filter 225 is connected to the bridge 203. The branches 204 and 210 of the latter are connected to branches 211 and 212. A further branch 230 including a capacitor 231 connected to earth is connected to the branch 211. The latter terminates at the non-inverting input 234 of an operational amplifier 233, the output of which is fed back to its inverting input 235. This amplifier operates as a non-inverting buffer.
Likewise, the branch 212 terminates at the non-inverting input 236 of an operational amplifier 237 with feedback to its inverting input 238. This amplifier also operates as a non-inverting buffer.
The buffers 233 and 237 are connected to a first operational amplifier 240 via resistors 241, 242 and 243, the latter being connected to earth at 244.
Via a further resistor 245, the buffer 233 is connected to the output 246 of the amplifier 240, which is connected to the inverting input 247 of a second amplifier 248, the non-inverting input 250 of which is connected to earth at 249.
These buffers and the two amplifiers 240 and 248 define the aforesaid differential amplifier 213.
The amplifier 248 is connected to the synchronous demodulator 214 via a capacitor 250 and a resistor 251 which integrate the output signal V S of the amplifier 213.
The demodulator 214 includes a switch member 253, an operational amplifier 254 and a plurality of resistors 255, 256, 257 and 258, of which the latter feeds back to said amplifier 254. The switch member (preferably a static switch) is controlled by a circuit part 260 which includes a comparator 261, resistors 262, 263, a diode 264 connected to earth at 265 and a capacitor 266. The comparator 261 compares a signal V Z fed to the base 267 of the transistor 221 (via an electrical branch 268) with its mean value, this comparison being enabled by the resistor 262 and the capacitor 264. From this comparison, the comparator generates a control signal V R for opening or closing the switch member 253. In this manner, the signal V S is sampled at precise time periods synchronized with the generation of the signal V Z by the oscillator 201.
A compared and synchronized signal V T is emitted by the demodulator 214 and reaches a circuit block 270 including resistors 271 and 272 and corresponding capacitors 273 and 274. This block filters the signal V T to make it acceptable to the control circuit 8, which it reaches after amplification by the amplifier 215. The latter obtains feedback from a circuit block 281 including a variable resistor 282 and a fixed resistor 283 (connected to earth at 284), and a capacitor 285. The resistor 282 allows the amplifier gain to be varied by adjusting it in accordance with the desired control signal V X which the circuit 8 emits in the direction of the control element (not shown in FIG. 9) of the heating element (also not shown).
The bridge 203 is connected to a circuit part 290 which rectifies the bridge output signal V K fed to the comparator 206. The latter receives the signal V L from a circuit block 291. It should be noted that the signal V K is taken from the branch 204 of the bridge 203, the branch 210 of the latter comprising high-resistance resistors 210A and 210B. This signal corresponds substantially to the mean value of a signal V H originating from the current generator 202.
On the basis of the comparison between V K and V L , the comparator 206 generates the signal V P which controls the oscillator 201. This control is effected in such a manner that the signal V K reaching its inverting input 206A equals the signal V L reaching its non-inverting input 206B.
The operation of the circuit 200 is apparent from the aforegoing description.
When the temperature of the resistor 5 varies, its resistance also varies. Consequently the signal V W originating from the bridge 203 via the branch 211 also varies. As a result of this, the signal V S and the signal V I reaching the circuit 8 from the amplifier 215 vary.
This variation is interpreted by circuit 8 (which as stated is preferably of microprocessor type), using comparison algorithms, as a variation in the temperature of the heating element 10 or of the cooking zone 3 of the hob plate 2. Therefore, following a request by the user for a defined heating power, the circuit 8 acts on the element 10 to modify its operation to accord with the requested power.
Likewise, if any variation occurs in the temperature of the zone 3 during food preparation (for example because the water in saucepan P has completely evaporated or the food in the saucepan is burning, or because the water in the saucepan has boiled over onto the hob plate 2) there is a consequent variation in the resistance of the resistor 5. Using usual comparison algorithms, this is considered by the circuit 8 as an undesirable happening to the food. Consequently, the circuit 8 acts on the heating element 10 corresponding to that zone and interrupts its operation. A possible acoustic and/or lighting warning device (not shown) associated with the hob plate or the actual lighting member associated with the knob are activated by said circuit 8 to warn the user that the food or its preparation has undergone a disturbance.
As can be seen in FIG. 9, the circuit 40 can be coupled with the circuit 200, the overall arrangement then being able to both measure the temperature of the cooking zone 3 or heating elements (for their protection), and detect the presence of a container placed on the glass ceramic hob plate.
The circuit 40 is also connected to the circuit 8 as already stated in relation to the previously described figures. Preferably, a single circuit 8 is able to control the operation of a plurality of heating elements 10 associated with one and the same glass ceramic hob plate.
Various embodiments of the invention have been described. However further different embodiments can be provided (for example in which the variation in the physical characteristic of the current-carrying element is evaluated directly), and are to be considered as falling within the scope of the present invention.
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A method and apparatus for detecting the presence of a saucepan on the hob plate of a glass ceramic cooking hob associated with a heating element includes measuring the variation in a physical characteristic of an electrical resistive element positioned between the heating element and the hob plate of the glass ceramic cooking hob caused by a body or saucepan being placed on the hob, the variation being evaluated by control means which, on the basis thereof, controls the heating element to change its operating parameters.
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The invention described herein was made by employees of the United States Government and may be manufactured and used by or for the Government for governmental purposes without the payment of any royalties thereon or therefor.
FIELD OF THE INVENTION
This invention relates generally to semiconductors and relates specifically to a fabrication process for making copper compensated, silicon doped, gallium arsenide for use as a base material in constructing bistable, photoconductive switches.
BACKGROUND OF THE INVENTION
Semi-insulating gallium arsenide has been explored as a candidate for use in photoconductive switching. Typically, gallium arsenide is made semi-insulating by a manufacturer using compensation mechanism which causes free electron charges in the material to become trapped or immobile. Since boat-grown gallium arsenide is inherently produced with silicon impurities (a shallow donor) throughout the crystal, deep acceptors such as carbon and chrome are frequently deliberately added to the melt in order to cause the donor electrons to become trapped at the deep acceptor levels. Copper also forms deep acceptors in gallium arsenide, however, copper compensated gallium arsenide cannot be obtained through industry (without enormous expense) because copper is considered to be a contaminant in processing systems. This is because the gallium arsenide processing industry focuses almost entirely on fast optoelectronic devices and semiconductor laser technology, and copper in gallium arsenide destroys the effects that are desired in both of these applications.
One application for copper compensated, silicon doped, gallium arsenide now in the development stages, is high power photconductive switching. Therefore, there is a need to establish processing standards for copper in gallium arsenide with respect to photoconductive switching applications to accelerate maturity and transition to industry of this switching technology.
Previous experiments have been conducted to show that low resistivity, silicon-doped, gallium arsenide can be made highly resistive by doping with known amounts of copper. Experiments allowing this unique material (GaAs:Si:Cu) to be used as a bistable photoconductive switch, known as BOSS (Bulk Optically controlled Semiconductor Switch), are disclosed in U.S. Pat. No. 4,825,061 to Schoenbach et al. The fabrication of BOSS devices, as disclosed by Schoenbach et al has involved the introduction of copper into silicon-doped gallium arsenide by thermal diffusion. Copper forms two dominant deep acceptor levels in gallium arsenide known as Cu A and Cu B . These acceptor levels trap the free electrons in the crystal at the deep copper centers. Thermal diffusion processes for introduction of copper into silicon-doped gallium arsenide has been noted by J. Blane, R. H. Bube, and H. E. MacDonald, J. Appl. Phys, 32(9), 1961; Kullendorf et al, "Copper-Related Deep Level Defects in III-IV Semiconductors", J. Appl. Phys. vol. 54, pp 3203-3312, 1983; and Hasegawa J. Appl. Phys. 45, 1944 (1974).
It has also been shown that this material can be used as a photoconductive switch which means that the electrons trapped at the deep copper levels can be excited into conduction by a laser pulse of wavelength 1.06 μum, and this temporary photocurrent can be extinguished by stimulating the GaAs:Si:Cu switch with another laser pulse intensity of 1.7 μum. Upon excitation by the first laser pulse (a few nanoseconds in duration) the switch current rises to a peak, and then decays with the laser pulse intensity until the current through the switch is dominated by electron current instead of the electron-hole plasma created during the laser pulse (FIG. 6). At that time, the magnitude of the current is dependent on the density of electrons that were elevated from the copper center, and the lifetime of these electrons is on the order of
During the time after the first laser pulse excites the photocurrent, the switch is said to be in the "on-state", and therefore the conductivity during this phase of the switching cycle can be called the on-state conductivity. This on-state conductivity is an important parameter in the design of the switch because it determines the efficiency of the switch in delivering power to a load. The saturation of the on-state conductivity (called σ ss [Ωcm] -1 ) occurs when the laser intensity is increased such that all of the electrons trapped at the Cu B level are excited into the conduction band. Past results have shown σ ss to be poor, and methods to control this important switching parameter are needed and have not been addressed previously.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a process for making improved on-state conductivity GaAs:Si:Cu crystals.
Another object of the present invention is a process of introducing additional copper in the form of Cu B into a silicon doped gallium arsenide crystal.
A further object of the present invention is a process of making copper compensated gallium arsenide for use as a photoconductive switching component.
Another object of the present invention is a process for copper compensation of silicon doped gallium arsenide crystals under controlled parameters of arsenic pressure, temperature, time, and silicon density.
Still another object of the present invention is a process for copper compensation of a silicon doped gallium arsenide crystal that produces a switching component having improved switch saturation on-state conductivity that can deliver power to a load with a minimum power dissipation in the switch.
A still further object of the present invention is a process for predicting the copper concentration and compensation temperatures for a gallium arsenide crystal that has been previously doped with a specific silicon shallow donor density.
An additional object of the present invention is a process of doping a gallium arsenide crystal with pure copper in the presence of arsenic.
Another additional object of the present invention is a process for copper compensation of silicon doped gallium arsenide crystals under specific and predictable arsenic pressure conditions.
A still further object of the present invention is a thermal diffusion process of doping a gallium arsenide crystal with copper within a quartz ampoule and in the presence of solid copper and solid arsenic.
Another object of the present invention is a process of thermal diffusion of a silicon doped gallium arsenide crystal in a reaction tube in the presence of controlled arsenic and copper vapor pressures.
According to the present invention the foregoing and additional objects are attained by providing a gallium arsenide crystal doped with silicon and heating the GaAs:Si in the presence of copper and arsenic, to at least 550° C. to anneal the copper and cause the vapor phased copper to be diffused into the GaAs:Si crystal.
By varying the initial silicon concentration, and matching this silicon concentration with copper concentrations to achieve compensation, the resulting higher copper concentration corresponds to higher Cu B concentration and thus, an enhanced σ ss .
This is because higher Cu B concentrations correspond to more electrons trapped at Cu B , which causes the saturation on-state conductivity to be enhanced. The same result is achieved by a process involving preferential formation of Cu B , or where the majority of the diffused copper forms Cu B instead of Cu A .
Gallium arsenide is obtained from the manufacturer with a known silicon concentration and this determines the amount of copper required to observe electrical compensation. The band diagram for silicon and copper levels are schematically shown in FIG. 1. At room temperature, the donor electrons associated with silicon are thermally ionized into the conduction band. Therefore, the material purchased from the manufacturer (GaAs:Si) is low resistively [<0.1 (Ω cm)], and the copper is thermally diffused into the GaAs:Si to establish the known deep copper acceptors (Cu A and Cu B ) which trap the free electrodes at energy levels that are not thermally ionized to any large degree at room temperature. The material thus becomes highly resistive [>10 5 (Ω cm)] -1 .
The fabrication process, according to one aspect of the present invention, involves loading the GaAs:Si into quartz ampoules along with solid sources of arsenic and copper of known masses. The copper source may be in the form of a copper lining on the quartz ampoule, a film of copper plate on the surface of the GaAs:Si sample, or a solid source of copper placed on the sample. Each ampoule is loaded with 10 mg arsenic and approximately 3 mg copper. The quartz ampoule is evacuated to low pressure (<5×10 -6 Torr) and sealed. The quartz ampoule is then placed in an oven furnace where the temperature around and across the ampoule is controlled to ±1° C. while heated to annealing temperature.
In another aspect of the present invention, a gallium arsenide, silicon doped, crystal is placed in a reaction tube loaded in a diffusion furnace and copper and arsenic partial pressures provided around the crystal and controlled by flowing copper and arsenic vapors into the tube.
Electrical compensation is achieved for four different silicon concentrations: 1×10 16 cm -3 ; 2×10 16 cm -3 ; 6×10 16 cm -3 ; and 7×10 17 cm -3 . The temperature at which compensation is achieved can be predicted by plotting the temperature at which the lowest dark conductivity is achieved (FIG. 7) against the initial silicon concentration.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic, graphical, band diagram of copper related energy levels in gallium arsenide and the silicon donor level;
FIG. 2 is a schematic flow chart of one fabrication process of copper compensating silicon doped, gallium arsenide according to the present invention;
FIG. 3 is a flow chart similar to FIG. 2 and illustrating an alternate source of copper for the copper compensating fabrication process of the present invention;
FIG. 4 is a view of a GaAs: Si sample plated with copper that may be employed in the process illustrated in FIG. 3;
FIG. 5 is a schematic, partial view of a reaction tube disposed in a diffusion furnace and employed to copper compensate silicon doped, gallium arsenide crystals, according to one aspect of the present invention;
FIG. 6 is a graphical illustration of the changes in current of a GaAs:Si:Cu switch element of the present invention upon excitation by a turn-on and a turn-off laser pulse;
FIG. 7 is a plot of the temperature at which the lowest dark conductivity was achieved by the process of the present invention against different initial silicon concentration samples;
FIG. 8 is a plot of the solubility of copper with the compensation temperature for different silicon concentrations of the present invention as compared with results achieved by other processes; and
FIG. 9 is a plot of the "on-state" conductivity measurements in GaAs:Si:Cu wafers prepared according to the present invention and for different silicon concentrations.
DETAILED DESCRIPTION
Referring now to the drawings, and more particularly to FIG. 1, the band gap between the conduction (Ec) and valence bands (Ev) in gallium arsenide is 1.42 eV. The silicon donor level in this band gap is at 6 meV. Copper forms two dominant deep acceptor levels in gallium arsenide known as Cu A , at 0.14 eV, and Cu B , at 0.44 eV. These acceptor levels trap the free electrons in the GaAs crystal at the deep copper center, as is known in the prior art.
Since it is known that a switch formed by GaAs:Si:CU crystal is excited by a laser pulse that has an energy which causes an electron to transition from the Cu B level into the conduction band, then the on-state conductivity of GaAs:Si:CU can be improved by introducing more copper, in the form of Cu B , into the crystal. Therefore, higher Cu B concentrations correspond to more electrons trapped at Cu B , which causes the saturation on-state conductivity to be enhanced.
Two basic processing methods are employed by the present invention to enhance the on-state conductivity (σ ss ). One of these processing methods involves varying the initial silicon concentration, which requires matching copper concentrations in order to achieve compensation, and with the higher copper concentration corresponding to higher Cu B concentrations and thus, an enhanced σ ss . The other processing method involves the preferential formation of Cu B , which means that the majority of the diffused copper forms Cu B instead of Cu A .
Referring now more particularly to FIG. 2, a gallium arsenide crystal 10 is received from a manufacturer with a known silicon concentration formed therein. The silicon concentration is important because it determines the amount of copper required to observe electrical compensation. Standard available concentrations of silicon in gallium arsenide crystals employed in the present invention include 1×10 16 cm -3 , 2×10 16 cm -3 , 6×10 16 cm -3 and 7×10 17 cm -3 . The band diagram of FIG. 1 described hereinabove illustrates the locations of the silicon and copper levels.
At room temperature, the donor electrons associated with silicon are thermally ionized into the conduction band. Therefore, the material crystal 10 purchased from the manufacturer (GaAs:Si) is low resistively (<0.1 (Ω cm)). The copper is thermally diffused into the GaAs:Si in order to establish the known deep copper acceptors (Cu A and Cu B ) which trap the free electrons at energy levels that are not thermally ionized to any large degree at room temperature, to render the crystal highly resistive (>10 5 (Ω cm) -1 .
The GaAs:Si crystal 10 is loaded into a quartz ampoule 12, along with a solid source of arsenic 14 and a solid source of copper. In the illustrated embodiment of FIG. 2, quartz ampoule 12 is provided with an internal coating, or lining, of copper as designated by reference numeral 16. After positioning of the 0.05 cm thick GaAs:Si wafer 10 in quartz ampoule 12, the ampoule is evacuated to low pressure (<5×10 -6 Torr), and sealed by cover 18. Ampoule 12 is then placed in a three zone furnace oven 20 wherein the temperature around and across the ampoule 12 is gradually increased over a six hour period to the desired temperature, while being controlled to ±1° C. In a specific example, ampoule 12 is loaded with approximately ten (10) mg of solid arsenic and approximately three (3) mg copper.
After the GaAs:Si crystal 10 has reached the desired annealing temperature, the ampoule 12 is removed from oven 20, cooled to room temperature, and cover 18 removed to permit recover of an electrically compensated GaAs:Si:CU crystal 10a that may serve as the base material for a bistable, photoconductive switch. The GaAs:Si:Cu annealed wafer 10a is polished and gold germanium (Au:Ge) contacts are applied to the n-type wafers and gold-zinc (Au:Zn) contacts are applied to the p-type wafers. These contact metallizations are achieved by annealing at 440° C. for five minutes.
Referring now to FIG. 3, an identical procedure is employed for achieving the compensation of a GaAs:Si crystal 10 except that the copper lining of quartz ampoule 12 is omitted. In this embodiment, an alternate copper source, in the form of a copper foil 22, is positioned directly on the GaAs:Si crystal 10 along with the solid arsenic 14.
Referring to FIG. 4, another source of the copper employed in the process described in reference to FIGS. 2 and 3 is in the form of a coating of copper 24 applied to the GaAs: Si crystal before placing it in furnace oven 20. The thickness of coating 24 would be designed to be only that which would be completely diffused into crystal 10 during the annealing process.
Referring now to FIG. 5, in lieu of the ampoule diffusion process described hereinabove in reference to FIGS. 2-4, the GaAs:Si crystal 10 is placed in a reaction tube 26 which is located in a diffusion furnace 28. The copper and arsenic partial pressure around crystal 10 in this procedure is controlled by flowing copper and arsenic vapor into reaction tube 26 via suitable glass tubing, designated by respective reference numerals 30, 31. The solid copper and solid arsenic are separately heated, in a conventional manner, and the vapor flow therefrom is controlled through suitable valves (not shown) leading to glass tubes 30,31.
The temperature at which compensation is achieved for a specific silicon concentration can be predicted by plotting the temperature at which the lowest dark conductivity was achieved against the initial silicon concentration, in control samples, as illustrated in FIG. 7. As shown therein, the compensation for each silicon concentration occurred when a sharp drop in the dark conductivity was attained. Thus, for a gallium arsenide silicon concentration of silicon of 1×10 16 cm -3 , copper compensation would be expected to be obtained at approximately 550° C.; while a concentration of silicon of 2×10 16 cm -3 in gallium arsenide would require a temperature of approximately 600° C.; a silicon concentration of 6×10 16 cm -3 in gallium arsenide would require a temperature of approximately 650° C.; and a silicon concentration of 7×10 17 cm -3 would be compensated at a temperature of approximately 875° C.
The condensation temperature may be defined as the temperature at which the GaAs:Si:Cu material wafer changes from the n-type to p-type, and as indicated in FIG. 7, the conductivity changes abruptly. As noted, the conductivity of the sample where N Si =1×10 16 cm -3 dropped by over seven orders of magnitude due to a change in temperature of only 2° C. At this temperature, the copper concentration is considered to be approximately equal to the silicon concentration such that the shallow silicon donors are compensated by the copper acceptors. The temperature corresponding to the lowest measured conductivity for exemplary specimens attained by the present invention are plotted against, and shown to agree with, copper solubility measurements made by others in FIG. 8. These values confirm that the compensation temperature can be predicted for a given silicon doping density, assuming that copper is singly ionized in GaAs:Si:Cu.
As illustrated in FIG. 8, the compensation temperature depends exponentially on the initial silicon density and the results of the present invention correspond favorably with results obtained in prior art processes. Since the copper concentration must be approximately equal to, or slightly greater than, the silicon deity in order for electrical compensator to be observed, then the density of Cu B is enhanced by using higher silicon densities and higher annealing temperatures. This means for higher silicon densities, σ ss will be enhanced due to the higher Cu B concentration. Thus, and as apparent from FIG. 7, higher silicon densities lead to drastic improvements in σ ss .
Another aspect of the present invention involves the preferential formation of Cu B as opposed to Cu A . For a given silicon density, the diffused copper can form either Cu B or Cu A , depending on the lattice effect throughout the GaAs crystal. A typical lattice defect in GaAs is an arsenic vacancy which has been proposed to be associated with Cu B . In order to cause a change in the arsenic vacancy distribution in the GaAs crystal, the arsenic mass added to the ampoule 12 before the anneal can be altered.
Once the compensation temperature is found for each wafer, the dependency of the conductivity on the arsenic partial pressure in the specimen ampoule may be determined. First, the wafer with a silicon density (N Si ) of 1×10 16 cm -3 was studied with arsenic masses of 0, 2, 11 and 93 mg added to ampoule 12. Care must be exercised when converting the arsenic mass in the ampoule to a partial pressure because of the tendency of copper and arsenic to form compounds (Cu 5 As 2 and/or Cu 3 As) during the anneal. Thus, if the copper mass of approximately 3 mg is similar to or much larger than the arsenic mass, a detailed knowledge of the reaction between arsenic and copper is needed to calculate the arsenic partial pressure in the ampoule for a given temperature. It is constructive to calculate the arsenic partial pressures without accounting for the possible reaction between copper and arsenic, using the ideal gas law and assumption that arsenic sublimates into As 4 . Thus, for a temperature of 550° C., the arsenic partial pressures are 13, 106, 796 Torr, corresponding to arsenic masses of 2, 11, and 93 mg respectively.
Experiments showed that the lowest conductivity was obtained using the highest arsenic mass in the ampoule for N Si =1×10 16 cm -3 . The conductivity of a sample was 0.4 (Ω cm) -1 without any arsenic, 2×10 -3 (Ω cm) -1 with 2 mg arsenic, and 2×10 -6 (Ω cm) -1 with 93 mg arsenic added to the ampoule. For higher values of N Si , the arsenic mass in the ampoule had no effect on the conductivity.
With increasing copper concentrations, the low conductivity regions rise to values which are predicted, using only copper acceptors and silicon donors. Also, a ratio of Cu A to Cu B densities that is much larger than one (1) can cause the low conductivity region of the curve to occur over a smaller temperature range.
The addition of large amounts of arsenic will cause few arsenic vacancies to be formed (and possibly create arsenic complexes) and therefore reduce the concentration of Cu B which causes σ ss to be reduced. FIG. 9 shows that the arsenic pressure in the ampoule does affect the saturation of the on-state conductivity, and lower arsenic pressures seem to give the best results. The amount of copper is chosen such that the partial pressure of copper in the ampoule provides a number density of copper atoms that is large compared to that required to be diffused into the GaAs.
In summary, the present invention involves improving the on-state conductivity of a GaAs:Si:Cu crystal by either (1) increasing silicon and copper concentration, or (2) by varying the arsenic pressure in the ampoule while heating the crystal to annealing temperature. It is noted that increased silicon concentrations lead to higher annealing temperatures to establish compensation, and the saturation of the on-state conductivity was improved dramatically using higher silicon concentrations. Also, the best σ ss was achieved using the lowest arsenic pressure in the ampoule (0 Torr).
The adjustment of the arsenic pressures allows the on-state conductivity of the material to be changed within a small range. This represents another parameter in the system which may be adjusted in order to customize the photoconductor to match the circuit or implementation requirements.
Therefore, it is readily seen that the present invention involves a process of fabricating electrically compensated gallium arsenide doped with a shallow donor to greater than 1×10 16 cm -3 , by the thermal diffusion of copper (≈3 mg) under an arsenic partial pressure (0-2500 Tort) and at temperatures exceeding 550° C. at which the diffused copper density equals the silicon density that may be predicted by the equation in FIG. 8.
The parameters of temperature, arsenic pressure, copper pressure, silicon density are all key factors, according to the present invention, in developing an optically activated switch that can operate with minimum resistance after the switch is turned on, while maintaining the desired high resistance when the switch is turned off. Although the specific examples described herein employ silicon as the shallow donor and copper as the deep acceptor, the invention is not so limited. The silicon density, as described herein, represents a density of free electrons in the material, since they are ionized at room temperature, and it is to be understood that any dopant which acts as a shallow donor may be used in place of silicon, within the scope of the present invention. Similarly, any deep acceptor, such as chrome and iron, which have energy levels that are between the copper level and the conduction band, are also applicable in practice of the present invention.
Although the specific example processes described herein are directed to gallium arsenide, the invention is not so limited and other materials which may be explored, by employing the process of the present invention, and with respect to photoconductive switching materials include, indium phosphide, zinc selenide, cadmium sulfide, gallium arsenic phosphide, and aluminum gallium arsenide. Each of these materials would represent a new start in the development of semiconductor processing techniques that could render effective switching components.
Numerous other variations and modifications of the present invention may be readily apparent to those skilled in the art in the light of the above teachings. It is therefore to be understood that any semiconductor compensating process that maintains the essential parameters of arsenic vapor pressure, temperatures, times, and silicon density, as described herein are considered within the scope of the present invention.
It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described herein.
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Semi-insulating gallium arsenide wafers manufactured with varying silicon nsity shallow donors are copper compensated by heating to temperature of at least 550° C. to thermally diffuse the copper into the wafers and thereby provide deep copper acceptors in the wafer. Higher annealing temperatures are employed for higher concentrations of silicon in the wafers and the thermal diffusion is accomplished in the presence of copper, and in some instances, in the presence of varying quantities of arsenic. The copper compensated, silicon doped, gallium arsenide wafers obtained have the electrical property characteristic capability of being used as photoconductive switching components. In one aspect of the invention the silicon doped gallium arsenide wafer is sealed in a quartz ampoule in the presence of solid copper and solid arsenic and heated to the annealing temperature. In another aspect of the invention, the copper and arsenic are flowed as vapors over the silicon doped gallium arsenide wafer disposed in a reaction tube within a diffusion furnace, while the wafer is heated to the annealing temperature.
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TECHNICAL FIELD OF THE INVENTION
The invention relates to gelled polymers for thickening water, more particularly to the use of such materials in oilfield operations, and most particularly to a crosslinker system and method of use that reduces costs and simplifies operations.
BACKGROUND OF THE INVENTION
Aqueous fluids that have been thickened, or viscosified, are useful in many industries, for example in the oilfield. Oilfield operations that use such fluids include, for example, enhanced oil recovery and well stimulation, for example hydraulic fracturing, gravel packing, and the combination of these two called frac-n-pack. Such fluids are commonly generated by incorporating, or forming, gels in them, for example viscoelastic surfactant gels or polymer gels. Polymer gels are typically formed by dissolving or hydrating a suitable polymer in water. Often, these aqueous fluids are further thickened or viscosified by crosslinking the polymers, for example with organic or metal crosslinkers. Typical metal crosslinkers include boron, titanium, and zirconium. Zirconium crosslinkers have been described, for example, in U.S. Pat. Nos. 5,614,475; 5,972,850; 5,950,729; 5,697,555; 4,799,550; 5,697,444 and 6,737,386.
For use in stimulation, valuable properties for fluids containing crosslinked polymer gels include low cost, simplicity of preparation, the ability to delay the gellation for a predetermined time (to minimize hydraulic horsepower required to pump the fluid), and thermal stability. In practice, moving toward those requirements with zirconium crosslinkers typically has meant that the crosslinking system had one or more of a known group of ligands on the zirconium (for example triethanolamine and/or lactate) in order to delay the crosslinking, and a pH modifier in order to increase the stability. Incorporation of such ligands increases the cost of the zirconium compounds. The amount (weight) of these ligands necessary for delay limits the zirconium concentration that can be provided in a crosslinker concentrate, and this plus potential competition for the zirconium between these ligands and pH modifier components means that pH modifiers are typically provided separately. Sometimes additional delay agents are also needed. This means that at least two additive streams are necessary just for the crosslinking and that the volume of crosslinker additive that must be used is large. These factors add to the complexity and cost of the operation.
There is a need for a crosslinking system that provides a high concentration of zirconium and a pH modifier in a single concentrate at reduced cost.
SUMMARY OF THE INVENTION
One embodiment is a fluid composition containing water, carbonate in solution, bicarbonate in solution, and soluble zirconium(IV) having carbonate and bicarbonate as the only carbon-containing multidentate ligands complexed with zirconium. The moles of carbonate plus the moles of bicarbonate is greater than about 4 times the moles of zirconium, for example greater than about 10 times the moles of zirconium, for example greater than about 15 times the moles of zirconium. The mole ratio of bicarbonate to carbonate is from about 1:4 to about 8:1, for example at least about 1:2, for example at least about 2:1. The zirconium content is from about 0.5 weight percent to about 15 weight percent, for example from about 5 weight percent to about 10 weight percent. The mole ratio of carbonate to zirconium is from about 1:1 to about 8:1, for example from about 2:1 to about 4:1. The mole ratio of bicarbonate to zirconium is from about 0.1:1 to about 8:1, for example from about 1:1 to about 4:1.
In another embodiment, the mole ratio of carbonate to zirconium is at least about 3:1 and the mole ratio of bicarbonate to zirconium is at least about 3:1, for example the mole ratio of carbonate to zirconium is at least about 5:1 and the mole ratio of bicarbonate to zirconium is at least about 5:1, for example the mole ratio of carbonate to zirconium is at least about 7:1 and the mole ratio of bicarbonate to zirconium is at least about 7:1.
In yet another embodiment, the ratio of bicarbonate to carbonate is optionally adjusted by the addition of hydroxide. The fluid may also contain an alcohol, for example methanol, ethanol or propanol.
A further embodiment is a method of fracturing a subterranean formation penetrated by a wellbore involving mixing a first fluid containing water and a hydratable polymer crosslinkable with zirconium with a second fluid containing water, carbonate in solution, bicarbonate in solution, and soluble zirconium(IV) having carbonate and bicarbonate as the only carbon-containing ligands complexed with zirconium, and injecting the mixed fluid into the formation.
Yet another embodiment is a method of forming a gelled fluid involving mixing a first fluid containing water and a hydratable polymer crosslinkable with zirconium with a second fluid containing water, carbonate in solution, bicarbonate in solution, and soluble zirconium(IV) having carbonate and bicarbonate as the only carbon-containing ligands complexed with zirconium.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the viscosity as a function of time at 121° C. (250° F.) for experiments in which three concentrations of a crosslinker/pH modifier concentrate were added to a standard linear fluid.
FIG. 2 shows the viscosity as a function of time at 121° C. (250° F.) for experiments in which various crosslinker/pH modifier concentrates were added to a standard linear fluid.
FIG. 3 shows the viscosity as a function of time at 130° C. (266° F.) for experiments in which three concentrations of a crosslinker/pH modifier concentrate were added to a standard linear fluid.
DETAILED DESCRIPTION OF THE INVENTION
An inexpensive, single-stream, effective crosslinking system (for convenience often called a “concentrate” here) for soluble or hydratable polymers contains a zirconium compound in which the only ligands significant to the crosslinking activity and behavior are carbonate and bicarbonate, the combination of which also serves as a pH modifier, and one component of which, the bicarbonate, further serves as a delay agent. The inclusion of bicarbonate in the formulation of the concentrate is optional; if there is no bicarbonate, the zirconium compound is a zirconium carbonate. Delay may not be needed or wanted in treatments other than stimulation or in very shallow wells. (Commercially, zirconium typically contains small amounts, for example about 2%, of hafnium, and this is meant to be included here in the term zirconium.) The zirconium compound may contain other ions or compounds, for example ammonia (or ammonium), alkali metal cations, halide, and alcohol (or alcoholate), and sulfate, that are much weaker zirconium ligands than carbonate and therefore do not affect the rate or extent to which the zirconium complexes with, and therefore crosslinks, the polymer as much as does carbonate. The zirconium compound may be made from compounds that contain, and therefore the concentrate may also contain, small amounts, for example less than about one mole of ligand per mole of zirconium, of ligands that are known to affect crosslinking in the absence of large amounts of carbonate, for example lactate, triethanolamine, and acetonyl acetate, provided that they do not significantly affect the rate or extent to which the zirconium in the concentrate of the present invention complexes with, and therefore crosslinks, the polymer. Similarly small amounts of these materials from other sources may be included in the concentrate or in the final crosslinked fluid, again provided that they do not significantly affect the rate or extent to which the zirconium in the concentrate of the present invention complexes with, and therefore crosslinks, the polymer. Generally, the sum of the moles of carbonate and bicarbonate in the concentrate exceeds four times the moles of zirconium. The amount of carbonate and bicarbonate in the concentrate is sufficiently high that the other potential ligands, such as lactate and triethanolamine, are not complexed with the zirconium. One skilled in the art will know which ligands are weaker than carbonate and so will not complex with zirconium in the presence of an excess of carbonate. However, it is known that the raw material that is used to prepare zirconium crosslinkers can affect the crosslinking reaction. This effect is expected to be minor in the presence of the excess of carbonate in the present concentrate, but specific preparations should be tested by laboratory experiment before use.
The optimal concentrations and ratio of carbonate to bicarbonate depends upon several factors, including the nature and concentration of the polymer that will be crosslinked, the nature and concentration of other additives in the fluid (for example biocides, iron control agents, surfactants, clay control agents, breakers, and other common oilfield chemical additives—some of which may inherently be buffers, acids, or bases) the desired delay time (typically related to the depth of the well and the pump rate), the temperature at which the crosslinking will occur, the final temperature which the fluid will reach, and the time for which the fluid must be stable (typically defined as having a viscosity above a certain level, for example 100 cP at 100 sec −1 ). The optimal concentrations and ratio of carbonate to bicarbonate for a given use may be determined by simple experiments such as those described in the experimental section below.
The crosslinker system concentrate may be made, as an example by mixing of a suitable zirconium source and suitable sources of carbonate and bicarbonate. The chemistry of these systems has been discussed by A. Veyland, et al, “Aqueous Chemistry of Zirconium(IV) in Carbonate Media,” Helvetica Chimica Acta, 83, 414-427 (2000). Potassium salts may be more soluble. Examples of suitable zirconium sources are zirconium oxychloride (ZrOCl 2 , usually as the octahydrate as a solid, also called zirconyl chloride, basic zirconium chloride, dichlorooxozirconium, and zirconium dichloride oxide), ammonium zirconium carbonate, sodium zirconium carbonate, potassium zirconium carbonate, and mixtures thereof. Examples of suitable carbonate and bicarbonate sources include ammonium, sodium, and potassium carbonate, bicarbonate and sesquicarbonate. All of these sources may be used as commercially available (solids, hydrates, liquids, or solutions). Any suitable water source may be used; water containing high salt concentrations, multivalent cations, or ligands for zirconium should be tested before use. The components may be mixed in any order, but typically the concentrate is prepared by adding a zirconium compound to a carbonate/bicarbonate mixture or solution. The concentrate may optionally contain a component or components that lower the freezing point, for use in cold weather locations. Any suitable solvent may be used, provided that it does not affect the solubility of the components and the efficacy of the system. Examples include methanol, ethanol and propanol. Even with such anti-freeze components, the crosslinking system concentrate of the invention has a much higher zirconium concentration than prior art zirconium crosslinker concentrates.
The as-received zirconium source, carbonate source, and bicarbonate source, and optional materials such as alcohols, may be blended in any order either in the field or at a separate location. Alternatively, any combination of some of the components can be premixed on site or at a separate location and then another component or components may be added later. Standard mixing equipment and methods may be used; heating and special agitation are normally not necessary but may be used. The concentrate is used in the field just as any other crosslinker concentrate is used, except that normally a separate buffer and a separate delay agent are not needed, and so one or two less additive streams are required. However, if necessary as dictated by the specific job requirements and situation, a separate buffer and/or delay agent and/or accelerator may be added, either to the concentrate or to another additive stream or to the final fluid being prepared; the separate buffer and/or delay agent and/or accelerator may be carbonate and/or bicarbonate or another material, such as hydroxide. If the source of water for the final fluid contains materials that might affect the final fluid, for example carbonate and or bicarbonate, then a separate buffer and/or delay agent and/or accelerator may need to be added to compensate for this or the amount of separate buffer and/or delay agent and/or accelerator may need to be adjusted.
The amounts of zirconium, carbonate and bicarbonate in the concentrate are optimized for the job needs, as determined for example by the choice and concentration of polymer and the temperature of the oilfield treatment and the time the crosslinked gel must be stable. Simple laboratory experiments, such as those in the experimental section below, are run to optimize the performance. Normally, the composition is formulated to maximize the concentration of zirconium and to provide sufficient carbonate to buffer the final fluid (to minimize the viscosity decline seen at higher temperatures) and sufficient bicarbonate to delay the crosslinking. However, the relative amounts of carbonate and bicarbonate are also important. Higher carbonate concentrations in the final fluid decrease the delaying capability of the bicarbonate. Carbonate in excess of that required to buffer the final fluid may decrease fluid stability. Too high bicarbonate may result in undesirably long delay times.
The concentration of zirconium in the composition varies, and is determined by a number of factors including the fluid performance required, the stability of the complex in the concentrate in storage, the volume and the related cost of transportation, and the equipment available and the volumes required to be used in the application, particularly during continuous-mixing operations. As an example, the concentrate contains about 0.5 to about 15 weight percent zirconium, for example from about 5 to about 10 weight percent. The ratio of carbonate to zirconium in the composition is normally at least about 1:1 on a molar basis, for example up to about 8:1, for example between about 2:1 and about 4:1. If the composition includes bicarbonate, the ratio of bicarbonate to zirconium is from about 0.1:1 to about 8:1, for example from about 1:1 to about 4:1. The molar ratio of carbonate plus bicarbonate is greater than about 4 times the amount of zirconium, for example greater than about 8 times, for example greater than about 16 times. Note that the amount of carbonate and, optionally, bicarbonate, in the concentrate exceeds the amount that is complexed with the zirconium, that is not all of the carbonate or bicarbonate present in the composition is associated with zirconium ions; in addition, more may be liberated or consumed during reaction.
Suitable polymers (typically referred to as water soluble or hydratable) include polysaccharides composed of mannose and galactose sugars, such as locust bean gum, karaya gum, guar gums, or guar derivatives such as hydroxypropyl guar (HPG), hydroxyethyl guar (HEG), carboxymethyl guar (CMG), carboxymethylhydroxyethyl guar (CMHEG), carboxymethylhydroxypropyl guar (CMHPG), and hydrophobically modified guar. Cellulose derivatives such as hydroxyethylcellulose (HEC), hydroxypropylcellulose (HPC), and carboxymethylhydroxyethylcellulose (CMHEC) are also used. Xanthan, diutan, scleroglucan, polyvinylalcohol, polyacrylamide and polyacrylate polymers and copolymers are also suitable. Mixtures of any of these polymers may be used.
The present invention can be further understood from the following examples.
Linear (uncrosslinked) fluids were prepared for use in these experiments with the following standard components in the indicated amounts to form a “standard” linear fluid:
Deionized water
1000
ml
Slurriable CMHPG
3
g
Acid Buffer
To pH 6.5-7.0 (approximately 0.6 ml)
Clay Stabilizer
2
ml
Gel Stabilizer
3
g
The acid buffer was a solution of sodium diacetate. This is used to lower the pH of the solution during polymer hydration to improve or increase initial polymer hydration. This should not be confused with a second pH modifier that is typically used in association with the crosslinker, but is not present in this linear fluid. This second pH modifier is normally used to raise the pH of the fluid to facilitate crosslinking of the polymer and to stabilize the crosslinked polymer at higher temperatures. It is this second pH modifier that is replaced by the carbonate/bicarbonate portion of the crosslinker/pH modifier concentrate of the present invention. The clay stabilizer is TMAC (tetramethyl ammonium chloride). Others, such as KCl, may be used. The gel stabilizer is sodium thiosulfate pentahydrate. Others, such as tetraethylenepentamine or triethylamine, may be used. It is to be understood that if the choices and concentrations of these components were different, the results would be different.
The components above were mixed together in a Waring blender cup for 30 minutes under constant shear until the polymer had fully hydrated. Portions of this fluid were removed and crosslinker/pH modifier concentrate was added to change the fluid pH, crosslink the polymer and viscosify the fluid. Fluid was then quickly transferred to a Fann 50 viscometer to measure the viscosity.
Crosslinker/pH modifier concentrates were also prepared in deionized water by the dropwise addition of zirconyl chloride (ZrOCl 2 ) solution to a solution containing potassium carbonate and potassium bicarbonate.
Crosslinked fluids were prepared by mixing 100 ml of the linear fluid, as described above, in a 250 ml Waring blender cup, increasing the blender speed to create a vortex in the fluid and adding the crosslinker/pH modifier solution quickly into the side of the vortex. The blender was then allowed to stir in the case of vortex closure tests or was turned off after 1-2 seconds if the fluid was to be transferred to a Fann 50 viscometer.
EXAMPLE 1
Fluids were made by adding 3.4 ml/L of the following crosslinker/pH modifier concentrates to the linear fluid already described. The concentrate formulations are shown in Table 1.
TABLE 1
Formulation
Component
A
B
C
D
ZrOCl 2 •8H 2 O (Zr Equivalents)
1
1
1
1
K 2 CO 3 (CO 3 2− Equivalents)
2
3
5
4.5
KHCO 3 (HCO 3 − Equivalents)
3
2
0
3
These concentrates each contained about 0.7 weight percent zirconium (they were 0.08 molar in zirconium). The fluids were evaluated at approximately 24° C. (75° F.). The performance of each crosslinker was evaluated by measurement of the vortex closure time, measurement of final fluid pH, visual appraisal of the fluid lip formed, the and the effect of heating the fluid in a microwave oven. (The lip test is a procedure in which a gel is poured very slowly from one container to another. The fluid demonstrates a “lip” if, when the pouring is stopped part way through and the initial container is slowly tipped back up, the fluid will climb back into the initial container because of its elasticity. This is a simple way to observe whether a fluid is viscoelastic (“has a lip” or “passes the lip test”), or is merely viscous (no lip). Viscoelastic fluids are much better at suspending solids, such as sand or proppant, than are merely viscous fluids having the same viscosity. If fluids did not crosslink quickly at ambient temperature they were heated in a microwave oven to see whether this would bring about crosslinking and to give a rough, qualitative, indication of how they would perform at higher temperatures.)
The performance of these fluids improved with increasing bicarbonate concentration in the crosslinker/pH modifier concentrate, although it is expected that at even higher bicarbonate concentrations the fluid performance may deteriorate, as will be shown later for the last crosslinker formulation in Table 3. For example, formulation A performed better than formulation B, which performed better than formulation C. However, the final fluid pH decreased from formulation C to formulation A; the low final fluid pH was believed to have negative implications for high temperature stability, so formulation B was chosen for further study. FIG. 1 shows the viscosity as a function of time at 121° C. (250° F.) for experiments in which three concentrations of formulation B were added to the standard linear fluid. The pH before and after each experiment is also given. In these experiments, the higher the zirconium concentration in the final fluid the higher the viscosity and stability. It is important to note that the viscosity and stability of all three fluids were within an acceptable range for use in fracturing operations (i.e., greater than 100 cP at 100 sec −1 ) for at least 2.5 hours. Note, however, that the pH's of all three had dropped after the experiments.
Performance in the bench top experiments also improved with increasing carbonate to zirconium ratio, possibly due to improved buffering capacity per equivalent of zirconium.
EXAMPLE 2
The fluids in Example 1 were non-delayed, and non-delayed systems typically exhibit better performance than would be expected for delayed fluids. Since zirconium-crosslinked fracturing fluids are usually delayed to minimize pumping pressure and prevent shear-induced fluid degradation, a method of delaying the crosslinking was investigated.
Formulation C was added at 5.4 ml/L (to make a final zirconium concentration of 40 ppm) to the base linear fluid containing sodium carbonate and/or sodium bicarbonate to study the effect on crosslink time. Fluid pH was measured before and after crosslinking, and the vortex closure time was also recorded, as shown in Table 2.
TABLE 2
Delay at
pH before
pH after
24° C. (75° F.)
Linear Fluid Composition
Crosslink
Crosslink
(seconds)
Linear fluid only
7.03
9.96
4
Linear + 200 ppm HCO 3 −
8.08
9.52
>300
Linear + 200 ppm CO 3 2−
10.51
10.43
5
Linear + 200 ppm HCO 3 − +
9.90
10.04
>300
200 ppm CO 3 2−
Linear + 200 ppm HCO 3 − +
9.89
10.05
64
NaOH to pH 9.90
Examination of the results above shows that although addition of formulation C to a CMHPG solution at pH 7 results in rapid crosslinking, the crosslinking is delayed by bicarbonate. Use of equal weights of carbonate and bicarbonate also results in a delayed crosslink, and pH is not the sole factor in determining the crosslink times of fluids containing carbonate/bicarbonate mixtures.
EXAMPLE 3
The fluids shown in Table 3 were prepared by the addition of potassium carbonate and potassium bicarbonate to a zirconium carbonate solution containing the equivalent of approximately 20 weight % Zr0 2 . The final solutions (containing 5.0 weight percent zirconium) were more concentrated than those in Example 1, so that they could be added to the linear fluid at a realistic oilfield concentration of 1.00 ml/L.
TABLE 3
Formulation
Component
E
F
G
H
I
Zirconium carbonate solution
1
1
1
1
1
(Zr Equivalents)
K 2 CO 3 (CO 3 2− Equivalents)
1.25
2
2.5
3
3.75
KHCO 3 (HCO 3 − Equivalents)
3.75
3
2.5
2
1.25
FIG. 2 shows the viscosity vs. time at 121° C. (250° F.) when 1 ml/L of each of these crosslinker/pH modifier concentrates was added. It can be seen that with all but formulation I there was a delay in the crosslinking (as compared, for example, to the experiments shown in FIG. 1 ; formulation I evidently did not have sufficient bicarbonate for this polymer, crosslinker, concentrations of the other components, and temperature. With increasing carbonate to bicarbonate ratio, at a constant sum of carbonate and bicarbonate, the stability of the final crosslinked fluid increased, until in formulation I there was apparently too much carbonate. The delay was most pronounced with the most bicarbonate (formulation E). All the fluids had the stability to be used in hydraulic fracturing.
FIG. 3 shows the results at about 130° C. (266° F.) when various concentrations of formulation G were used. In these experiments, the greater the amount of the crosslinker/pH modifier concentrate used, the higher the crosslinked polymer fluid viscosity; however, it is expected that too high a concentration of crosslinker/pH modifier will result in syneresis and poor performance. In commercial practice, the operator chooses the lowest amount of zirconium that gives the desired viscosity.
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A composition useful for making gelled fluids by crosslinking hydratable polymers is an aqueous solution of zirconium complexed with carbonate and bicarbonate as the only multidentate ligands complexed with zirconium. The composition also provides pH modifying capability and the crosslinking is delayed, so that the single composition replaces several liquid additives previously necessary for generation of fluids used, for example, in hydraulic fracturing.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application Serial No. 60/308,211, filed Jul. 27, 2001, which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to the recovery of metals from metal-containing support materials, and more particularly relates to a method and apparatus for recovering metals from support materials with hydrocarbon-utilizing bacteria.
BACKGROUND INFORMATION
[0003] Precious metal ores such as gold ores can be categorized as either free milling or refractory. Free milling ores are those that can be processed by simple gravity techniques or direct cyanidation. Refractory ores, on the other hand, are not amenable to conventional cyanidation treatment. Such ores are often refractory because of their excessive content of metallic sulfides such as pyrite or organic carbonaceous matter. A large number of refractory ores consist of ores with a precious metal such as gold occluded in iron sulfide particles. The iron sulfide particles consist principally of pyrite and arsenopyrite. If gold or other precious metals remain occluded within the sulfide host, even after grinding, then the sulfides must be oxidized to liberate the encapsulated precious metal values and make them amenable to a leaching agent.
[0004] Conventional biological methods have focused on the recovery of precious metals using sulfur-oxidizing bacteria. A conventional process includes the steps of distributing a concentrate of refractory sulfide minerals on top of a heap of material, biooxidizing the concentrate of refractory sulfide minerals, leaching precious metal values from the biooxidized refractory sulfide minerals with a lixiviant, and recovering precious metal values from the lixiviant.
[0005] Problems exist using sulfur-oxidizing organisms in bioleaching processes. These problems include nutrient access, air access, carbon dioxide access, the generation of sulfuric acid from reactions of the sulfur-oxidizing bacteria, and the generation of heat during the exothermic biooxidation reactions which can kill growing bacteria. Ores that are low in sulfide or pyrite, or ores that are high in acid consuming materials such as calcium carbonate or other carbonates, may also be problematic during heap biooxidation processes. The acid generated by these low pyrite ores is insufficient to maintain the low pH and high iron concentration needed for bacteria growth.
[0006] The bioremediation of various pollutants using butane-utilizing bacteria is disclosed in U.S. Pat. Nos. 5,888,396, 6,051,130, 6,110,372, 6,156,203, 6,210,579, 6,244,346 and 6,245,235, which are herein incorporated by reference.
SUMMARY OF THE INVENTION
[0007] In accordance with the present invention, metals such as precious metals are recovered from metal-containing support materials such as mineral ores. The support material is contacted with a solution containing a hydrocarbon which stimulates the growth of hydrocarbon-utilizing bacteria. The hydrocarbon may comprise one or more alkanes, such as butane, methane, ethane and/or propane, or other types of hydrocarbons.
[0008] Gold, silver, platinum, copper, zinc, nickel, uranium, palladium and the like may be recovered using the present invention. One embodiment of the present invention provides for the treatment of metal-containing support materials in the form of slurries contained in lagoons, tanks or other vessels. Another embodiment of the present invention provides a bioleaching technique, which initially uses hydrocarbon-utilizing bacteria under anaerobic conditions to pretreat ore-containing materials for subsequent biooxidation using hydrocarbon-utilizing bacteria under aerobic conditions. The process can be used to biooxidize metal-containing support materials such as precious metal-bearing refractory sulfide ores. A further embodiment of the present invention provides a heap bioleaching process. In one embodiment of this process, ores that are low in sulfide minerals, or ores that are high in acid consuming materials such as calcium carbonate, may be treated.
[0009] In addition to precious metal-bearing sulfide minerals, there are many other sulfide ores that can be treated using the present process, such as copper ores, zinc ores, nickel ores and uranium ores. Biooxidation with hydrocarbon-utilizing bacteria can be used to cause the dissolution of metal values such as copper, zinc, nickel and uranium from concentrates of these ores.
[0010] An aspect of the present invention is to provide a method of recovering a metal from a metal-containing support material. The method includes contacting the support material with a hydrocarbon to stimulate the growth of hydrocarbon-utilizing bacteria, and recovering the metal from the support material.
[0011] Another aspect of the present invention is to provide a system for recovering metal from a metal-containing support material. The system includes means for contacting the support material with a hydrocarbon to stimulate the growth of hydrocarbon-utilizing bacteria, and means for recovering the metal from the support material.
[0012] A further aspect of the present invention is to provide a system for metal recovery from a support material, wherein the system includes a source of hydrocarbon, a hydrocarbon injection system in communication with the hydrocarbon source and the support material, and a deposition material upon which the metal is deposited.
[0013] These and other aspects of the present invention will be more apparent from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] [0014]FIG. 1 is a schematic diagram illustrating the use of anaerobic and aerobic hydrocarbon-utilizing bacteria to bioleach and precipitate (biooxidize) metals from a metal-containing support material.
[0015] [0015]FIG. 2 is a schematic diagram illustrating the use of aerobic hydrocarbon-utilizing bacteria in a heap to biooxidize and precipitate metals from a metal-containing support material.
DETAILED DESCRIPTION
[0016] In accordance with the present invention, hydrocarbon-utilizing bacteria are used to liberate metals from metal-containing support materials such as mineral ores. The process may be used to biooxidize metals from ore-containing material using hydrocarbons under aerobic conditions only. Alternatively, the process may use anaerobic and aerobic processes to pretreat and biooxidize metals from ore-containing materials. The ore type and metal composition may determine which process would yield the most favorable metal recover. Under anaerobic conditions, the hydrocarbon may serve as an electron donor and carbon source while sulfate originating from the ore may serve as a final electron acceptor. Other electron acceptors may be used, such as nitrate, iron or carbon dioxide. Subsequently, aerobic hydrocarbon-utilizing organisms and their operative enzymes may be used to precipitate metals from solution, which may then be recovered.
[0017] In accordance with an embodiment of the present invention, a hydrocarbon such as butane may be utilized to drive a treatment process anaerobic, thereby encouraging the growth of anaerobic microorganisms capable of reducing sulfur-containing compounds. Under anaerobic conditions, sulfate and elemental sulfur may serve as electron acceptors while the hydrocarbon substrate is oxidized. The anaerobic processes may include, for example, desulfurization, sulfur respiration and dissimilatory sulfate reduction. A hydrocarbon such as butane may be used to enhance anaerobic microbiological processes thereby liberating precious metals from recalcitrant sulfide ore bodies. Subsequently, aerobic hydrocarbon-utilizing bacteria may be used to precipitate (biooxidize) metals from solution, which may then be recovered.
[0018] The metal-containing support material may include sulfide-containing mineral ores, such as precious metal-containing ores, copper ores, zinc ores, nickel ores and uranium ores. The sulfide-containing minerals and ore material may be, for example, coarsely or finely ground ore. The support material may also include lava rock, gravel, sand deposits or any other geologic materials. The recovered metals may include gold, silver, platinum, palladium, copper, zinc, nickel and uranium or any other metal or precious metal.
[0019] The hydrocarbon may comprise one or more alkanes, alkenes, alkynes, poly(alkene)s, poly(alkyne)s, aromatic hydrocarbons, aromatic hydrocarbon polymers or aliphatic hydrocarbons. The hydrocarbons preferably comprise at least one alkane such as butane, methane, ethane or propane. In a preferred embodiment, the hydrocarbon comprises butane which may serve as an electron donor under aerobic or anaerobic conditions. The high solubility of butane facilitates dispersion of the hydrocarbon food source throughout the metal-containing support material. Furthermore, the high solubility of butane may accelerate the transformation of aerobic conditions to anaerobic by initially stimulating the growth of aerobic butane-utilizing microorganisms in the presence of oxygen to produce carbon dioxide. As the oxygen is depleted and anaerobic conditions prevail, butane or another hydrocarbon may serve as an electron donor to enhance anaerobic microbiological processes that will aid in the leaching of metals from the metal-containing support material.
[0020] In accordance with a preferred embodiment, butane is the most prevalent compound of the hydrocarbon substrate on a weight percent basis, and typically comprises at least about 10 weight percent of the hydrocarbon substrate. The other constituents of the hydrocarbon substrate may include other alkanes or other hydrocarbons, as well as inert gases such as nitrogen, helium or argon. The hydrocarbon substrate preferably comprises at least about 50 weight percent butane. More preferably, the hydrocarbon substrate comprises at least about 90 weight percent butane. In a particular embodiment, the hydrocarbon substrate comprises at least about 99 weight percent n-butane. The butane may contain straight (n-butane) and/or branched chained compounds such as iso-butane.
[0021] Suitable hydrocarbon-utilizing bacteria may include the following Groups (in addition to fungi, algae, protozoa, rotifers and other aerobic and anaerobic microbial populations found in decaying materials):
[0022] Group 1: The Spirochetes
[0023] Group 2: Aerobic/Microaerophilic, motile, helical/vibroid, gram-negative bacteria
[0024] Group 3: Nonmotile (or rarely motile), gram-negative bacteria
[0025] Group 4: Gram-negative aerobic/microaerophilic rods and cocci
[0026] Group 5: Facultatively anaerobic gram-negative rods
[0027] Group 6: Gram-negative, anaerobic, straight, curved, and helical bacteria
[0028] Group 7: Dissimilatory sulfate- or sulfur-reducing bacteria
[0029] Group 8: Anaerobic gram-negative cocci
[0030] Group 10: Anoxygenic phototrophic bacteria
[0031] Group 11: Oxygenic phototrophic bacteria
[0032] Group 12: Aerobic chemolithotrophic bacteria and associated organisms
[0033] Group 13: Budding and/or appendaged bacteria
[0034] Group 14: Sheathed bacteria
[0035] Group 15: Nonphotosynthetic, nonfruiting gliding bacteria
[0036] Group 16: The fruiting, gliding bacteria and the Myxobacteria
[0037] Group 17: Gram-positive cocci
[0038] Group 18: Endospore-forming gram-positive rods and cocci
[0039] Group 19: Regular, nonsporing, gram-positive rods
[0040] Group 20: Irregular, nonsporing, gram-positive rods
[0041] Group 21: The mycobacteria
[0042] Groups 22-29: The actinomycetes
[0043] Group 22: Nocardioform actinomycetes
[0044] Group 23: Genera with multiocular sporangia
[0045] Group 24: Actinoplanetes
[0046] Group 25: Streptomycetes and related genera
[0047] Group 26: Maduromycetes
[0048] Group 27: Thermomonospora and related genera
[0049] Group 28: Thermoactinomycetes
[0050] Group 29: Genus Glycomyces, Genus Kitasatospira and Genus Saccharothrix
[0051] Group 30: The Mycoplasmas—cell wall-less bacteria
[0052] Group 31: The Methanogens
[0053] Group 32: Archaeal sulfate reducers
[0054] Group 33: Extremely halophilic, archaeobacteria (halobacteria)
[0055] Group 34: Cell wall-less archaeobacteria
[0056] Group 35: Extremely thermophilic and hyperthermophilic S 0 -metabolizers.
[0057] In addition, suitable bacteria may include facultative anaerobes and microaerophilic anaerobes, which are capable of surviving at low levels of oxygen. These bacteria do not require strict anaerobic conditions such as the obligate anaerobes. Acidophilic, alkaliphilic, anaerobe, anoxygenic, autotrophic, chemolithotrophic, chemoorganotroph, chemotroph, halophilic, methanogenic, neutrophilic, phototroph, saprophytic, thermoacidophilic, and thermophilic bacteria may be used. Hydrocarbon and oxygen injection may encourage the growth of other microorganisms such as fungi, protozoa and algae that may be beneficial to the metal recovery process. The injected oxygen may be in the form of air (e.g., dry air comprising 20.9 percent oxygen), a gas stream with varying concentrations of oxygen, substantially pure oxygen, or the like.
[0058] Recovery of the metal involves the removal of at least a portion of the metal contained in or on the metal-containing support material. For example, from about one percent to substantially all of the metal contained in the support material may be recovered. Recovery may be achieved using various techniques such as heaps, slurries, precipitation lagoons and bioreactors. During the treatment process, metals may be deposited on a metal deposition material comprising, for example, a polymer, felt, rubber, metallic or natural fiber material that is porous or non-porous. The deposition material may be provided in sheet form or in other forms that provide increased surface area such as spheres and other geometric shapes.
[0059] [0059]FIG. 1 schematically illustrates an anaerobic and aerobic metal recovery system 10 in accordance with an embodiment of the present invention. A metal-containing support material such as low grade ore 12 is fed to a rock crusher 14 . Crushed ore 16 from the rock crusher 14 is fed to a bioleaching lagoon 18 lined with a membrane 19 and equipped with mixers 20 and 21 . A source of hydrocarbon 22 such as butane is connected to hydrocarbon injectors 24 in the bioleaching lagoon 18 .
[0060] After treatment in the bioleaching lagoon, the material is pumped 26 to a precipitation lagoon 28 equipped with mixers 30 and 31 . A hydrocarbon/oxygen source 32 is connected to injectors 34 in the precipitation lagoon 28 . A membrane 36 lines the precipitation lagoon 28 . After treatment in the lagoon 28 , liquid 38 comprising water and the support material is removed from the precipitation lagoon 28 . Metal deposited on the membrane liner 36 may be recovered from the precipitation lagoon 28 at suitable intervals.
[0061] In the embodiment shown in FIG. 1, the first phase of the metal recovery process occurs in the bioleaching lagoon 18 under anaerobic conditions. Within the lagoon 18 , the metal-containing support material is contacted with the hydrocarbon to accelerate the transformation of aerobic conditions to anaerobic conditions. This is accomplished by initially accelerating the activity of aerobic hydrocarbon-utilizing bacteria in the presence of oxygen present in the lagoon 18 in order to produce carbon dioxide. Under the resultant anaerobic conditions, the hydrocarbon will serve as an electron donor, thereby accelerating anaerobic microbiological treatment processes. In the bioleaching lagoon, the crushed ore 16 is pretreated for subsequent recovery in the precipitation lagoon. The second phase of the metal recovery process occurs in the precipitation lagoon 28 , where the aerobic cycle with air injection may be used to accelerate metal precipitation.
[0062] [0062]FIG. 2 schematically illustrates an aerobic metal recovery system 40 in accordance with another embodiment of the present invention. A heap 42 comprising the metal-containing support material is subjected to water spray by a sprinkler system 44 . A hydrocarbon/oxygen supply 46 is connected to injectors 48 in the heap 42 . An effluent trench 50 under the heap 42 carries effluent to a precipitation lagoon 52 equipped with mixers 54 and 55 . Alternatively, the effluent could be pumped to the lagoon 52 . Another hydrocarbon/oxygen supply 56 is connected to injectors 58 in the lagoon 52 . A membrane liner 60 lines the lagoon 52 . After treatment in the lagoon 52 , liquid 62 comprising water and the support material is removed from the lagoon 52 . Metal deposited on the membrane liner 60 may be recovered from the lagoon 52 at suitable intervals.
[0063] In the embodiment shown in FIG. 2, the heap 42 may comprise ore deposits. The piping 48 through which the hydrocarbon/oxygen mixture or hydrocarbon alone is delivered may be operated under steady or intermittent pulses. The sprinkler system 44 flushes the oxidized metal values from the heap 42 and creates an effluent solution, which flows to the precipitation lagoon 52 . In the precipitation lagoon 52 , the hydrocarbon-utilizing bacteria and injected oxygen deposit the metal values onto the membrane deposition material 60 for recovery.
[0064] Based on the molecular weight of specific metals, the different metal precipitate out of solution at differing time intervals, thereby providing the opportunity to replace the membrane liners during successive depositional events. Alternatively, electrolysis methods may be employed to further separate the precipitating metals. The metals may then be easily assayed and further refined using conventional techniques.
[0065] Whereas particular embodiments of this invention have been described above for purposes of illustration, it will be evident to those skilled in the art that numerous variations of the details of the present invention may be made without departing from the invention.
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Methods and apparatus are disclosed for recovering metals from metal-containing support materials such as mineral ores. In one embodiment, the metal may be separated from crushed support material or ore in a bioleaching lagoon by the action of hydrocarbon-utilizing bacteria under anaerobic conditions. The bioleached material is then pumped into a precipitation lagoon where hydrocarbon-utilizing bacteria oxidize the metals under aerobic conditions. In another embodiment, metals may be directly biooxidized from a heap of the metal-containing support material having a hydrocarbon/oxygen injection system embedded therein. A water sprinkler system may be used to wet the heap while the hydrocarbon/oxygen injection system stimulates the growth of hydrocarbon-utilizing bacteria. The resulting effluent solution may be pumped or gravity fed to an aerobic precipitation lagoon where aerobic hydrocarbon-utilizing bacteria are used to precipitate or otherwise deposit the metals onto a deposition material.
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FIELD OF THE INVENTION
The present invention relates to synchronous optical networks (SONET) and, more particularly, to a system and method for extending the management of a SONET network to encompass extension network elements within a single addressing area.
BACKGROUND OF THE INVENTION
Optical networks have become a standard technology for the transport of information in the telecommunications industry. A number of different optical network standards have been defined, with each having advantages and disadvantages for different uses. Synchronous optical network (SONET) is one standard for optical telecommunications transport. SONET is expected to provide the transport infrastructure for worldwide telecommunications for at least the next two or three decades. The increased configuration flexibility and bandwidth availability of SONET provides significant advantages over the older telecommunications system, such as reduction in equipment requirements, increase in network reliability, ability to carry signals in a variety of formats, a set of generic standards that enable products from different vendors to be connected, and a flexible architecture capable of accommodating future applications, with a variety of transmission rates. SONET is often used for long-haul, metro level, and access transport applications. In metropolitan areas, the access network often includes high-capacity synchronous optical network (SONET) rings, optical T3 lines, and copper-based T1s.
The management (control, monitoring, and provisioning) of a given SONET network is typically done via operator initiated command messages on a designated controlling host computer system directly connected to one of the network elements (NE's) in the SONET network. Command messages targeted for NE's, other than the directly connected NE, are transported over the optical connections between the NE's using a small portion of the optical bandwidth of the data transport overhead referred to as the Data Control Channel (DCC). Typically, NE's are optically connected to more than one NE in the SONET network requiring an NE to employ routing tables to direct messages on a DCC path leading to the NE for which it is targeted. SONET networks most generally employ OSI routing protocol also over the DCC's between NE's to dynamically populate the routing tables for each NE in the SONET network.
For SONET networks that employ OSI protocol (or any routing protocol scheme, such as OSPF), wherein each NE maintains a routing table entry for every NE in the network) there is generally a limit on the number of directly addressable NE's (for example 255 NE's). This limit is enforced to prevent the DCC's between NE becoming overburdened with OSI protocol messages used to exchange routing information between NE's). Such a limit assures that most of the DCC bandwidth between NE's is used to carry command messages.
Conventionally, one way to reduce the OSI routing burden in a SONET network is to split the network into more than one addressing area. For example, a single SONET network may be split into two separate address areas. Then, to interconnect the networks, one network element in the newly configured network becomes a member of both addressing areas. In this configuration, all control messages from one network area destined for the other network area must pass through the network element sharing membership with both network areas. For this reason, splitting the network into two separate addressing areas often results in a crippling burden on the network element sharing membership in both network areas due to extra control message traffic between the two areas.
Accordingly, there is a need for a technique for addressing additional network elements within a single SONET network. There is a further need for a technique to configure a SONET network to have a large number of network elements in a single addressing area that does not suffer from an excessive OSI routing burden.
SUMMARY OF THE INVENTION
According to the present invention, the number of network elements within a SONET network is configured to exceed the number addressable by the routing tables within the network elements themselves. This is achieved through the selective use of SONET extension network elements that do not participate in the OSI network and a TL1 command message protocol. An network element that has only one optical path (protected or unprotected) to an adjacent network element in the SONET network may become an extension network element (ENE). TL1 command messages may be targeted to an extension network element through its adjacent network element based on the identity of the network element's physical port connecting the network element to the extension network element.
According to an embodiment of the present invention, a method for addressing a network extension element is achieved using the fourth TL1 message field. The method includes receiving a command message that includes an extension network element identifier. The network extension element identifier is replaced with a session identifier and the modified command message is transmitted to a network extension element. The network extension element receives and processes the modified command and transmits a command response, including the session identifier, back to the network element.
The network element may in turn, accept the command response at the network element and determine the port to transmit the command response based on the session ID. The network element may then replace the session ID with an extension network element identifier and forward the modified command response to the source of the original command.
According to another embodiment of the present invention, a method of extending an optical network includes receiving a command message from the optical network including a port identifier specifying the port of a network element that is connected to an extension network element; processing the command message at the extension network element; and sending a response message to the network element.
According to another embodiment of the present invention, a system for extending an optical network includes an extension network element for connection to a network element. The extension network element is configurable to process command messages received from a network element without regard to the terminal identifier within the messages. The extension network element is further configurable to process command messages received from a network element in connection with a local session identification established between the network element and the extension network element. The network element and the extension network element may exchange command and response messages over a DCC connection. In addition, the extension network element does not have a separate terminal identification stored in the routing table of network elements within the network to which the extension network element is connected.
BRIEF DESCRIPTION OF THE FIGURES
The above described features and advantages of various embodiments of the invention will be more fully appreciated with reference to the attached drawings and detailed description.
FIG. 1 depicts a typical configuration between a LAN and a WAN system.
FIG. 2 depicts a SONET ring having a plurality of network elements and an extension network element according to an embodiment of the present invention.
FIG. 3 depicts a format for a command message according to an embodiment of the present invention.
FIG. 4 depicts a method of processing a command message for an extension network element by a network element according to an embodiment of the present invention.
FIG. 5 depicts a method of processing a command message by an extension network element according to an embodiment of the present invention.
FIG. 6 depicts a method of processing a response to a command message from an extension network element by a network element according to an embodiment of the present invention.
DETAILED DESCRIPTION
According to the present invention, the number of network elements within a SONET network is configured to exceed the number addressable by the routing tables within the network elements themselves. This is achieved through the use of SONET extension network elements and a special TL1 message protocol. The extension network elements are added to the SONET ring by connecting each extension network element to a network element via a DCC line. TL1 messages may then be addressed from any network element to the extension network element based on the port assigned to interconnect the network element to the extension network element.
Overview of a SONET/LAN System
An exemplary block diagram of a system 100 in which the present invention may be implemented is shown in FIG. 1 . System 100 includes a Wide Area Network 102 (WAN), one or more Local Area Networks 104 and 106 (LAN), and one or more LAN/WAN interfaces 108 and 110 . A LAN, such as LANs 104 and 106 , is computer network that spans a relatively small area. Most LANs connect workstations and personal computers. Each node (individual computer) in a LAN has its own CPU with which it executes programs, but it also is able to access data and devices anywhere on the LAN. This means that many users can share expensive devices, such as laser printers, as well as data. Users can also use the LAN to communicate with each other, by sending e-mail or engaging in chat sessions.
There are many different types of LANs, Ethernets being the most common for Personal Computers (PCs). Most Apple Macintosh networks are based on Apple's AppleTalk network system, which is built into Macintosh computers.
Most LANs are confined to a single building or group of buildings. However, one LAN can be connected to other LANs over any distance via longer distance transmission technologies, such as those included in WAN 102 . A WAN is a computer network that spans a relatively large geographical area. Typically, a WAN includes two or more local-area networks (LANs), as shown in FIG. 1 . Computers connected to a wide-area network are often connected through public networks, such as the telephone system. They can also be connected through leased lines or satellites. The largest WAN in existence is the Internet.
Among the technologies that may be used to implement WAN 102 are optical technologies, such as Synchronous Optical Network (SONET) and Synchronous Digital Hierarchy (SDH). SONET is a standard for connecting fiber-optic transmission systems. SONET was proposed by Bellcore in the middle 1980s and is now an ANSI standard. SONET network elements employ the OSI seven-layer model for the transport of management messages between network elements and controlling host computer systems. The standard defines a hierarchy of interface rates that allow data streams at different rates to be multiplexed. SONET establishes Optical Carrier (OC) levels from 51.8 Mbps (about the same as a T-3 line) to 2.48 Gbps. Prior rate standards used by different countries specified rates that were not compatible for multiplexing. With the implementation of SONET, communication carriers throughout the world can interconnect their existing digital carrier and fiber optic systems.
SDH is the international equivalent of SONET and was standardized by the International Telecommunications Union (ITU). SDH is an international standard for synchronous data transmission over fiber optic cables. SDH defines a standard rate of transmission at 155.52 Mbps, which is referred to as STS-3 at the electrical level and STM-1 for SDH. STM-1 is equivalent to SONET's Optical Carrier (OC) levels-3.
LAN/WAN interfaces 108 and 110 provide electrical, optical, logical, and format conversions to signals and data that are transmitted between a LAN, such as LANs 104 and 106 , and WAN 102 . It may also be used to transport telecommunication voice signals from telecommunication switches.
SONET Network Extension
FIG. 2 depicts a SONET network 200 , also known as a SONET ring, which includes a plurality of network elements 210 interconnected by optical links 220 . The network 200 may be used to implement the WAN 102 shown in FIG. 1 . The network 200 further includes an extension network element 230 which is associated with one particular network element 240 . The network elements 210 are each part of the network 200 and are addressable by the network 200 as nodes. Each network element 210 in the network 200 includes a stored routing table with the node identification of each other node stored therein. The network elements receive and route conventional frame data based on the routing table in a well-known manner. Unlike the network elements 210 , however, the extension network element 230 is not addressable by the network 200 and its terminal identification is not stored in the routing table of the other network elements associated with the network 200 .
The extension network element 230 is coupled to the network element 240 via a SONET connection including a data communications channel (DCC). The DCC may be used to exchange commands such as TL1 commands and control information between the network element 210 and the extension network element 230 . In order to configure the network 200 so that the extension network element is operative, command messaging such as TL1 (transaction language 1) messaging may be used.
FIG. 3 depicts the format of a TL1 message 300 for addressing an extension network element according to an embodiment of the present invention. Referring to FIG. 3 , the TL1 message includes a verb target 305 , a TID (terminal identifier) 310 , an AID (access identifier) 315 , a CTAG (correlation tag) 320 , and a general block 325 . The TL1 message fields are generally separated by a delimiter such as colon. It will be understood, however, that any convenient delimiter may be used.
TL1 messages may be used to cause a network and network elements within the network to exchange information and perform a variety of tasks. For example, a TL1 message may be used to command a network element to perform a task and return a result, to report an error or alarm condition or to send an acknowledgement of a command. The verbs form the command and may include: connect, disconnect, activate, change, compare, enter and corrupt to name a few. Many additional commands are generally available and supported by network elements. A summary of these commands and their syntax is available from Telecordia technologies, Inc.
The TID field 310 identifies a terminal with alphanumeric information. The AID field 315 identifies a port corresponding to the terminal identified in the TID. The general field 325 is conventionally left blank in TL1 messaging. According to the present invention, however, the general field 325 is used to store values of interest to enable the extension network element 230 to be addressed by TL1 messages without allocating to the extension network element a separate TID. The extension network element 230 is coupled to a network element 240 and is addressable from the network 200 by identifying in a TL1 message the TID of the network element 240 , the AID for the incoming message and the port (AID) of the network elements' DCC signal which connects the extension network element 230 to the network element 210 .
FIG. 4 depicts a method of processing a command message for an extension network element 230 by a network element 240 to which the extension network element is connected according to an embodiment of the present invention. Prior to the method Of FIG. 4 , the network element 210 and the extension network element 230 should be configured first to set up a DCC between the network element and the extension network element and second to configure the elements to process command messages according to FIG. 4-6 . The processes of FIGS. 4-6 may be handled by software or by altering routing protocols stored in memory with the network element 210 and extension network element 230 .
Referring to FIG. 4 , in step 400 , the network element 240 receives a TL1 message from another network element 210 within the network 200 . The network element 240 identifies the message as destined for it based on the terminal identifier within the TID field 310 . Then in step 410 , the network element 240 retrieves the information stored in the general field 325 of the TL1 message. The information includes the ENE-AID, which specifies the port of the network element corresponding to the DCC through which the network element 240 is connected to the extension network element 230 .
In step 420 , the network element 240 identifies the DCC associated with the port based on the ENE-AID information. Then in step 430 , the network element 240 replaces the general field 325 with a local TL1 session ID value. In step 440 , the network element 240 transmits the modified TL1 message to the extension network element 230 .
FIG. 5 depicts a method of processing a command message by an extension network element according to an embodiment of the present invention. The method of FIG. 5 begins at the conclusion of the method of FIG. 4 . Referring to FIG. 5 , in step 500 , the extension network element 230 receives and accepts the TL1 message from the network element 240 . In step 510 , the extension network element processes the TL1 command, ignoring the TID field 310 the session ID stored in the general field 325 by the network element. Then, in step 520 , for a command and response message, the extension network element transmits a response back to the network element 240 over the same DCC from which the message was received. The response includes the session ID in the general field 325 .
FIG. 6 depicts a method of processing a response to a command message from an extension network element by a network element according to an embodiment of the present invention. The method of FIG. 6 begins where the method of FIG. 5 ends. Referring to FIG. 6 , in step 600 the network element 240 accepts the command response from the extension network element 230 . Then in step 610 , the network element 240 determines the port within the network 200 to transmit the command response to based on the session ID from the command response. The network element performs this determination by retrieving from storage the session ID and correlating the session ID to the port from which the original message was received.
In step 620 , the network element replaces the session ID in the general field 325 with the ENE AID corresponding to the port to which the extension network element is coupled. Then in step 630 , the network element 240 forwards the modified response message to the source of the original command.
In this manner, the methods of FIGS. 4-6 permit TL1 messages to be exchanged with extension network elements, even though the extension network elements are not separately addressable by the network 200 . The general field 325 within a TL1 message is exploited to embed information that is used to access the extension network elements. Therefore, the extension network elements are addressable through the network element without increasing the size of the routing table of any elements within the network 200 . Numerous network extension elements may be added in this manner to a network and more than one network extension element may be added to each network element.
While particular embodiments of the present invention have been shown and described, it will be understood by those having ordinary skill in the art that changes may be made to those embodiments without departing from the spirit and scope of the invention.
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The number of managed network elements within a SONET network is configured to exceed the number addressable elements in a given address area. This is achieved through the use of SONET extension network elements and a special TL1 command message protocol. Any network element that has only one optical path (protected or unprotected) to an adjacent network in the SONET network can become an extension network element. TL1 command messages may be targeted to an extension network element through its only adjacent network element based on the network element's physical port connecting the network element to the extension network element.
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This application is a continuation of application Ser. No. 874,629, filed June 16, 1986, abandoned, which is a continuation of Ser No. 580,954, filed Feb. 16, 1984, U.S. Pat. No. 4,622,596.
FIELD OF THE INVENTION
The present invention relates to an image pickup apparatus which can effectively suppress the blooming.
BACKGROUND OF THE INVENTION
Generally, in solid state image sensors such as a CCD or the like, there has been considered a method whereby an overflow drain is provided in the photosensing surface to prevent the blooming or the overflow carriers are extinguished using the surface recombination.
In particular, the latter method is known by, for example, United Kingdom Patent Publication Gazette GB No. 2,069,759A (applicant, N. V. Philips; inventors, Marnix Guillaume Collet et al), and the like. Such a method has advantages such that sensitivity is high since an aperture in the photosensing surface is not sacrificed and that horizontal resolution is raised since the integration degree can be improved, and the like.
FIGS. 1-3 show diagrams to describe such a method of preventing the blooming by the surface recombination, in which FIG. 1 shows a front view of an ordinary frame transfer type CCD.
In the drawings, a reference numeral 1 denotes a photosensing part consisting of a plurality of vertical transfer registers having photosensitivity.
On the other hand, a numeral 2 indicates a storage part consisting of a plurality of vertical transfer registers which are shielded against the light. represents a horizontal transfer register which simultaneously shifts the information in the respective vertical transfer registers of the storage part 2 by one bit, thereby taking them in this horizontal transfer register, then by allowing the register 3 to perform the horizontal transfer operation, a video signal can be obtained from an output amplifier 4.
Generally, the information formed in each vertical transfer register of the photosensing part 1 is vertically transferred to the storage part 2 in the vertical blanking interval in the standart television system and is sequentially read out on a line by line basis by the horizontal transfer register 3 in the next vertical scanning interval.
The photosensing part 1, storage part 2 and horizontal transfer register 3 are respectively two-phase driven and their respective transfer electrodes are indicated by P 1 , P 2 , P 3 , P 4 , P 5 , and P 6 and the transfer clocks are represented by φ P1 , φ P2 , φ P3 , φ P4 , φ P5 and φ P6 respectively.
FIG. 2 is a diagram showing a potential profile under such transfer electrodes P 1 -P 6 . Low-potential portions and high-potential portions are formed under the respective electrodes provided on, for example, a p-type silicon substrate 6 through an insulating layer 5 by way of ion implantation or the like. For example, when a low-level voltage -V 1 is applied to the electrodes P 2 , P 4 and P 6 and a high-level voltage V 2 is applied to the electrodes P 1 , P 3 and P 5 , the potentials such as indicated by the solid lines in FIG. 2 are formed. On the other hand, when the low-level voltage -V 1 is supplied to the electrodes P 1 , P 3 and P 5 and the high-level voltage V 2 is supplied to the electrodes P 2 , P 4 and P 6 , the potentials such as indicated by the broken lines in FIG. 2 are formed.
Therefore, by applying the alternating voltages having opposite phases to each other to the electrodes P 1 , P 3 , P 5 and to the electrodes P 2 , P 4 , P 6 the carriers are sequentially transferred in one direction (to the right in the drawing).
In addition, the alternate long and short dash lines in FIG. 2 show the potentials when a large positive voltage V 3 is applied to the electrodes. Since the wells of these potentials are in the inverting state, the overflow carrier of not smaller than a predetermined amount will have been recombined with majority carrier and have been extinguished.
FIG. 3 is a diagram showing such a relation between the electrode voltage and the shape of the interval potential with respect to the direction of thickness of the semiconductor substrate 6. It can be seen from FIG. 3 that the potential well for the electrode voltage V 3 is shallow, so that the overflow carrier is in a second state in that it is recombined with the majority carrier at the interface with the insulating layer.
On the other hand, the potential state becomes the accumulation state as a first state at the electrode voltage -V 1 , so that the majority carrier is easily collected around the interface; for example, this majority carrier is supplied from a channel stopper region (not shown).
Therefore, by alternately applying the voltages -V 1 and V 3 to the electrode P 1 in the state in that a varrier is formed by, for example, applying the voltage -V 1 to the electrode P 2 , the minority carrier to be accumulated under the electrode P 1 is limited to not larger than a predetermined amount.
However on the contrary, to effectively extinguish the overflow carrier, the accumulation state and the inverting state have to be alternately formed at a high speed in the semiconductor substrate in the accumulating interval; therefore, this causes a problem such that an electric power consumption is large. In addition, if such a pulse control is performed at high speed, there will be also caused a problem such that the noise to be caused by this pulse is mixed to the signal. Also, there is a problem such that the dark current drift may easily occur due to such a pulse.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an image pickup apparatus which can solve such drawbacks in conventional technology.
Another object of the invention is to provide an image pickup apparatus which can effectively prevent the blooming and which has a high electric power saving effect.
Still another object of the present invention is to provide an image pickup apparatus which can eliminate the noise upon recording.
In addition, it is a further object of the present invention to provide an image pickup apparatus having a higher electric power saving effect in a system which can shield a photosensing part against the light by a shutter.
Another object of the invention is to provide an image pickup apparatus having a high electric power saving effect and a high noise preventing effect in a system which forms an image signal of one picture by a trigger signal.
A further another object of the present invention is to provide an image pickup apparatus which enables the optimum prevention of the blooming in response to the state of an object to be photographed.
The above and other objects, features and advantages of the present invention will be apparent from the following detailed description in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram showing an example of an image sensor;
FIG. 2 is a diagram showing an example of a potential profile under each electrode;
FIG. 3 is a diagram showing potential characteristics in accordance with the electrode potentials;
FIG. 4 is a diagram showing a constitution of a first embodiment of an image pickup apparatus of the present invention;
FIG. 5 shows drive timing charts of the constitution shown in FIG. 4;
FIG. 6 is a diagram showing a constitution of a second embodiment of the image pickup apparatus of the present invention;
FIG. 7 shows drive timing charts of the constitution shown in FIG. 6;
FIG. 8 is a diagram showing an example of the constitution in which a part of the embodiment shown in FIG. 6 is changed;
FIG. 9, is a diagram showing a third embodiment of the image pickup apparatus of the present invention;
FIG. 10 shows timing charts thereof;
FIG. 11 is a diagram showing a fourth embodiment invention;
FIG. 12 is a diagram showing a fifth embodiment of the present invention;
FIG. 13 is a diagram showing a sixth embodiment of the present invention;
FIG. 14 is a diagram showing a seventh embodiment of the present invention;
FIG. 15 is a diagram showing an eighth embodiment of the present in addition; and
FIG. 16 is a diagram showing a ninth embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will be described in detail hereinbelow with respect to embodiments.
FIG. 4 is a diagram showing a first embodiment of a constitution of an image pickup apparatus of the present invention and FIG. 5 shows timing charts thereof, in which a reference numeral 100 denotes an image sensor as image pickup means. This image sensor may be a CCD such as shown in FIG. 1 or may be an XY address image sensor of the MOS type.
In this embodiment, the case will be described where the frame transfer type CCD shown in FIG. 1 is used.
A reference numeral 7 represents a driver circuit as readout means for supplying transfer pulses φ P1 -φ P6 which are necessary for the transfer of this CCD image sensor and an anti-blooming pulse φ AB which will be described later. Numeral 9 is a first clock generator as a clock signal source for forming timing signals of φ P1 -φ P6 among these pulses. Numeral 8 is a second clock generator as recombination means and the driver circuit 7 forms the anti-blooming pulse φ AB in response to the timing signal from this clock generator 8 and supplies to the electrode P 1 or P 2 of the image sensor.
After the output of the image sensor 100 was amplified by an amplifier 10, it is subjected to the γ-compensation, aperture-compensation, etc. in a processor 11 and is introduced through a gate 12 to a head 13 and is recorded in a recording medium 14. The head 13, medium 14, etc. constitute recording means. The output of the gate 12 may be supplied not only to the recording means but also to, for example, a transmitting apparatus, printer, or the like.
A reference numeral 19 is a trigger circuit as trigger means for forming a pulse signal by operating an operating switch TB. This trigger circuit is provided to selectively perform the recording, transmission, printing, or the like of the image of one field or one frame as will be described later by operating this operating switch TB at a proper timing while, for example, observing the output of the processor 11 by a video monitor. As shown in FIG. 5, a high-level signal is output from a one-shot circuit 18 for only a predetermined interval (e.g., one vertical sync interval) synchronously with the trailing edge of the pulse output from the trigger circuit 19.
Numeral 16 is a one-shot circuit for outputting a high-level pulse for a predetermined interval synchronously with the trailing edge of a vertical sync pulse V D from the clock generator 9. The output of this one-shot circuit 16 is input to a clock input terminal of a D-flip-flop.
Therefore, as shown in FIG. 5, the gate 12 is open for an interval of time from a time point t 1 when the first vertical sync signal V D was obtained after the trigger pulse from the trigger circuit 19 had been outputted to a time point t 2 when the next vertical sync signal is obtained. Thus, the signal of one field is recorded in the recording medium 14 through the head 13. The recording medium 14 is driven by a motor MT which rotates synchronously with the phase of the vertical sync signal.
On the other hand, while this gate 12 is open, the output of the second clock generator 8 is stopped through an inverter 20. A control block 15 consisting of the one-shot circuits 16 and 18, a flip-flop 17, etc.
Furthermore, as shown in FIG. 5, the anti-blooming pulse φ AB is made inoperative during the vertical transfer intervals t 1 -t 2 , t 3 -t 4 , t 5 -t 6 and t 7 -t 8 .
Also, the pulse φ AB is switching controlled by the driver 7 so as to be alternately added to the pulse φ P1 or pulse φ P2 for every field. In addition, the phases of the pulses φ P1 and φ P2 are shifted by only one field; therefore, the locations of the potential well and potential barrier are shifted by only the amounts corresponding to the electrodes P 1 and P 2 for every field. Due to this, the interlacing is performed. The pulse φ AB is added to the electrode which does not form the potential barrier, i.e., to the electrode whose potential is 0 level in case of FIG. 5.
In addition, in this embodiment, although the formation of the pulse φ AB is stopped for only the interval when the output of the image sensor is being recorded, it may be possible to the pulse φ AB for only a proper period of time, e.g., a few V (vertical intervals) after the recording was started.
In this way, since there is an operating time lag until the next recording operation is done after the recording operation was finished, a larger electric power saving effect will be obtained if a system is constituted so as to stop the pulse φ AB for only a predetermined time after the recording was started as described above.
In addition, although the case has been described where only one field in the video signal to be formed continuously is extracted and is recorded in this embodiment, the present invention is of course effective to a constitution in which the image sensor is exposed a predetermined time by a shutter or the like and thereafter the picture image on this image sensor is read out and is recorded for example as the image information of two fields which were mutually interlaced.
Moreover, in this embodiment, φ AB is set into 0 level and is made inoperative for only a predetermined time after the recording was started by opening the gate 16; however, it may be possible to apply the potential of for example -V 1 in this interval except the vertical transfer interval. In this case, an effect such that the dark current is difficult to be generated is produced.
As described above, in this embodiment, the supply of the high-frequency pulse for the anti-blooming is stopped in association with the starting of the recording of the signal output to be read out from the image pickup means; therefore, it is possible to save an electric power consumption. Moreover, the blooming is difficult to be caused in the video signal to be recorded.
On the other hand, since the noise to be caused due to the pulse for the above-mentioned anti-blooming is not generated during the recording, an S/N ratio of the recording signal does not deteriorate.
Next, FIG. 6 is a diagram showing a second embodiment of the image pickup apparatus of the present invention and FIG. 7 shows timing charts thereof. In FIGS. 6 and 7, the same elements as those in FIGS. 1-5 are designated by the same reference numerals. This embodiment shows the case where a shutter 628 is provided in front of the image sensor 100.
In this embodiment, the output of the one-shot circuit 16 and the output of the one-shot circuit 18 are input to an AND gate 620.
Therefore, as shown in FIG. 7, a high-level signal is output from the AND gate 620 synchronously with the trailing edge of the first vertical sync signal V D after the trigger pulse was outputted. A reference numeral 617 denotes a timer for specifying the exposure time by the shutter 628. When the high-level signal is inputted from the AND gate 620, the timer 617 outputs a high-level pulse at a time point when a time Ts which was set by a setting resistor 622 passed after the trailing edge of that high-level signal.
Numeral 621 is a timer for outputting a high-level signal for only a predetermined time in response to this pulse. The shutter 628 is closed for this high-level signal interval in response to the output from a shutter control circuit 627.
The shutter 628 is energized ordinarily by a spring and the like so as to be opened.
In addition, the second clock generator 8 is controlled so as to be stopped by an inverter 626 during the interval when this shutter is closed.
This inverter 626 and the timer 621 constitute stop means according to the present invention.
The output of a one-shot circuit 624 for forming a pulse synchronously with the leading edge of the timer 621 and the output of the one-shot circuit 16 are supplied to a timer circuit 625 through an AND gate 623.
The timer circuit 625 is the circuit for outputting high-level signal synchronously with the leading edge of the input signal for only, e.g., 1 V (vertical interval) and opens the gate 12 during only this high-level interval.
Thus, the recording is started synchronously with the first vertical sync signal after the shutter was closed and the signal for one field interval is recorded.
On the other hand, the formation of the pulse φ AB is stopped for only the interval when the light incidence to the image sensor 100 is blocked by the shutter 628 in this embodiment; however, it may be possible to stop the pulse φ AB for only a proper time, e.g., a few V (fertical interval) after the closing of the shutter was started.
FIG. 8 is a diagram showing such an embodiment. In this embodiment, the output of the timer circuit 621 is inputted to the shutter control circuit 627 and is used for the opening and closing controls of the shutter 628, and at the same time it is inputted to a timer circuit 629. This timer circuit 629 outputs a high-level signal for a predetermined time (e.g., a few V intervals) after the leading edge of the output of the timer circuit 621.
The output of this timer circuit 629 is inputted to the clock generator 8 through the inverter 626.
Therefore, once the output of the timer circuit 621 rises, it is possible to disable φ AB irrespective of the opening/closing of the shutter 628.
Since there is a time lag with regard to the operation until the next image pickup operation is further performed after the recording operation was carried out upon completion of the image pickup operation using the shutter, if a system is constituted in the manner such that the pulse φ AB is stopped for only a predetermined time after the closing of the shutter was started as described above, a larger electric power saving effect will be obtained and will be actually useful.
As described above, according to the second embodiment, the shutter for blocking the light incidence to the image pickup means is provided, thereby making the exposure time control possible by this shutter and enabling the smear during the vertical transfer interval to be prevented, and at the same time while at least the light incidence is blocked by this shutter, the pulse φ AB for the anti-blooming is not formed; therefore, the electric power to be consumed can be remarkably saved.
In addition, since almost only the dark current exists while the shutter is closed, no blooming occurs; on the other hand, while the shutter is open, the overflow carrier is extinguished by the pulse φ AB , so that the blooming is effectively suppressed.
The dark current drift and noise are certainly reduced while the pulse φ AB is stopped, so that the recording signal and the like are not adversely affected.
Now, FIG. 9 is a diagram showing a third embodiment of the present invention and FIG. 10 shows timing charts thereof, in which the same elements as those shown in FIGS. 1-8 are designated by the same reference numerals. In FIG. 9, a reference numeral 926 denotes an RS flip-flop which is set in response to the leading edge of the output of the AND gate 620 and is reset responsive to the leading edge of the output of the timer 617. The Q output of this RS flip-flop controls the on-off operations of the second clock generator 8. Namely, when the Q output is high, the generator 8 is turned off and when the Q output is low, it is turned on.
According to this embodiment, the recombination control means for preventing the blooming is made operative only for the interval when the picture image information to be selected by the selecting means is being accumulated by the image sensor, so that the electric power to be consumed can be extremely reduced.
In addition, since the dark current drift and noise are decreased while the pulse φ AB is stopped, the recording signal and the like are not adversely influenced.
On one hand, in the second and third embodiments, since the shutter 628 is closed even while the signal selected by the gate 12 is being recorded or the like, there is not a fear of mixture of the blooming noise on the next screen into the above-mentioned signal selected.
Although the exposure time control and the prevention of the smear during the vertical transfer interval are performed by the shutter in this embodiment, the present invention can be of course applied to a system using no shutter.
Next, FIG. 11 is a block diagram showing a fourth embodiment of the image pickup apparatus of the present invention. In the drawing, a light incidence from an object to be photographed passes through an optical system indicated by 407 and a diaphragm 408 disposed on the optical path thereof. This incident light is formed on the image sensor 100 such as, for example, a CCD or the like as shown in FIG. 1 and at the same time it enters a photometric photosensing device 414 through a beam splitter 409 and a deflecting mirror 413.
The photosensing device 414, an operational amplifier 427 and a resistor 426 constitute a well-known photoelectric converter. In addition, a resistor 428, a resistor 429, an operational amplifier 431, and a reference voltage source 430 which are connected to the output of the operational amplifier 427 constitute an inverting amplifier for comparing the output from the operational amplifier 427 with the reference voltage source 430 and invertedly amplifying it. The output thereof is connected to one input terminal of an OR gate 422 and at the same time it is connected to a driving coil 432 for driving the diaphragm. The diaphragm driving coil 432 serves tc open the diaphragm 408 when a positive voltage is applied by the operational amplifier 431 and to close the diaphragm 408 when a negative voltage is applied. The output of the image sensor 100 is connected to a luminance separating circuit 411 and the output of the circuit 411 is further connected to an integrating circuit 412 and a peak-hold circuit 418, respectively. The output of the integrating circuit 412 is connected to an inverting input of a comparator 416 and a non-inverting input of the comparator 416 is connected to a reference voltage source 417. The output of the comparator 416 is connected to one input of an AND gate 421. The integrating circuit may be a smoothing circuit, mean value circuit or low-pass filter. The output of the peak-hold circuit 418 is connected to an inverting input of a comparator 419 and a non-inverting input of the comparator 419 is connected to a reference voltage source 420. The output of the comparator 419 is connected to the other input of the AND gate 421. The output of the AND gate 421 is connected to the other input of the OR gate 422. The output of the OR gate 422 is connected to a control terminal of a switching circuit 436. The output of the peak-hold circuit 418 is connected to a voltage controlled oscillator 424 through the switching circuit 436. The output of the voltage controlled oscillator 424 is connected to a driver 434 for forming a driving pulse of the CCD 100. A reference numeral 435 is a clock generator for outputting timing signals of various pulses to drive the CCD 100.
The driver 434 outputs the pulses φ P1 -φ P6 in response to these timing signals.
On the other hand, the driver 434 forms the alternating pulse φ AB which changes between the voltages -V 1 and +V 3 in FIG. 3 in response to the output of the voltage controlled oscillator 424 and supplies this pulse φ AB to the CCD.
Numeral 437 indicates a setting value circuit connected to the b side of the switching circuit 436. While a high-level signal is output from the OR gate 422, the contact of this switching circuit 436 is switched to the b side in response to this high-level signal, so that a predetermined set value V is input to an input terminal of the voltage controlled oscillator 424. The set value is for example 0 (volt) and the oscillator, 424 is constituted in the manner such that the oscillating frequency is zero, namely, the oscillation is stopped for the 0-volt input.
In addition, the circuits 412, 416, 418-420, 422, 414, 426-431, etc. constitute object information detecting means for forming information with respect to the brightness or the like of the object. Also, the circuits 424, 436, 437, etc. constitute second control means for controlling the recombination state in response to the signal from this forming means.
The operation of the constitution shown in FIG. 11 will now be described. In the case where the amount of light incidence into the photosensing device 14 is smaller than a appropriate value, the output of the photoelectric converter becomes low voltage, so that the output of the inverting amplifier 431 becomes positive high voltage. Therefore, the positive voltage is applied to the diaphragm driving coil 432, so that the diaphragm is driven so as to be open. On the contrary, in the case where an amount of light incidence into the photosensing device 414 is larger than the appropriate value, the opposite operation to the above is performed, so that a current flows through the diaphragm driving coil 432 in the direction such as to close the diaphragm, thereby reducing the light incident amount.
On the other hand, the object image formed on the image sensor 100 is photoelectric converted and the charge information is formed in the image sensor 100. The luminous component is separated from the output of the image sensor 100 by the luminance separating circuit 411 and is integrated by the integrating circuit 412, thereby detecting the mean luminous level of the object.
The comparator 416 compares this level with a predetermined reference level and when the output of the integrating circuit 412 is lower than the predetermined level, a high-level signal is outputted from the comparator 416.
Namely, when the mean luminous level of the object is lower than that by a certain value, a high-level signal is obtained from the comparator.
On one hand, the output of the luminance separating circuit 412 is connected to the peak-hold circuit 418, thereby detecting the peak in the luminance signal. The comparator 419 compares the peak thus detected with the voltage of the reference voltage source 420 and when the peak level is lower than that, a high-level signal is outputted. Only in the case where both outputs of the comparators 416 and 419 are at high level, i.e., only when the mean luminance of the object is low and the highest luminance is also low, the AND gate 421 outputs a high-level signal and the OR gate 422 also outputs a high-level signal, so that the switch 436 is switched to the b side, thereby stopping the oscillation of the voltage controlled oscillating circuit 424.
In addition, since the outputs of the integrating circuit 412 and peak-hold circuit 418 are delayed by only the output scanning time of the image sensor 100 and at the same time the time lag to be caused due to the diaphragm (stop) adjusting operation is further added to those outputs, in the case where the light incidence into the photosensing device 414 is too weak as a result of that, for example, the diaphragm was adjusted to be too narrow, namely, in the case where a positive voltage is applied to the diaphragm driving coil 432 and it is driven so as to open the diaphragm, a high-level signal is inputted to the OR gate 422, so that the OR gate 422 outputs a high-level signal. Consequently, the oscillation of the oscillator 424 is stopped similarly as described before.
In the state where this oscillation was stopped, the image sensor 100 is ordinarily periodically driven by the pulses φ P1 -φ P6 shown in FIG. 1 and φ AB is not added.
Furthermore, when the output of the OR gate 422 is at low level, the output of the peak-hold circuit 418 is inputted to the voltage controlled oscillator 424 through the switch 436 and the oscillator 424 generates the pulse train of higher frequency in response to the peak value as the peak value is larger, so that the pulse φ AB in accordance with that pulse train is supplied to the image sensor 100.
In addition, in this embodiment, when a power supply (not shown) is turned on, the pulses φ P1 -φ P6 are always supplied at the cycle in accordance with an ordinary standard television system and at the same time its pulse voltage is set so as to change between -V 1 and +V 2 in FIG. 3.
Also, the pulse φ AB is supplied to the transfer electrodes of the image sensor by being added to these pulses φ P1 -φ P6 .
Moreover, the pulse φ AB is controlled by the driver 434 so as to be at 0 level while the charge information in the photosensing part 1 of the image sensor 100 is being vertically transferred to the storage part 2. Therefore, φ AB does not disturb the vertical transfer.
As described above, according to the present invention, an object image is converted into charge information by the image pickup means, this charge information is read out to obtain a luminance signal, and the frequency of the recombination pulse of the charges is controlled in dependence upon the peak level of this luminance signal; therefore, it is possible to effectively utilize the electric power necessary for recombination.
In addition, in this embodiment, in the case where the average level of the luminance signal is smaller than a predetermined level and at the same time when the peak level of the luminance signal is smaller than a predetermined level, the formation of the pulse φ AB for recombination is stopped; thus, this enables unnecessry electric power consumption to be effectively reduced.
Moreover, since the pulse φ AB is also stopped in the case where the photometric output of another photometric device other than the image pickup means is smaller than a predetermined level, even in the case where, for example, a picture plane is suddenly switched from a bright object to a dark object, or the like, unnecessary pulse φ AB can be omitted with high response speed.
On the other hand, in this embodiment, although the oscillating frequency of the voltage controlled oscillator (VCO) 424 is changed in accordance with the output of the peak-hold circuit 418, i.e., with the peak value of the luminance signal, it may be possible to control the oscillating frequency of the VCO 424 in dependence upon the output level of the integrating circuit 412 of FIG. 11 as a fifth embodiment as shown in FIG. 12. In this case, the frequency of the VCO 424 may be set to be high in dependence upon an increase in the output of the circuit 412.
Or as shown in FIG. 13 as a sixth embodiment, by connecting the photosensing device 414, operational amplifier 427 and a diode 260 for logarithm compression as shown in the drawing, the logarithm compression value responsive to the incident light amount into the photosensing device is outputted and the frequency of the pulse φ AB may be controlled depending upon the logarithm of the incident light amount into the photosensing device 414 by inputting this output value to the VCO 424.
This frequency φ AB is controlled so as to become high in response to an increase in the incident light amount in the similar manner as in the fourth and fifth embodiments.
In addition, the photosensing device 414 may be the device for measuring the TTL (Through The Lens) light or the device for measuring the outside light.
On the other hand, the oscillating frequency of the VCO 424 may be continuously controlled in the 4th-6th embodiments and the frequency may be changed step by step by being divided into several stages.
These 5th and 6th embodiments allow the constitution to be simplified.
FIG. 14 is a diagram showing a seventh embodiment of the present invention, in which an oscillator 438 for forming the pulse φ AB for recombination of constant frequency by the driver 434 is provided in place of the oscillator 424 shown in FIG. 11, thereby stopping this oscillator 438 while the output of the comparator 431 shown in FIG. 11 is at high level.
Although not shown, even in this case, the output of the photosensing device 414 shown in FIG. 11 is inputted through the resistor 428 to the comparator 431 and this photosensing device 414 may be the device for measuring the outside light.
FIG. 15 is a diagram showing an eighth embodiment of the present invention, in which the on-off operations of the oscillator 438 in the 7th embodiment are performed by the comparator 416 shown in FIG. 11, and the oscillator 438 is turned off while the comparator 416 outputs a high-level signal.
FIG. 16 is a diagram showing a ninth embodiment, in which the oscillator 438 of FIG. 15 is turned off while the output of the comparator 419 shown in FIG. 11 is at high level.
As described above, in the embodiments shown in FIGS. 14-16, the oscillation of the pulse φ AB is turned off in any one case of the cases where the output of the photosensing device is lower than a predetermined level, where the mean value of the luminance signal is lower than a predetermined level, and where the peak value of the luminance signal is lower than a predetermined level; therefore, a high electric power saving effect is obtained and a circuit constitution is also simplified.
As described above, according to these embodiments, the oscillating frequency of the pulse for recombination is controlled in a predetermined range including zero in accordance with the state of the luminance of an object (for example, output level of the photosensing device, average level of the luminance signal, peak value of the luminance signal, etc.), so that the electric power in association with the formation of the pulse for recombination can be effectively saved and at the same time there is an effect such that the blooming is difficult to be caused. That is to say, since the frequency of the pulse φ AB becomes higher as the peak of the luminance level or of a part thereof becomes higher, the recombination speed of the overflow charges becomes faster in accordance with that frequency, thereby enabling the overflow charges to be efficiently extinguished.
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An image pickup apparatus comprises: an image sensor for converting an optical image into distribution information of minority carrier; a control circuit for periodically forming a first state in that majority carrier is accumulated in the image sensor and a second state in that at least a part of the minority carrier is recombined with this majority carrier; a readout circuit for reading out the information in the image sensor; a recording apparatus for selectively recording the information for a predetermined interval from the information to be read out by the readout circuit with regard to the trigger operation for a still photograph; and a stopping circuit for stopping the control operation of the control circuit in association with the start of the recording by the recording apparatus or the closing of a shutter or in response to a low luminous condition or the like.
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BACKGROUND OF THE INVENTION
The invention relates to an earth boring device and a threaded element with a thread retention for an earth boring device.
Earth boring devices, in particular in the field of trenchless installation and rehabilitation of lines and pipes, are known in many forms.
One type of earth boring devices involves so-called soil displacement hammers, which are characterized by an internal percussion drive having a percussion piston which oscillates, i.e. strikes alternately, inside a housing of the soil displacement hammer and is operated by a pressure fluid and which impacts—depending on the feed direction of the soil displacement hammer—a leading or trailing impact surface of the housing or an attached structure and thereby transfers its kinetic energy onto the earth boring device for propelling the latter into the earth.
The impact surfaces of the percussion piston as well as of the housing must evidently withstand very high stress. Therefore, the impact surfaces of the percussion piston and the housing are hardened. Furthermore, it may be provided to integrate at least the leading impact surface of the housing in a structure which is replaceable, when worn out. In this way, maintenance costs of the soil displacement hammer can be limited. Such a replaceable structure thus assumes the task of transferring the impact energy from the percussion piston to the housing. As a result, the connection thereof with the housing has to meet stringent requirements.
Conventionally, such replaceable structures having an impact surface are normally connected to the housing through intervention of a thread, wherein the threaded connection is oftentimes further secured by means of a thread retention adhesive. This prior art solution suffers shortcomings in operation. Firstly, hardening of the thread retention adhesive requires a wanted time period during which the soil displacement hammer cannot be operated for safety reasons. Such a delay causes added operating costs in particular when the percussion structure is replaced during a drilling need. Moreover, detachment of a percussion structure that has been secured by a thread retention adhesive is very difficult.
SUMMARY OF THE INVENTION
The invention is thus based on the object to provide an earth boring device which at least reduces prior art shortcomings. In particular, it is desired to provide a soil displacement hammer which includes a structure with impact surface, which structure can easily be assembled and disassembled while yet ensuring a secure hold.
According to one aspect of the present invention, .the object is attained by an earth boring device which includes a housing having at least one portion with an inner thread, and a threaded element having a corresponding outer thread, wherein the threaded element is slotted and has a receptacle for a securing element which increases the outer diameter of the threaded element and the contact pressure of the threaded connection between threaded element and housing, when inserted in the receptacle.
According to another aspect of the present invention, a threaded element for connection with the housing of an earth boring device is provided which is slotted and has a receptacle for a locking bolt in the area of the slot, wherein the outer diameter of the threaded element undergoes an enlargement, as the locking bolt is inserted.
According to another aspect of the present invention, a method of fastening a slotted threaded element in the housing of an earth boring device, includes the steps of screwing the threaded element with its outer thread into a corresponding thread of the housing, and inserting a locking bolt in a receptacle arranged in the area of the slot for enlarging the outer diameter of the threaded element and the contact pressure of the threaded connection.
According to another aspect of the present invention, a threaded ring with an outer thread is provided which is slotted at least at one area in length direction, and a receptacle is provided in the area of the slot for accepting a locking bolt, wherein the outer diameter of the threaded ring is enlarged, as the locking bolt is inserted.
According to another aspect of the present invention, a method of securing a threaded connection between a longitudinally slotted threaded ring with an outer thread and a corresponding inner thread includes the steps of inserting a locking bolt in an off-center receptacle within the threaded ring so that the outer diameter of the threaded ring is enlarged.
The essence of the invention is the connection of a threaded element, which is slotted at least in one area and preferably provided directly or indirectly for transmission of the impact energy from a percussion piston of the earth boring device onto the housing, to a housing via a thread, and the securement of this thread connection by a locking bolt which is inserted into a receptacle provided in the area of the slot of the threaded element to thereby effect an enlargement of the outer diameter of the threaded element. The enlargement of the outer diameter increases the contact pressure of the threaded connection so that an unwanted detachment can be prevented.
The term “threaded element” is to be understood as relating to a structure having at least one portion of circular cross section, with an outer thread being additionally provided in this portion.
The slot in the threaded element should be configured such that it can be spread as the locking bolt is inserted. The locking bolt extends preferably in the direction of the length axis of the threaded element, although it is equally possible to orient the slot at an angle of up to <90° in relation to the length axis of the threaded element. Furthermore, the slot extends preferably over the entire portion of the threaded element that is provided with a thread. As far as the depth of the slot is concerned, it is preferably provided to run the slot from the perimeter of the threaded element up to the length axis of the threaded element or to have it terminate in an inner bore (in a threaded element in the form of a threaded ring). The slot may hereby extend radially or inclined.
The receptacle preferably includes for the locking bolt a portion which tapers, i.e. the cross section decreases steadily in this portion. Preferably, the portion of the receptacle tapers conically. Such a (conical) taper of the receptacle causes together with a locking bolt, which is pushed into the receptacle, a widening of the slot of the threaded element and thus an enlargement of its outer diameter.
In addition, or as an alternative, the locking bolt has a—preferably conically—tapered portion by which the slot is widened, when the locking bolt is inserted.
According to an advantageous configuration, the locking bolt has a portion with an outer thread which corresponds to a portion of the receptacle with an internal thread. The locking bolt can thus be screwed into the receptacle.
The earth boring device is preferably configured as striking boring device (soil displacement hammer), i.e. it has an internal percussion drive with an oscillating, i.e. reciprocating percussion piston. The latter is preferably operated by a pressure fluid, preferably compressed air and/or hydraulic fluid which can be supplied from outside to the boring device. Such a configuration of the earth boring device enables the threaded element to directly or indirectly transmit the impact energy onto the housing of the boring device.
According to a further advantageous configuration, the treaded element is constructed as threaded ring. A percussion bolt may be movably guided at least in longitudinal axial direction within the threaded ring. In this case, it may be provided to arrange the receptacle for the locking bolt off-center, i.e. in the marginal area of the threaded ring. The percussion bolt may extend through the threaded ring beyond the housing of the boring device and connected there with a drill head so that the drill head itself is arranged for movement in relation to the housing of the boring device.
In such a configuration of the boring device, the percussion piston is able to impact the percussion bolt in one operative state, for example when the boring device is moved forward, wherein the percussion bolt moves then initially in relation to the housing and displaces hereby with the drill head soil located anteriorly of the boring device. In a second propulsion stage, the remaining impact energy can then be transmitted via the percussion bolt or the percussion piston directly or indirectly onto the threaded ring in order to push forward the housing in the borehole which has been established by the drill head. In this way, a multistage transmission of the impact energy can be realized which positively affects the attainable advance speed Besides the mentioned two-stage transmission, any number of propulsion stages may be provided, wherein the last (in time) stage normally involves the transmission of the impact energy via the threaded ring onto the housing.
A threaded element according to the invention may, advantageously, also be installed in existing boring devices. It is thus, i.a., also possible to facilitate the assembly of new boring devices as well as the maintenance of already existing boring device, when using the threaded element according to the invention.
By using the threaded element according to the invention, it can be easily screwed, in part even by hand, into the housing of the boring device. Then, the locking bolt is placed in the receptacle of the threaded element, thereby increasing the contact pressure of the threaded connection and preventing an unwanted detachment. The boring device can thus be used directly, without waiting for a hardening, as required in adhering thread retainers for example.
The threaded element represents a wearing part and can be replaced by simply removing the locking bolt to thereby reduce the contact pressure again in the threaded connection. The threaded element can then be unscrewed, in part by hand, from the housing without significant force application,
According to a preferred embodiment, the securing element is made of several parts. It is especially preferred, when the locking bolt has a sleeve, which is placed in the receptacle of the threaded element, and a bolt. Especially preferred is the placement of the bolt, at least in part, in the sleeve.
According to a preferred embodiment, the receptacle extends through the threaded element and has an opening on one side of the threaded element and an opening on an opposite side of the threaded element. It is preferred to insert the sleeve from one side in the receptacle and to insert the bolt from the other side of the receptacle, in particular in such a way that the bolt engages, at least in part, the sleeve, for example with an outer thread that engages an inner thread of the sleeve.
According to a preferred embodiment, the bolt, which is inserted in the sleeve at least in part, has an anti-rotation mechanism by which the bolt can be restrained against rotating in the receptacle. The bolt may, for example, have a protrusion which engages a corresponding recess of the threaded element.
According to a preferred embodiment, the bolt has a conical configuration. In addition, or as an alternative, the sleeve may have a conical configuration.
According to a preferred embodiment, the receptacle has a guide portion for receiving a sleeve constructed as a block. The sleeve is guided in the guide portion by two opposing guide surfaces for movement along these guide surfaces. The guide surfaces converge in direction of the spreading movement of the sleeve. It is especially preferred, when the block, except for contacting the guide surfaces and the engagement with the bolt, is free from any contact with other elements.
The block may have grooves for engagement of the portions of the receptacle that form the guide surfaces.
According to a preferred embodiment, the locking bolt has an outer thread which engages an inner thread of the block. The bolt may have a head for abutment against a portion of the threaded element. The head and/or the pertaining portion of the threaded element may have a conical configuration. As a result, the head can contribute to the spreading effect.
According to a preferred embodiment, the slot of the threaded element traverses the threaded element in direction of its length axis and in radial direction and traverses also the receptacle. A threaded element in which the slot of the threaded element fully traverses in length direction from a first end to a second end, it is of advantage to provide spreading means on the first end as well as on the second end. As a result, the threaded element can be evenly expanded over its length direction. As an alternative, it is, of course, also possible that only one end undergoes an expansion. This reduces the number of components. The even expansion is attained for example by the afore-described embodiments in which the securing element is made of several parts and a bolt is inserted from the one end into the receptacle and engages a sleeve which is inserted from the other end of the receptacle.
In addition to the application for boring devices, the threaded element according to the invention may be used in all fields that seek an effective and detachable thread retention.
BRIEF DESCRIPTION OF THE DRAWING
An exemplary embodiment of the invention will now be described in greater detail with reference to the drawings.
The drawings show in
FIG. 1 a sectional side view of an earth boring device according to the invention with threaded element and locking bolt,
FIG. 2 an isometric view of the threaded element of FIG. 1 ,
FIG. 3 an isometric view of the securing element (locking bolt) of FIG. 1 ,
FIG. 4 a sectional side view of an alternate embodiment of a threaded element,
FIG. 5 a sectional side view of a third embodiment of a threaded element, and
FIG. 6 a perspective view of the threaded element of FIG. 5 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 depicts a sectional side view of the leading part of an earth boring device according to the invention, including a housing 1 in which a percussion piston 2 is operated in an oscillating manner under the influence of compressed air and thereby impacts periodically an impact surface of a percussion bolt 3 which is movably connected with the housing 1 through intervention of a threaded ring 4 . The threaded connection between the threaded ring 4 and the housing 1 is secured by means of a locking bolt 10 .
The percussion bolt 3 extends through the threaded ring 4 beyond the housing 1 and is connected there via pins 5 with a stepped drill head 6 .
Impact of the percussion piston 2 upon the impact surface of the percussion bolt 3 causes the percussion bolt 3 and the attached drill head 6 to move in relation to the housing 1 so that the drill head 6 pushes aside the soil surrounding the boring device to establish a borehole absent any initial movement of the housing 1 . Only after a defined movement of the percussion bolt 3 in relation to the housing 1 is a shoulder 7 of the percussion bolt 3 able to strike against a sleeve 8 which transmits the impact energy again onto the threaded ring 4 which is screwed onto the housing 1 . In this way, the housing 1 of the boring apparatus tracks the already advancing drill head 6 .
A spring 9 disposed within the sleeve 8 causes the drill head 6 to return to the retracted position after each stroke.
As shown in FIG. 2 , the threaded ring 4 has an inner bore 15 and a longitudinal slot 16 in which a receptacle 17 is integrated for the locking bolt 10 . One portion of the receptacle 17 is provided with a thread 11 for threaded engagement of the locking bolt 10 which has a complementary portion with an outer thread 14 (cf. FIG. 3 ).
In addition, the receptacle in the threaded ring 4 as well as the locking bolt 10 have corresponding conical portions 12 , 13 . As the locking bolt 10 is screwed into the receptacle, the longitudinal slot of the threaded ring 4 is expanded by the relative movement of the two conical portions so that the contact pressure of the threaded connection between the threaded ring 4 and the housing 1 is increased at the same time.
The alternate embodiment illustrated in FIG. 4 shows a securing element 110 made of several parts. The securing element has a sleeve 111 , which is placed in the receptacle of the threaded element 104 , and a bolt 112 . The bolt 112 is inserted in part in the sleeve 111 . The receptacle traverses the threaded element 104 and has an opening on one side of the threaded element and an opening on an opposite side of the threaded element. The sleeve 111 is inserted from one side in the receptacle and the bolt 112 is inserted from the other side in the receptacle, with an outer tread 113 of the bolt 112 engaging an inner thread 114 of the sleeve 111 . The bolt 112 has a protrusion 115 as constraint against rotation. The protrusion 115 may engage in a corresponding recess of the threaded element 104 .
The bolt 112 as well as the sleeve 111 have a conical configuration such that the respective cone tapers in the opposite direction.
The third embodiment depicted in FIGS. 5 , 6 shows a multipart securing element 210 . The securing element 210 has a block-like sleeve 211 which is inserted in a guide portion 220 of the receptacle of the threaded element 204 , and a bolt 212 . The bolt 212 has an outer thread for engagement in an inner thread of the sleeve 211 . The threaded element 204 is traversed by a gap 221 in length direction as well as in radial direction of the threaded element 204 . The gap 221 also extends through the receptacle.
The threaded element 204 has an outer thread 226 with which it can be screwed into an unillustrated housing.
The guide portion 220 of the receptacle has two guide surfaces 222 and 223 for guiding the sleeve 211 for movement along these guide surfaces 222 , 223 . The guide surfaces 222 , 223 converge in movement direction of the sleeve 211 . This is the movement direction in which the sleeve 211 has to be moved to expand the threaded element 204 .
Except for the contact with the guide surfaces 222 , 223 and the engagement with the bolt 212 , the sleeve 211 is free of any contact with other elements. The portions of the receptacle, which form the guide surfaces 222 , 223 , engage the grooves 224 , 225 of the sleeve 211 .
The threaded element 204 has a trailing portion having an interior which is provided with an abutment for support of a head 226 of the bolt 212 . This abutment is configured preferably conically (not shown) to interact with the conically designed head (not shown) and to apply a spreading effect on the threaded element 204 . The threaded element has adjacent to the abutment a sleeve-like portion which is traversed by the part of the bolt 212 adjacent to the head 226 .
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The invention relates to an earth boring device including a housing which has at least one portion with an inner thread, and a threaded element which has a corresponding outer thread, wherein the threaded element is slotted and has a receptacle for a securing element which increases the outer diameter of the threaded element and the contact pressure of the threaded connection between threaded element and housing, when inserted in the receptacle.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of application Ser. No. 11/336,685, filed Jan. 20, 2006 now abandoned, which is a continuation of Ser. No. 10/202,220, filed Jul. 24, 2002 now abandoned, the disclosures of which are incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
This invention relates to 3-dimensional computer graphics systems and in particular to systems of the type described in our British patent numbers 2282682 and 2298111.
BACKGROUND OF THE INVENTION
British patent number 2282682 describes a system that uses a ray casting method to determine the visible surfaces in a scene composed of a set of infinite planar surfaces. An improvement to the system is described in UK Patent Application number 2298111, in which the image plane is divided into a number of rectangular tiles. Objects are stored in a display list memory, with ‘object pointers’ used to associate particular objects with the tiles in which they may be visible. The structure of this system is shown in FIG. 1 .
In FIG. 1 , the Tile Accelerator 2 is the part of the system that processes the input data, performs the tiling calculations, and writes object parameter and pointer data to the display list memory 4 . The layout of data in the display list memory is as shown in FIG. 2 . There are numerous possible variations on this, but essentially, there is one list of object pointers per tile, and a number of object parameter blocks, to which the object pointers point. The layout of objects in the display list memory is shown in FIG. 2 . The top part of the diagram shows the basic system, with parameters stored for two objects, A and B. Object A is visible in tiles 1 , 2 , 5 , 6 , and 7 , and so five object pointers are written. Object B is visible only in tiles 3 and 7 , so only two object pointers are written. It can be seen that the use of object pointers means that the object parameter data can be shared between tiles, and need not be replicated when the objects fall into more than one tile. It also means that the Image Synthesis Processor 6 of FIG. 1 (ISP) is able to read the parameters for only the objects that may be visible in that tile. It does this using the ISP Parameter Fetch unit 8 . In the example of FIG. 2 , the ISP would read only the parameters for object B when processing tile 3 , but would read the parameters for both objects when processing tile 7 . It would not be necessary to read data for tile 4 . The lower part of FIG. 2 shows the memory layout that is used with the macro tiling Parameter management system, which is described later.
When the Tile Accelerator has built a complete display list, the Image Synthesis Processor (ISP) 6 begins to process the scene. The ISP Parameter Fetch unit 8 processes each tile in turn, and uses the object pointer list to read only the parameter data relevant to that tile from the display list memory 4 . The ISP then performs hidden surface removal using a technique known as ‘Z-buffering’ in which the depth values of each object are calculated at every pixel in the tile, and are compared with the depths previously stored. Where the comparison shows an object to be closer to the eye than the previously stored value the identity and depth of the new object are used to replace the stored values. When all the objects in the tile have been processed, the ISP 6 sends the visible surface information to the Texturing and Shading Processor (TSP) 10 where it is textured and shaded before being sent to a frame buffer for display.
An enhancement to the system described above is described in UK Patent Application number 0027897.8. The system is known as ‘Parameter Management’ and works by dividing the scene into a number of ‘partial renders’ in order to reduce the display list memory size required. This method uses a technique known as ‘Z Load and Store’ to save the state of the ISP after rendering a part of the display list. This is done in such a way that it is possible to reload the display list memory with new data and continue rendering the scene at a later time. The enhancement therefore makes it possible to render arbitrarily complex scenes with reasonable efficiency while using only a limited amount of display list memory.
As 3D graphics hardware has become more powerful the complexity of the images being rendered has increased considerably, and can be expected to continue to do so. This is a concern for display list based rendering systems such as the one discussed above because a large amount of fast memory is required for the storage of the display list. Memory bandwidth is also a scarce resource. Depending upon the memory architecture in use, the limited bandwidth for writing to and reading from the display list memory may limit the rate at which data can be read or written, or it may have an impact on the performance of other subsystems which share the same bandwidth, e.g. texturing.
SUMMARY OF THE INVENTION
Embodiments of the present invention address these problems by examining the depth ranges of objects and tiles, and culling objects from the scene that can be shown not to contribute to the rendered result.
Embodiments of the invention use the depth values stored in the ISP to compute a range of depth values for the whole tile. By comparing the depths of objects with the range of stored depth values it is possible to cull objects that are guaranteed to be invisible without needing to process them in the ISP.
The Parameter Management system referred to above allows renders to be performed in a limited amount of memory, but it can have a significant impact on performance compared to a system with a sufficient amount of real memory.
Embodiments of the invention mitigate the inefficiencies of the Parameter Management system by culling objects before they are stored in the display list. Reducing the amount of data stored in the display list means that fewer partial renders are required to render the scene. As the number of partial renders is reduced, the significant memory bandwidth consumed by the Z Load and Store function is also reduced.
To perform this type of culling the Tile Accelerator compares incoming objects with information about the range of depths stored in the ISP during previous partial renders.
FIG. 3 , shows a graph illustrating the depths for a previous partial render and for a new object to be rendered. The new object lies within a depth range of 0.7 to 0.8, and during the previous partial render all pixels in a tile were set to values between 0.4 and 0.6. There is no way that the object can be visible since it is further away and therefore occluded by the objects drawn previously. Therefore the object need not be stored in the display list memory since it cannot contribute to the image.
A second stage of culling, in the parameter fetch stage of the ISP, occurs in a further embodiment. This is at the point at which object pointers are dereferenced, and parameter data is read from the display list memory. This works on a very similar principle to the first stage culling shown in FIG. 3 . By storing a little additional information in the object pointer, and by testing this against depth range information maintained in the ISP, it is possible to avoid reading the parameter data for some objects altogether. This type of culling reduces the input bandwidth to the ISP, and the number of objects that the ISP must process, but it does not reduce the amount of data written into the display list memory.
Unlike the first stage of culling, the second stage works with object pointers that correspond to the tile that is currently being processed by the ISP. The ISP's depth range information can be updated more quickly, and more accurately, than the range information used in the first stage culling, and this allows objects to be culled that were passed by the first stage.
The invention is defined in its various aspects in the appended claims to which reference should now be made.
BRIEF DESCRIPTION OF THE DRAWINGS
Specific embodiments of the invention will now be described in detail by way of example with reference to the accompanying drawings in which:
FIG. 1 shows a known system;
FIG. 2 shows schematically the layout of the display list memory;
FIG. 3 shows a graph illustrating the differences between previously stored depths and the depth of an incoming object;
FIG. 4 is a block diagram of an embodiment of the invention;
FIGS. 5 a ) and b ) shows graphically how stored depth range changes as objects are processed;
FIG. 6 shows a block diagram of the comparator arrays required to derive the depth range in an embodiment of the invention;
FIG. 6A shows enlarged views of certain cells from FIG. 6 ;
FIG. 7 shows schematically various depth compare modes of operation;
FIG. 8 shows the effect of pipeline delay; and
FIG. 9 shows the effect of movement of the depth range during pipeline delay.
DETAILED DESCRIPTION
FIG. 4 is an expanded and modified version of the block diagram of FIG. 1 . The ISP Z range generation unit 12 computes the range of Z values stored in the ISP 6 and feeds it back to the first stage of culling, located in the TA2, via the Z range memory 14 . A second feedback path sends Z range data to the second stage of culling, located in the ISP parameter fetch unit 8 .
ISP Range Generation
The embodiment described uses a range of depths that represent the minimum and maximum depths of the objects stored in the ISP 6 . This range is computed in the ISP as objects are processed, and represents the actual range of depth values that are stored in the tile at that moment. This range has to be updated constantly, as stored values are continually being replaced and the range may grow and shrink as the scene is rendered. FIGS. 5 a ) and b ) show respectively before and after a situation in which an incoming object is rendered into the pixels which previously determined the maximum Z value of the tile, thus causing both the minimum and maximum depth values to be reduced.
The ISP 6 contains storage for each pixel in the tile, which may vary in size depending on the particular implementation of the technology. A typical tile size might be 32.times.16 pixels. The ISP also contains a number of PEs (Processor Elements) which are hardware units which operate in parallel to perform the functions of the ISP by determining depth values at each pixel. Typically there are fewer PEs than there are pixels in the tile. For example, there may be 32 PEs arranged as a grid of 8.times.4 pixels. In this case 32 (8.times.4) pixels can be computed simultaneously, and the PEs will perform the computations up to 16 (4.times.4) times at fixed locations within the tile in order to process an entire object. FIG. 6 shows a possible arrangement of PEs 16 within a tile, as well as the comparator structures described below.
To compute the range of depths the PEs compute the range of depths for the set of pixels on which they are currently working. This range, together with range information from the other possible PE positions, is then used to update the overall depth range for the tile. A typical implementation would use comparators in tree structures to find the range of values stored in a set of pixels. For example, a set of 32 PEs would require 16+2.times.(8+4+2+1)=46 comparators to calculate both the maximum and minimum values. This tree structure can be seen at the bottom of FIG. 6 . In this diagram, blocks marked “Min/Max” 18 contain one comparator to determine the minimum and maximum of two input values from two PEs 16 , and blocks marked “Min/Max 2 ” 20 contain a pair of comparators, in order to compute the minimum and maximum of two input ranges. The output of the comparator tree is a pair of values representing the minimum and maximum set of depth values in those 32 pixels, which is stored in memory associated with that particular set of pixels.
Each Min/Max block 18 is coupled to the outputs of two of the PEs 16 and compares the minimum and maximum values output by these elements and stores these in its memory, passing a range to the Min/Max 2 unit 20 . The Min/Max 2 unit 20 receives input from a second Min/Max unit 18 and passes the output to the next Min/Max 2 unit 20 in the tree. All PE ranges ultimately feed into a single Min/Max 2 unit 20 at the bottom of the tree. This gives a PE Z range output 22 for the array of 32 PEs 16 .
Once the PEs have computed a polygon in all areas of the tile, i.e. at every pixel, it is necessary to combine the stored depth values into a single value for the whole tile. Again, a tree of comparators may be used. In the case of the 32.times.16 tile, there are 16 sets of ranges to be reduced to one, and so 2.times.(8+4+2+1)=30 comparators are required. This structure is shown at the top-right of FIG. 6 , where each “Min/Max 2 ” block 20 contains a pair of comparators. The output of the final pair of comparators 26 gives the range of depth values for the whole tile, updated with the depths of the triangle that has just been processed. The inputs to the tree are the block Min/Max range memories 24 which store range information corresponding to each of the PE array positions. These memories are updated with the PE Z range data 22 after the PE array has been processed.
The comparators 18 , 20 , 26 of FIG. 6 and the other Z range generation circuiting are all contained within the ISP Z range generation unit 12 in FIG. 4 . Thus, this generates and stores the Z range for the whole tile.
It is also necessary to know whether a valid depth value has been stored at every pixel in the ISP. Normally there is a polygon near the beginning of each frame that is used to initialize the values in the Z buffer, however this cannot be relied on. Any uninitialised depth value will obviously affect the validity of any range information, and so this condition must be detected and the range marked as being invalid. Depth based object culling must be avoided until the range information becomes valid.
Precision
The large number of comparators used in the ISP's Z range generation hardware 12 is expensive to build, as it will use a considerable amount of silicon area. In order to reduce the size of the hardware 12 the precision of the calculations can be reduced. For example, while the Z values coming into the ISP can be stored as floating point values with 24 bit mantissas, the Z range comparators can operate on shorter words, e.g. 8 or 16 bit mantissas.
As values are truncated to the smaller word length it is important that the values are rounded appropriately, since it is unlikely that the shorter word will be able to represent the value of the long word precisely. When dealing with ranges, the minimum value must be rounded to the nearest value that is smaller than the original, and the maximum value must be rounded to the nearest value that is larger than the original. In this way, the truncation errors always cause the Z range to expand. Expansion of the Z range reduces the efficiency slightly since fewer objects are found to lie entirely outside the range, but it maintains the correctness of the generated image. If the range is allowed to contract it is found that objects close to the edge of the range are discarded when in fact they should be visible in the image. This is obviously not desirable.
In order to maintain the required precision at the output of a comparator tree it is necessary to use progressively higher levels of precision at higher levels in the tree.
The use of full precision Z range values is also impractical in other parts of the system. For example, in the discussion of the ISP parameter fetch culling stage, it will be seen that at least one value representing the Z range of the object is stored inside the object pointer. For reasons of space efficiency it may be desirable to store a reduced precision value here also. In this case there is little point in the ISP generating a range using more precision than is available in the object pointer values. On the other hand, the culling stage in the tile accelerator benefits from higher precision ranges from the ISP, since it does not have the same storage constraints.
In practice the benefits of higher precision Z range calculations are small, and typically a reduced mantissa length of between 8 and 16 bits will be found to be optimal. The exact sizes used will be determined by the requirements of the particular device being implemented.
Z Range Testing
The minimum and maximum Z values of a polygonal object can be determined easily by examination of the vertex coordinates. When valid range information is available from the ISP in the Z range generation unit 12 it is possible to conditionally cull the object based on comparison of the two ranges of values.
Each object in the score has a “Depth Compare Mode” (DCM) which takes one of eight values and is an instruction that tells the ISP's depth comparison hardware how to decide whether the object passes the depth test at a pixel. The culling test must be modified according to the DCM of the object. The eight possible values of DCM, and the appropriate culling test for each, are shown in Table 1.
TABLE 1
Depth Compare Modes
DCM
Condition
Culling Test
DCM_ALWAYS
The object always
N/A
passes the depth
test, regardless of
Z values.
DCM_NEVER
The object never
N/A
passes the depth
test, regardless of
Z values.
DCM_EQUAL
The object passes
Cull if
the depth test if
(Obj: Max < ISP: Min)
its z value is equal
OR
to the z value
(Obj: Min > ISP: Max)
stored in the ISP.
DCM_NOT_EQUAL
The object passes
N/A
the depth test if
its z value is not
equal to the z value
stored in the ISP.
DCM_LESS
The object passes
Cull if (Obj: Min >=
the depth test if
ISP: Max)
its z value is less
than the z value
stored in the ISP.
DCM_LESS_EQ
The object passes
Cull if (Obj: Min >
the depth test if
ISP: Max)
its z value is less
than or equal to the
z value stored in
the ISP.
DCM_GREATER
The object passes
Cull if (Obj: Max <
the depth test if
ISP: Min)
its z value is
greater than the z
value stored in the
ISP.
DCM_GREATER_EQ
The object passes
Cull if (Obj: Max <=
the depth test if
ISP: Min)
its z value is
greater than or
equal to the z value
stored in the ISP.
Depth comparisons in the ISP are performed for every pixel in the object for each tile being processed, with depths being iterated across the surface of the polygon. Depth based culling performs a single test per object, and must therefore perform appropriate comparison between suitable ranges of values.
The depth compare mode must be taken into account when performing the depth based culling tests. The diagrams in FIG. 7 show three of the simple conditions that correspond to DCM modes DCM_EQUAL, DCM_LESS, and DCM_GREATER. The shaded areas indicate the range of depths stored in the ISP, which are made available by the Z range generation unit 12 to the culling stages, and the triangles indicate candidates for culling. Triangles marked ‘OK’ would be passed while triangles marked ‘X’ would be culled.
In the DCM_EQUAL example, objects will only be stored in the ISP if they have a depth value equal to one of the currently stored depth values. This means that any object with a depth range that intersects the stored range (objects marked ‘OK’) may pass the depth test and so must not be culled. The objects that do not intersect the stored range (objects marked ‘X’) cannot possibly pass the depth test, and can therefore be safely culled.
In the DCM_LESS example, objects will be stored in the ISP if they have depth values that are less than the corresponding stored value. Objects with depths that are entirely less than the stored range are very likely to be visible, and are therefore not culled. Objects with depth ranges that intersect wholly or partly with the stored range may also be visible, and are not culled. Only objects whose range is entirely greater than the stored depth range are guaranteed to be completely occluded, and may therefore be culled. These objects are marked with ‘X’.
The DCM_GREATER example is the opposite of the DCM_LESS example. Objects with depth ranges entirely greater than the stored range can be culled, while those with depths that intersect or have depth values greater than the stored range cannot be culled.
The DCM modes DCM_LESS_EQ and DCM GREATER_EQ are very similar to DCM_LESS and DCM_GREATER respectively, but differ in whether an equality condition is considered to be an intersection of the ranges or not.
For the remaining modes, DCM_ALWAYS, DCM_NEVER, and DCM_NOT_EQUAL, it is not possible to use depth based culling. It is clear that there is no comparison of depth values that can be used to indicate whether the object can be culled in these cases.
Notice that four of the DCM modes, (the LESS and GREATER modes) require only one value from each of the ranges, while the test for DCM_EQUAL requires both values from each range.
The DCM_NEVER mode appears to be of somewhat limited usefulness as it will never pass the depth test, and will never be visible in the scene. We have to assume that such objects have been added to the scene for a good reason, and therefore should not be culled. One possible reason would be if the object has a side-effect, such as performing stencil operations. In fact, it is essential that any object that may have side-effects should not be culled.
Handling Changes in Depth Compare Mode
The design of 3D rendering hardware relies heavily on pipelining, which is a technique in which the processing that is required is divided up into a large number of simpler stages. Pipelining increases the throughput of the system by keeping all parts of the hardware busy, and allows results to be issued at the rate achieved by the slowest stage, regardless of the length of the pipeline itself.
Pipelining is a useful technique, and it is essential in the design of high performance rendering systems. However, it presents some problems to the z based culling system, where the culling ideally happens at an early stage in the pipeline, but the ISP depth range generation happens much later. The effect is that of a delay, between determining that an object can be culled, and the time when that object would actually have been rendered in the ISP. Any change in the state of the ISP between the culling test and the actual rendering time could cause the culled object to become visible again, and thus cause an error in the rendered image. The things that can, and will, cause changes in the state of the ISP are the other non-culled objects already in the pipeline.
For an example of a situation in which the delay caused by the pipeline causes a problem, consider a large number of objects with a DCM of DCM_LESS. This is a typical mode for drawing scenes, where objects closer to the viewpoint obscure the view of those further away Now consider a single object in the middle of the scene, with a DCM of DCM_ALWAYS. This situation in shown in FIG. 8 , where all objects except ‘B’ are DCM_LESS, and the object marked ‘B’ is DCM_ALWAYS. Object ‘C’ is currently being processed in the ISP, object ‘A’ is being culled, and there are eight objects (including ‘B’) at intermediate stages in the pipeline.
As object ‘C’ is processed, the range of values in the ISP is between 0.5 and 0.6. This is the range that is fed back to the culling unit and used for the culling of object ‘A’. Object A has a Z value of 0.8, which when compared with the ISP's Z range, means that it will be culled. Now suppose that object ‘B’ covers the entire tile, and has a Z value of 0.9. The DCM_ALWAYS mode means that it will replace all the stored depths in the ISP with 0.9, and so object ‘A’, if it had not been culled, would actually be closer to the viewpoint than the stored object ‘B’, and should therefore be rendered as a visible object. It can be seen that the use of depth based culling produces incorrect results when the Z range feedback is delayed, either by a pipeline, or for any other reason.
This problem occurs due to the pipeline length between the ISP parameter fetch and ISP depth range generation hardware units, and also due to the delay between processing an object in the Tile Accelerator, and that object being rendered in the ISP. In the latter case the delay is considerably larger, and the problem is exacerbated if the Z range information from the ISP is updated only at the end of each partial render. Solutions to these problems are described below.
In the majority of cases, objects are grouped such that objects with a constant depth compare mode occur in long runs. In a typical application, a single depth compare mode, such as DCM_LESS or DCM_GREATER will account for the majority of the objects in the scene, since it is these modes that allow hidden surface removal to occur. Where other modes are used, these tend to be for special effects purposes, and the objects are few in numbers and are often grouped together at the end of the display list. It is fortunate that delayed Z range feedback is not a problem in the case where the DCM does not change.
As an example of correct behaviour, consider the case of a number of DCM_LESS objects, shown in FIG. 9 . The objects will replace the objects stored in the ISP only if their Z value is less than the currently stored value. This means that the numbers in the ISP can only ever become smaller, and because objects are replaced it is possible that both the minimum and maximum stored depth values will be reduced. The appropriate culling test for a DCM_LESS object is to discard the object if the minimum Z value of the object is greater than the maximum extent of the ISP's Z range. Since the delay can only cause the ISP's maximum value to be larger than it would otherwise be, the culling is safe. Slightly fewer objects will be culled than in the ideal case, but the conservative culling behaviour does not cause errors in the rendered output.
Z Range Culling in the Tile Accelerator
Culling in the Tile Accelerator operates when parameter management is active. That is, when the system begins to render small parts of the screen (called macro tiles) before the whole image has been stored in the display list memory. The rendering of a macro tile is known as a “partial render” and typically renders only a fraction of the number of objects that will eventually be rendered in that macro tile. The parameter management system allows the display list memory associated with the macro tile to be released and used for the storage of further objects. This allows scenes of arbitrary complexity to be rendered in a finite amount of memory space. Parameter management is described fully in UK Patent Application number 0027897.8.
A small amount of memory is used, shown as “Z Range Memory” 14 in FIG. 4 , in a feedback loop to store the Z range information generated by the ISP. A separate memory location is used for each tile, and it contains the Z range generated at the end of the partial render that occurred most recently in that tile.
The tile accelerator works by calculating the set of tiles in which each object must be rendered, and adding the object to each of those tiles by writing an object pointer into the appropriate list. In a basic system a single copy of the parameter data is written to the display list memory, but in a system using parameter management a copy of the data must be written for each macro tile in which the object is to be rendered. This arrangement is shown in the lower part of FIG. 2 .
Z range culling works by reducing the set of tiles to which the objects are added. This is done by comparing the Z range of the object with the stored Z range for the tile, for each tile in which the object occurs. Tiles can then be removed from the set when the test fails. The comparison test must of course be chosen according to the DCM of the object.
The reduction in memory consumption occurs because the reduced set of tiles also tends to use fewer macro tiles, and therefore fewer copies of the object parameter data must be made.
As described above, changes in the depth compare mode have to be dealt with in order to prevent errors occurring. The situation is slightly more complicated than that shown in FIG. 8 , because the Tile Accelerator and ISP are unlikely to be working on the same tile at the same time. The parameter management system makes the interval between processing an object in the TA and it being rendered in the ISP unpredictable, and there will be an unknown number of DCM changes stored in the display list.
In order to deal with changes of DCM it is necessary to depart a little from ideal behaviour and update the stored range values in Z range memory 14 from within the TA as objects are processed. The disadvantage of this method is that although the system begins with the range generated by the ISP, the updated range will be a worst case estimate based on the vertex coordinates of all the objects processed by the TA. The range generated in this way will tend to be larger than the range that the ISP would generate itself since it is not possible to take into account objects that overdraw each other. Table 2 shows the range updates required for objects with different DCMS. The stored range cannot shrink, but always grows, and is replaced again by the ‘accurate’ values from the ISP at the end of the next partial render.
An advantage of this type of operation is that the stored Z range, although larger than necessary, is not delayed by the pipeline, and so changes in DCM do not cause problems.
TABLE 2
Range updates in the TA
DCM
Condition
DCM_ALWAYS
Extend range min/max to include
object min/max.
DCM_NEVER
Do not modify range.
DCM_EQUAL
Do not modify range.
DCM_NOT_EQUAL
Extend range min/max to include
object min/max.
DCM_LESS
Extend range min to include
object min.
DCM_LESS_EQ
Extend range min to include
object min.
DCM_GREATER
Extend range max to include
object max.
DCM_GREATER_EQ
Extend range max to include
object max.
Z Range Culling in the ISP Parameter Fetch Unit
Culling objects in the ISP parameter fetch is slightly simpler than culling in the tile accelerator, since the parameter fetch hardware and ISP are always operating on the same tile at the same time. The situation is exactly as illustrated in FIG. 8 , and an appropriate comparison on minimum and maximum Z values can be used to cull objects.
The ISP's Z range values can be taken directly from the Z range generation unit, and fed back to the parameter fetch unit as shown in FIG. 8 . The Z range of the object itself is more problematic, since it would defeat the purpose of culling if it were necessary to read the object parameters from memory in order to compute the Z range. Instead, all appropriate information (the Z range and DCM) must be read from the object pointer, by the parameter fetch unit 8 .
To store Z range information in the object pointer the range must be computed in the tile accelerator. This is not a problem, since the TA culling stage also requires hardware to compute the Z range, and the same hardware can be used for both purposes.
Free space is scarce in the object pointer word, and it is desirable to keep the length of the word as short as possible. The DCM code requires the storage of three bits. Once the DCM is known, the culling tests for DCM_LESS and DCM_LESS_EQ require only the minimum Z value of the object, and culling tests for DCM_GREATER and DCM_GREATER_EQ require only the maximum Z value of the object. In these cases is therefore possible to store the one value, maximum or minimum, whichever is appropriate to the DCM of the object.
The DCM_EQUAL culling test, as shown in Table 1, does need both values and therefore requires the storage of two depth values in the object pointer. The increase in size of the object pointer necessary to store the second value may not be desirable, particularly since the DCM_EQUAL mode is not commonly used for large numbers of objects. In this case it is possible to perform incomplete culling by performing only one half of the full test, and thus using only one value from the object pointer.
As discussed previously, it is not necessary to store full precision values in the object pointer, provided that care is taken in rounding. Additional space savings can be gained in this way.
To deal with the problem of changing depth compare modes, a simple counter is employed in the parameter fetch unit. The length of the pipeline is known in advance, as is the maximum number of objects which it can possibly contain. In order to ensure correct operation it is required that the triangle being fetched and the triangle being processed in the ISP both belong to one run of triangles, all with the same DCM. The counter is reset to zero when the DCM changes, and is incremented as each triangle is fetched. Culling is disabled when the counter is less than the maximum possible number of objects in the pipeline, thus ensuring that the object in the ISP is part of the same run of objects as the object currently being fetched. Efficiency is reduced slightly because a number of objects at the beginning of each run cannot be culled, but correctness is guaranteed. With a pipeline length of approximately 20 objects, and typical applications in which the DCM does not change frequently, the number of objects that cannot be culled is only a small proportion of the total scene. With scene complexity expected to rise in the future, the resultant reduction in efficiency will become less significant.
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An apparatus and a method for generating 3-dimensional computer graphic images. The image is first sub-divided into a plurality of rectangular areas. A display list memory is loaded with object data for each rectangular area. The image and shading data for each picture element of each rectangular area are derived from the object data in the image synthesis processor and a texturizing and shading processor. A depth range generator derives a depth range for each rectangular area from the object data as the imaging and shading data is derived. This is compared with the depth of each new object to be provided to the image synthesis processor and the object may be prevented from being provided to the image synthesis processor independence on the result of the comparison.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is related to the following co-pending U.S. patent applications filed on even date herewith, and incorporated herein by reference in their entirety:
Serial Number 11/086,721, entitled “METHOD AND SYSTEM FOR REDUCTION OF AND/OR SUBEXPRESSIONS IN STRUCTURAL DESIGN REPRESENTATIONS”.
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates in general to verifying designs and in particular to performing reduction of subexpressions. Still more particularly, the present invention relates to a system, method and computer program product for performing reduction of XOR and XNOR subexpressions in structural design representations.
2. Description of the Related Art
With the increasing penetration of processor-based systems into every facet of human activity, demands have increased on the processor and application-specific integrated circuit (ASIC) development and production community to produce systems that are free from design flaws. Circuit products, including microprocessors, digital signal and other special-purpose processors, and ASICs, have become involved in the performance of a vast array of critical functions, and the involvement of microprocessors in the important tasks of daily life has heightened the expectation of error-free and flaw-free design. Whether the impact of errors in design would be measured in human lives or in mere dollars and cents, consumers of circuit products have lost tolerance for results polluted by design errors. Consumers will not tolerate, by way of example, miscalculations on the floor of the stock exchange, in the medical devices that support human life, or in the computers that control their automobiles. All of these activities represent areas where the need for reliable circuit results has risen to a mission-critical concern.
In response to the increasing need for reliable, error-free designs, the processor and ASIC design and development community has developed rigorous, if incredibly expensive, methods for testing and verification for demonstrating the correctness of a design. The task of hardware verification has become one of the most important and time-consuming aspects of the design process.
Among the available verification techniques, formal and semiformal verification techniques are powerful tools for the construction of correct logic designs. Formal and semiformal verification techniques offer the opportunity to expose some of the probabilistically uncommon scenarios that may result in a functional design failure, and frequently offer the opportunity to prove that the design is correct (i.e., that no failing scenario exists).
Unfortunately, the resources needed for formal verification, or any verification, of designs are proportional to design size. Formal verification techniques require computational resources which are exponential with respect to the design under test. Simulation scales polynomially and emulators are gated in their capacity by design size and maximum logic depth. Semi-formal verification techniques leverage formal algorithms on larger designs by applying them only in a resource-bounded manner, though at the expense of incomplete verification coverage. Generally, coverage decreases as design size increases.
Techniques for reducing the size of a design representation have become critical in numerous applications. Logic synthesis optimization techniques are employed to attempt to render smaller designs to enhance chip fabrication processes.
Numerous techniques have been proposed for reducing the size of a structural design representation. For example, redundancy removal techniques attempt to identify gates in the design which have the same function, and merge one onto the other. Such techniques tend to rely upon binary decision diagram (BDD)-based or satisfiability (SAT)-based analysis to prove redundancy, which tend to be computationally expensive. Another technique is subexpression elimination, wherein a system rewrites logic expressions to attempt to enable a representation with fewer gates. For example, given two expressions A&B&C and D&A&B, subexpression elimination would translate those to (A&B)&C and (A&B)&D, enabling a sharing of node (A&B) between both expressions, requiring a total of three 2-bit AND expressions vs. four. Traditionally, such subexpression elimination algorithms require the use of logic factoring algorithms for obtaining covers of expanded forms of logic expressions, which also tend to be costly in terms of computational resources. Similar subexpression elimination algorithms are needed for XOR and XNOR subexpressions.
What is needed is a method, system, and computer program product for heuristic XOR and XNOR subexpression elimination on a structural design representation.
SUMMARY OF THE INVENTION
A method, system and computer program product for reducing XOR/XNOR subexpressions in structural design representations are disclosed. The method comprises receiving an initial design, in which the initial design represents an electronic circuit containing an XOR gate. A first simplification mode for the initial design is selected from a set of applicable simplification modes, wherein the first simplification mode is an XOR/XNOR simplification mode, and a simplification of the initial design is performed according to the first simplification mode to generate a reduced design containing a reduced number of XOR gates. Whether a size of the reduced design is less than a size of the initial design is determined, and, in response to determining that the size of the reduced design is less than a the size of the initial design, the initial design is replaced with the reduced design.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objects and advantages thereof, will best be understood by reference to the following detailed descriptions of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
FIG. 1 depicts a block diagram of a general-purpose data processing system with which the present invention of a method, system and computer program product for performing reduction of subexpressions in structural design representations containing XOR and XNOR gates may be performed; and
FIG. 2 is a high-level logical flowchart of a process for performing reduction of subexpressions in structural design representations containing XOR and XNOR gates.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention provides a method, system, and computer program product for subexpression elimination in a structural design representation. The present invention uses polynomial structural algorithms, discussed below, and is robust in the sense that it does not increase design size. The present invention may also be configured to preserve as much of the original design representation as possible. The present invention increases verification speed (due to operation upon structural design representations without a need for expanding logic expressions, or SAT or BDD-based analysis), and is applicable to very large designs. Under the prior art, in very large and complex combinational equivalence checking examples, software packages cannot feasibly expand the expression of the cone under evaluation to utilize subexpression elimination techniques. The present invention heuristically enables subexpression elimination “deep” in logic cones.
With reference now to the figures, and in particular with reference to FIG. 1 , a block diagram of a general-purpose data processing system, in accordance with a preferred embodiment of the present invention, is depicted. Data processing system 100 contains a processing storage unit (e.g., RAM 102 ) and a processor 104 . Data processing system 100 also includes non-volatile storage 106 such as a hard disk drive or other direct-access storage device. An Input/Output (I/O) controller 108 provides connectivity to a network 110 through a wired or wireless link, such as a network cable 112 . I/O controller 108 also connects to user I/O devices 114 such as a keyboard, a display device, a mouse, or a printer through wired or wireless link 116 , such as cables or a radio-frequency connection. System interconnect 118 connects processor 104 , RAM 102 , storage 106 , and I/O controller 108 .
Within RAM 102 , data processing system 100 stores several items of data and instructions while operating in accordance with a preferred embodiment of the present invention. These include an initial design (D) netlist 120 and an output table 122 for interaction with a verification environment 124 . In the embodiment shown in FIG. 1 , initial design (D) netlist 120 contains targets (T) 132 and constraints (C) 134 . Other applications 128 and verification environment 124 interface with processor 104 , RAM 102 , I/O control 108 , and storage 106 through operating system 130 . One skilled in the data processing arts will quickly realize that additional components of data processing system 100 may be added to or substituted for those shown without departing from the scope of the present invention. Other data structures in RAM 102 include reduced design (D′) netlist 140 .
A netlist graph, such as design (D) netlist 120 , is a popular means of compactly representing problems derived from circuit structures in computer-aided design of digital circuits. Such a representation is non-canonical and offers the ability to analyze the function from the nodes in the graph. A netlist, such as initial design (D) netlist 120 , contains a directed graph with vertices representing gates and edges representing interconnections between those gates. The gates have associated functions, such as constants, primary inputs (e.g. RANDOM gates), combinational logic (e.g., AND gates), and sequential elements (hereafter referred to as registers). Registers have two associated components; their next-state functions and their initial-value functions, which are represented as other gates in the graph. Certain gates in the netlist may be labeled as “primary outputs”, “targets”, “constraints”, etc.
Semantically, for a given register, the value appearing at its initial-value gate at time “0” (“initialization” or “reset” time) will be applied by verification environment 124 as the value of the register itself; the value appearing at its next-state function gate at time “i” will be applied to the register itself at time “i+1”. Certain gates are labeled as targets (T) 132 and/or constraints (C) 134 . Targets (T) 132 correlate to the properties that require verification. Constraints (C) 134 are used to artificially limit the stimulus that can be applied to the RANDOM gates of initial design (D) netlist 120 ; in particular, when searching for a way to drive a “1” to a target (T) 132 , the verification environment 124 must adhere to rules such as, for purpose of example, that “every constraint gate must evaluate to a logical 1 for every time-step” or “every constraint gate must evaluate to a logical 1 for every time-step up to, and including, the time-step at which the target is asserted.” For example, in verification environment 124 , a constraint could be added which drives a 1 exactly when a vector evaluates a set of RANDOM gates to simulate even parity. Without its constraint, the verification environment 124 would consider valuations with even or off parity to those RANDOM gates; with the constraint, only even parity would be explored. The present invention will, with respect to some designs, preserve the expression of some targets (T) 132 and constraints (C) 134 .
Processor 104 executes instructions from programs, often stored in RAM 102 , in the course of performing the present invention. In a preferred embodiment of the present invention, processor 104 executes verification environment 124 .
In a preferred embodiment, the present invention is applied to a netlist representation where the only combinational gate type is a 2-input AND, and inverters are represented implicitly as edge attributes. Registers have two associated components, their next-state functions, and their initial-value functions. Both are represented as other gates in design (D) netlist 120 . Semantically, for a given register, the value appearing at its initial-value gate at time ‘0’ (“initialization” or “reset” time) will be applied as the value of the register itself; the value appearing at its next-state function gate at time “i” will be applied to the register itself at time “i+1”. Certain gates are labeled as “targets” and/or “constraints”.
Hereafter, the explanation of the present invention assumes that OR gates are represented as AND gates with inversion attributes pushed on all their incoming edges and outgoing edges, and INVERTER gates are folded into inverted attributes on edges between their source and sink gates. The implementation in the preferred embodiment of this assumption increases the power of the present invention by “shifting” to an alternate logic representation. In a 2-input AND representation, note that A XOR B may be represented either as (NOT (A & NOT B) & NOT (NOT A& B)) or (NOT (A & B) & NOT (NOT A & NOT B)). XNOR toggles the top level inversion.
Targets (T) 132 represent nodes whose Boolean expressions are of interest and need to be computed. The goal of the verification process is to find a way to drive a ‘1’ on a target (T) 132 node, or to prove that no such assertion of the target (T) 132 is possible. In the former case, a “counterexample trace” showing the sequence of assignments to the inputs in every cycle leading up to the fail event getting triggered is generated and recorded to output table 122 .
Verification environment 124 includes a computer program product, stored in RAM 102 and executed on processor 104 , which provides a series of tools for activities such as equivalence checking, property checking, logic synthesis and false-paths analysis. Generally speaking, verification environment 124 contains rule-based instructions for predicting the behavior of logically modeled items of hardware.
Verification environment 124 uses the series of rules contained in its own instructions, in conjunction with design netlist 120 , to represent the underlying logical problem structurally (as a circuit graph). In a preferred embodiment, verification environment 124 includes a Cycle-Based Symbolic Simulator (CBSS), which performs a cycle-by-cycle simulation on design netlist 120 symbolically by applying unique random, or non-deterministic, variables to the netlist inputs in every cycle. In order to reduce the size of designs on which it operates, such as initial design (D) netlist 120 , verification environment 124 includes a reduction tool package 126 .
A Cycle-Based Symbolic Simulator (CBSS), such as is included verification environment 124 , performs a cycle-by-cycle symbolic simulation on a netlist representation of the design in initial design (D) netlist 120 . Verification environment 124 extends the cycle simulation methodology to symbolic values. Verification environment 124 applies symbolic functions to the inputs in every cycle and propagates them to the targets 132 . Hence, state-variables/next-state functions and the targets are expressed in terms of the symbolic values applied in the various cycles. If a target is hit, a counterexample may generated simply by assigning concrete values to the symbolic values in the cycles leading up to the failure.
Reduction tool package 126 is comprised of several tools, which one skilled in the art will quickly realize may be embodied as separate units or as lines of code within an integrated package.
An AND/OR identification module 142 identifies certain gates initial design (D) netlist 120 (referred to as “roots”) whose functions must be preserved when eliminating common subexpressions within AND/OR trees, which in turn indicate which gates may be replaced by the process of the present invention. AND/OR identification module 142 identifies AND roots in four steps. First, AND/OR identification module 142 labels all pre-defined gates whose functions need to be preserved as roots. For example, in a verification setting, targets (T) 132 and constraints (C) 134 may need to be preserved. Similarly, in a synthesis setting, “primary outputs” may need to be preserved. Second, AND/OR identification module 142 marks the “cone of influence” of the pre-defined gates. The cone-of-influence is identified transitively as the set of gates which source incoming edges to this pre-defined set, including next-state functions and initial-value functions for registers. Third, for any register marked as in the cone-of-influence, AND/OR identification module 142 labels its next-state function and initial-value function as roots. Finally, for any non-register gate “g” in the cone-of-influence, the AND/OR identification module 142 analyzes all gates that source the incoming edges to “g”. If “g” is not an AND gate, AND/OR identification module 142 tags all such source gates as roots. Otherwise, for each incoming edge, if that edge is tagged as “inverted”, AND/OR identification module 142 marks the corresponding source gate as a root.
AND/OR elimination module 144 executes a heuristically optimal structural algorithm for eliminating common AND/OR subexpressions from the identified roots. For all AND-gate roots tagged by AND/OR identification module 142 , AND/OR elimination module 144 traverses fanin-wise exclusively through AND gates and uninverted edges, queueing up “leaves” of the AND tree as all “edges” at which the traversal stops (where an “edge” correlates to both the source gate and the “inverted” attribute of the edge). These edges will include either inverted edges (sourced by arbitrary gate types), or uninverted edges to non-AND gate types. Any gates traversed “through” which are not marked as roots will effectively be replaced by subexpression elimination process, as explained later.
AND/OR elimination module 144 then builds an intermediate data structure representing the common subexpression data. AND/OR elimination module 144 ignores any gate not marked in the cone of influence identified by AND/OR identification module 142 . For any AND gate marked as a root, AND/OR elimination module 144 translates it as a multi-input gate (of the same function) in the intermediate representation whose inputs are the identified leaves. The resulting netlist will include all AND gate roots, and all gates queued up as literals for those roots, with edges between them. AND/OR elimination module 144 then eliminates subexpressions from the created data structure via the algorithm embodied in the following pseudocode:
for each gate “i” which is a literal of an AND root{
for each polarity of “i”, i.e. for each literal “j” involving “i” {
// the present invention will check for instances of “i” as well as “NOT
i” in roots
roots = all AND gate roots in the fanout of “j”
// the roots including literal “j” that the present invention may refactor
from
if (roots has fewer than two elements) {continue;}
// no subexpression elimination possible with “j”
leaves = all literals occurring in 2+ roots
// the literals that the present invention may refactor out of roots; this
will include j
leaves = leaves MINUS “j”
// leaves is now the set of literals that the present invention will try to
refactor of roots, along with j
while (leaves) {
“k” = pop (leaves)
// grab another literal; the present invention will try to refactor both “j”
and “k” out of roots
roots' = subset of roots containing {“j”, ”k”}
// see which roots include both “j” and “k”
if (roots' has fewer than two elements) {continue;}
// a small optimization - due to adding newly created AND gates as roots
below
leaves' = maximal set of common literals in each element of roots'
// a superset of {j,k}; see if they include additional common literals
cur = create AND gate whose inputs are leaves'
// an AND gate representing the common subexpression
refactor leaves' out of roots'
// remove connections between leaves' and each of roots'
add cur as leaf of roots'
// remove connections between leaves' and each of roots'
add cur as leaf of roots'
// add cur as an input to each of roots'
add cur to roots
// may need to further refactor cur
}
}
}
When AND/OR elimination module 144 terminates the algorithm above, all common subexpressions will be eliminated from the roots. To complete the process of minimizing the original design (D) netlist 120 , reduction tool package 126 replaces the roots in the original design (D) netlist 120 with new logic consistent with the solution obtained in the intermediate representation. The present invention therefore synthesizes all “cur” gates created in the intermediate representation, then re-synthesizes the roots as AND functions over the original roots and the synthesized “cur” gates, to map the solution from the intermediate representation to one in original design (D) netlist 120 .
A simple example illustrates the operation of the algorithm above. Assume three roots, such that A 1 ={A, B, C, D} A 2 ={A, B, C, E} A 3 ={A, C, E}. Assume that AND/OR elimination module 144 processes literals in the outer loops in the order A, B, C, D, E. In the first loop, “j” is “A”. Roots will be {A 1 , A 2 , A 3 }. Leaves will initially be {A, B, C, E} and will not include D, because that literal occurs only in a single root A 1 . Reduction tool package 126 then prunes A from leaves. AND/OR elimination module 144 then enters the inner loop, and sets k=“B”. Roots will be {A 1 , A 2 }; leaves will be {A, B, C}. AND/OR elimination module 144 will create a new AND gate A 4 ={A, B, C} and remove those three literals from each of the roots, rendering the roots at the end of the first pass through the inner loop as:
A1={A4, D} A2={A4, E} A3={A, C, E} A4={A,B,C}
For the second pass through the inner loop, AND/OR elimination module 144 sets k=“C”. Roots will be {A 3 , A 4 }; leaves will be {A, C}. AND/OR elimination module 144 will create a new AND gate A 5 ={A, C}, rendering the roots at the end of the second pass through the inner loop as:
A1={A4, D} A2={A4, E} A3={A5, E} A4={A5,B}A5={A, C}
For the third inner loop AND/OR elimination module 144 sets k=“B”; the set of roots is empty, because no remaining roots have {A, B}. Hence AND/OR elimination module 144 continues out of this inner loop. For the fourth and final pass through the inner loop, AND/OR elimination module 144 sets k=“E”; the set of roots is again empty since no remaining roots have {A, E}. AND/OR elimination module 144 proceeds to the next pass through the outer loop.
In the next pass through the outer loop, AND/OR elimination module 144 chooses “j”=“B”. There is only one root with B (which is A 4 ) and, AND/OR elimination module 144 continues to the next pass through the outer loop, and iterates similarly with C and D. For the final loop, the AND/OR elimination module 144 chooses “j” =“E”, resulting in two roots {A 2 , A 3 }. Leaves will only be {E}, because the other literals A 4 and A 5 in {A 2 , A 3 } appear only in a single root. As a result, AND/OR elimination module 144 will not enter the inner loop.
Overall, assuming that AND/OR elimination module 144 started with the above roots A 1 =A&(B&(C&D)), A 2 =A&(B&(C&E)), A 3 =A&(C&E), there are 8 2-input AND expressions. AND/OR elimination module 144 yields A 1 =A 4 &D A 2 =A 4 &E A 3 =A 5 &E A 4 =A 5 &B A 5 =A&C, with only 5 2-input AND expressions.
Extensions to the common AND/OR subexpression elimination algorithm of AND/OR elimination module 144 provide redundancy removal capability. There are several facets to AND/OR elimination module 144 extensions. After queueing the literals in the AND roots in AND/OR elimination module 144 , and before creating the intermediate format, AND/OR elimination module 144 prunes the queue in five steps. First, AND/OR elimination module 144 deletes any constant-one gates from the queue. Second, if a constant-zero gate is in the queue, AND/OR elimination module 144 empties the queue and put only a constant-zero gate in the queue. Third, AND/OR elimination module 144 deletes any redundant edges from the queue (i.e., if two edges sourced by the same gate, with the same “inverted” attributes, are in the queue, AND/OR elimination module 144 deletes one of them). This step will ensure that every literal in the queue is unique. Fourth, if any opposite-polarity literals are in the queue, AND/OR elimination module 144 empties the queue and puts only a constant-zero gate in the queue. Finally, if any inverted literal is in the queue, and that literal is an AND root, and the literals of that AND root are all present as literals in the current queue, AND/OR elimination module 144 empties the queue and put only a constant-zero gate in the queue.
Since these queues within AND/OR elimination module 144 represent literals of an AND expression, the steps above are a structural application of propositional “conjunction simplification” rules. If the resulting queue has only a constant-zero literal, then AND/OR elimination module 144 will replace the corresponding root by constant-zero. If the queue has no literals whatsoever, the situation must have arisen due to elimination of constant-one literals, and AND/OR elimination module 144 will replace the corresponding literal by constant-one. Otherwise, AND/OR elimination module 144 uses a hash table to identify the literals of the AND roots. After pruning the queue for a new AND root, AND/OR elimination module 144 checks to see if an AND root with the identical literals exists. If so, AND/OR elimination module 144 replaces the current AND root by the existing one with identical literals. Otherwise, AND/OR elimination module 144 adds the AND root literals to the hash table and proceeds to the next AND root. AND/OR elimination module 144 then proceeds to the common subexpression elimination aspect.
AND/OR synthesis module 146 executes an algorithm to synthesize 3+ input AND gates to minimize gate depth, and/or to retain as much of the original design representation in initial design (D) netlist 120 as possible. When synthesizing 3+ input AND gates into 2-input AND gates for a 2-input AND representation, AND/OR synthesis module 146 may create the set of 2-input AND gates in any possible configuration without risking suboptimality with respect to the total number of gates in the final design. Any non-root gates will be replaced by synthesis of the intermediate representation, which maximally eliminated all common subexpressions from the root expressions. Synthesis of 3+ input AND gates could be an arbitrary cascade (e.g., given a 4-input AND over A,B,C,D, AND/OR synthesis module 146 could form (((A&B)&C)&D)). Alternatively, it is often desired to limit the “depth” of logic levels (i.e., the maximum number of combinational gates that can be traversed through fanin-wise without stopping at a register or primary input). For that reason, a balanced AND tree such as ((A&B)&(C&D)) is often preferred.
Furthermore, rather than arbitrarily pairing literals as in the last example to minimize the depth of the synthesized logic, the AND/OR synthesis module 146 yields even greater reductions in maximum logic depth through the use of a 3-step method. First, AND/OR synthesis module 146 labels each literal in the multi-AND representation with its “depth”, where depth is defined such that all constant gates, RANDOM gates, and registers have level 0. The level of other combinational gates is equal to the maximum level of any of their sourcing gates plus one. AND/OR synthesis module 146 then sorts the literals of the 3+ input AND tree by increasing depth in a queue. Finally, while there are 2+ literals in the queue, AND/OR synthesis module 146 removes the two “shallowest” literals and create a 2-input AND over them and add the resulting 2-input AND gate to the queue, again sorting by depth.
Note that AND/OR synthesis module 146 defers creating an AND gate over gates that are already “deep” as long as possible, resulting in a solution where the maximum level of any created AND gate is minimal. When there is only one literal left in the queue, AND/OR synthesis module 146 replaces the root, which was found in initial design (D) netlist 120 with this literal.
Additionally, AND/OR synthesis module 146 may rebuild the AND gates to maximize the amount of reuse of the prior design representation, to in turn minimize the amount of change to the design representation caused by subexpression elimination. Such a criteria may be used as a “tie-breaker” when AND/OR synthesis module 146 is selecting among arbitrary equal-cost solutions (e.g., if more than 2 “shallowest nodes” exist when using the minimum-depth creation algorithm above, AND/OR synthesis module 146 could select those whose conjunctions already exist in the original design); or it could be the only criteria. Assume that AND/OR synthesis module 146 has a “queue” of literals to build an AND tree over, and AND/OR synthesis module 146 will retain as much similarity with the original gates as possible. Again, this priority may relate either to the entire queue that AND/OR synthesis module 146 synthesizes, or to a subset of the queue representing equal-cost solutions for another criteria, such as min-depth above.
AND/OR synthesis module 146 may use an additional method, which is expressed as the algorithm embodied in the following pseudocode:
for each literal A in the queue
for each AND gate over A in the original cone-of-influence, look at the other AND literal B or NOT B; call the match “C” (which is either B or NOT B) if (B is in queue)
delete A and B from the queue add the existing AND gate for (A & B) to the queue
XOR/XNOR identification module 152 executes a method for identifying gates of initial design (D) netlist 120 whose functions must be preserved when eliminating common subexpressions within XOR/XNOR trees (referred to as “roots”), which in turn indicate which gates may be replaced by the process of the present invention. XOR/XNOR identification module 152 identifies roots in five steps. First XOR/XNOR identification module 152 labels all pre-defined gates whose functions need to be preserved as roots. For example, in a verification setting, targets (T) 132 and constraints (C) 134 may need to be preserved. In a synthesis setting, “primary outputs” may need to be preserved.
Second, XOR/XNOR identification module 152 marks the “cone of influence” of the pre-defined gates. The cone-of-influence is identified transitively as the set of gates which source incoming edges to this pre-defined set, including next-state functions and initial-value functions for registers. Third, for any register marked as in the cone-of-influence, XOR/XNOR identification module 152 labels its next-state function and initial-value function as roots. Fourth, if initial design (D) netlist 120 does not include a 2-input AND representation, for any non-register gate “g” in the cone-of-influence, XOR/XNOR identification module 152 analyzes all gates that source the incoming edges to “g”. If “g” is not an XOR or XNOR gate, XOR/XNOR identification module 152 tags all such source gates as roots. If initial design (D) netlist 120 does include a 2-input AND representation, for every node in the cone of influence, XOR/XNOR identification module 152 uses pattern matching to detect the top AND clause of expressions of the form (NOT(A & NOT B) & NOT(NOT A & B)), which is an XNOR structure, and (NOT(A & B) & NOT(NOT A & NOT B)), which is an XOR structure.
If such a structure is detected, XOR/XNOR identification module 152 labels the internal two AND gates as “xor_internals”. Finally, for every XOR/XNOR gate, XOR/XNOR identification module 152 analyzes its fanout gates. If any of the fanout gates are in the cone-of-influence, but not tagged as xor_internals, XOR/XNOR identification module 152 labels them as sinks. As a post-processing step, XOR/XNOR identification module 152 clears the xor_internal flag from any node identified XOR/XNOR root.
XOR/XNOR elimination module 154 executes a heuristically optimal structural algorithm for eliminating common XOR/XNOR subexpressions from roots. XOR/XNOR elimination module 154 exploits the propositional logic fact that ((A XOR B) XNOR C) is equivalent to ((A XNOR B) XOR C), NOT((A XOR B) XOR C) and ((A XOR NOT B) XOR C). Further XOR/XNOR elimination module 154 exploits the propositional logic fact that ((A XNOR B) XNOR C) is equivalent to ((A XOR B) XOR C). This allows XOR/XNOR elimination module 154 to cancel NOTs in pairs, and if any NOT remains, XOR/XNOR elimination module 154 may apply the NOT to the top of the XOR expression.
If initial design (D) netlist 120 does not include a 2-input AND representation, for all XOR/XNOR-gate roots tagged above, XOR/XNOR elimination module 154 traverses fanin-wise exclusively through XOR/XNOR gates and inversions.
XOR/XNOR elimination module 154 maintains an inverted_flag, initialized to false. Any XNOR gate traversed through causes XOR/XNOR elimination module 154 to toggle the inverted_flag, and any inversion present on an edge “between” XOR and XNOR gates causes XOR/XNOR elimination module 154 to toggle the inverted_flag. Finally, XOR/XNOR elimination module 154 queues the UNINVERTED gates sourcing edges at which this traversal stops (i.e., inputs to the terminal XOR/XNOR gates). For each such gate that is inverted, XOR/XNOR elimination module 154 toggles the inverted_flag.
If initial design (D) netlist 120 does include a 2-input AND representation, for all XOR/XNOR-gate roots tagged above, XOR/XNOR elimination module 154 traverses fanin-wise exclusively through XOR/XNOR structures using a get_xor_literals function. For XOR/XNOR gate “g”, XOR/XNOR elimination module 154 calls a get_xor_leaves(g, false, literals) function with an empty queue “literals” to get its queue of literals, and its inverted_flag. In a preferred embodiment of XOR/XNOR elimination module 154 the get_xor_leaves(g, false, literals) implements the algorithm embodied in the following pseudocode:
xor_type is either NOT_XOR_TYPE
or XNOR_TYPE
or XOR_TYPE
// the bool return indicates the inverted_flag
bool get_xor_leaves(gate g, bool inverted_edge, queue literals) {
xor_type type bck_xor_type(p, false);
if(type == XNOR_TYPE) {flag = true;)
else {flag = false;)
if(type == NOT_XOR_TYPE) {
push(literals, g);
// note - only uninverted literals are pushed. inversions for those are reflected in inverted_flag
//by XNORTYPE and XOR_TYPE processing
return false;
}else{
inp1 = input_gate_1 (input_gate_1 (g));
inp2 = input_gate_2(input_gate_1 (g));
if(get_xor_leaves(inp1, in put_edge1_is_inverted(input_gate_1 (g)), literals) { flag = NOT flag;
}
if(get_xor_leaves(inp2, input_edge2_is_inverted (input_gate_1 (g)), literals) { flag = NOT flag;
}
)
return flag;
}
xor_type get_xor_type(gate g, bool inverted_edge) {
if(g is a 2-input AND gate) {
if(input_gate_1 (g) is a 2-input AND gate && //first input gate of “g” is also an AND
input_gate_2(g) is a 2-input AND gate && //second input gate of “g” is also an AND
input_edge1_is inverted(g) && //first input edge of “g” is inverted
input_edge2_is inverted(g) && //first input edge of “g” is inverted
((input_gate_1 (input_gate_1 (g)) == input_gate_1 (input_gate_2(g))) || // source of first input gate
to first child of “g” is
(input_gate_1 (input_gate_1 (g)) == input_gate_2(input_gate_2(g)))) && //also a source of second
child of g
((input_gate_2(input_gate_1(g)) == input_gate_1 (input_gate_2(g))) || //source of second input gate
to first child of “g” is
(input_gate_2(input_gate_1 (g)) == input_gate_2(input_gate_2(g))))) { // also a source of second
child of g
//the present invention now knows this is an XOR or XNOR type
if(input_edge1_is_inverted(input_gate_i (g)) input_edge1_is_inverted(input_gate_1 (g))) {
type = XNOR_TYPE;
}
else{
type = XOR_TYPE;
}
if(!inverted_edge) {return type;}
else if(type == XNOR_TYPE) {return XOR_TYPE;} // flip type since called on an inverted edge
for gate g
else {return XNOR_TYPE;}// flip type since called on an inverted edge for gate g
}
}
return NOT_XOR_TYPE;
}
Any gates traversed “through” by XOR/XNOR elimination module 154 on either traversal, which are not marked as roots, will effectively be replaced by the cross-elimination module 136 , as explained later.
XOR/XNOR elimination module 154 will then build an intermediate data structure representing the common subexpression data. XOR/XNOR elimination module 154 ignores any gate not marked in the cone of influence. For any XOR/XNOR gate marked as a root, XOR/XNOR elimination module 154 translates it as a multi-input XOR gate in the intermediate representation whose inputs are the identified leaves. XOR/XNOR elimination module 154 labels the gate with the “inverted_flag”, indicating if an even or odd number of inversions were detected. XOR/XNOR elimination module 154 then adds all literals of the multi-input XOR gate, and edges from those literals to the multi-input XOR gate, to the intermediate representation.
Next, XOR/XNOR elimination module 154 eliminates subexpressions from the created data structure in a manner that implements the algorithm embodied in the following pseudocode:
for each gate “i” which is a literal of an XOR/XNOR root {
for each polarity of “i” i.e. for each literal “j” involving “i” {
//the present invention will check for instances of “i” as well as “NOT i”
in roots
roots = all XOR/XNOR gate roots in the fanout of “j”
//the roots including literal “j” that the present invention may refactor from
if(roots has fewer than two elements) {continue;}
// no subexpression elimination possible with “j”
leaves = all literals occurring in 2+ roots
//the literals that the present invention may refactor out of roots
leaves = leaves MINUS “j”
//leaves is now the set of literals that the present invention will try
to refactor out of roots, along with “j”
while(leaves) {
k = pop(leaves)
//grab another literal; the present invention will try to refactor both “j”
and “k” out of roots
roots' = subset of roots containing {j,k}
//see which roots include both
“j” and “k”
leaves' = maximal set of common literals in each element of roots'
//a superset of {j,k}; see if they include additional common literals
roots' has fewer than two elements) {continue;}
//a small optimization - due to adding newly created AND gates as roots
below
cur = create XOR gate whose inputs are leaves'
//an XOR gate representing the common subexpression
refactor leaves' out of roots'
//remove connections between leaves' and each of roots'
add cur as a leaf of roots'
//add cur as an input to each of
roots'
add cur to roots
//may need to further refactor
cur
}
}
}
When the above algorithm terminates, all common subexpressions will be eliminated from the roots by XOR/XNOR elimination module 154 . To complete the process of minimizing initial design (D) netlist 120 , XOR/XNOR elimination module 154 replaces the roots found in initial design (D) netlist 120 with new logic consistent with the solution obtained on the intermediate representation. XOR/XNOR elimination module 154 therefore synthesizes all “cur” gates created in the intermediate representation, which will be XOR gates. XOR/XNOR elimination module 154 next re-synthesizes the roots as XOR functions over the original roots and the synthesized ‘cur” gates.
Finally, if the “inverted_flag” of the root is not set, XOR/XNOR elimination module 154 replaces the original XOR/XNOR gate with this synthesized XOR gate. Otherwise, XOR/XNOR elimination module 154 replaces the original XOR/XNOR gate with the inversion of the synthesized XOR gate. This step effectively maps the solution from the intermediate representation to one in the original design.
Extensions to XOR/XNOR elimination module 154 can provide redundancy removal capability. After queueing up the literals in the XOR/XNOR roots in and before creating the intermediate format, XOR/XNOR elimination module 154 prunes the queue in three steps. First, XOR/XNOR elimination module 154 deletes any constant-one gates from the queue, and toggles the “inverted_flag” associated with the node. XOR/XNOR elimination module 154 then deletes any constant-zero gates from the queue. If two identical literals are in the queue, XOR/XNOR elimination module 154 deletes them both to ensure that every literal in the queue is unique.
Because these queues represent literals of an XOR expression, the steps above provide a structural application of propositional “conjunction simplification” rules. If the resulting queue is empty, and the “inverted_flag” is false, XOR/XNOR elimination module 154 replaces the corresponding root by constant-zero. If the resulting queue is empty, and the “inverted_flag” is true, XOR/XNOR elimination module 154 replaces the corresponding root by constant-one.
Additionally, XOR/XNOR elimination module 154 uses a hash table to identify the literals of the XOR roots. After pruning the queue for a new XOR root, XOR/XNOR elimination module 154 checks to see if an XOR root with the identical literals exists. If so, and if the “inverted_flags” for the current and matching roots are equal, XOR/XNOR elimination module 154 replaces the current XOR root by the matching one with identical literals. If so, and if the “inverted_flags” for the current and matching roots differ, XOR/XNOR elimination module 154 replaces the current XOR root by the inverse of the matching one with identical literals. Otherwise, XOR/XNOR elimination module 154 adds the XOR root literals to the hash table.
XOR/XNOR synthesis module 156 executes an algorithm to synthesize 3+ input XOR gates to minimize gate depth, and/or to retain as much of the original design representation in initial design (D) netlist 120 as possible. XOR/XNOR synthesis module 156 could perform an arbitrary cascade, (e.g. given a 4-input XOR over A,B,C,D the present invention could form (((A XOR B) XOR C) XOR D))). Alternatively, it is often desired to limit the “depth” of logic levels (i.e., the maximum number of combinational gates that can be traversed through fanin-wise without stopping at a register or primary input. For that reason, a balanced XOR tree such as ((A XOR B) XOR (C XOR D)) is preferred.
Furthermore, rather than arbitrarily pairing literals as in the last example to minimize the depth of the synthesized logic, XOR/XNOR synthesis module 156 yields even greater reductions in maximum logic depth. XOR/XNOR synthesis module 156 performs three steps. First, XOR/XNOR synthesis module 156 labels each literal in the multi-XOR representation with its “depth”. Depth is defined where all constant gates, RANDOM gates, and registers have level 0. The level of other combinational gates is equal to the maximum level of any of their sourcing gates plus one. Second, XOR/XNOR synthesis module 156 sorts the literals of the 3+ input XOR tree by increasing depth in a queue. Third, while there are 2+ literals in the queue, XOR/XNOR synthesis module 156 removes the 2 “shallowest” literals and create a 2-input XOR over them (using either of the 2-input AND decompositions for XOR, if desired) and adds the resulting 2-input XOR gate to the queue, again sorting by depth.
Note that XOR/XNOR synthesis module 156 defers creating an XOR gate over gates that are already “deep” as long as possible, resulting in a solution where the maximum level of any created XOR gate is minimal. When there is only one literal left in the queue, XOR/XNOR synthesis module 156 replaces the root in the original netlist with this literal (if its inverted_flag is false), else by the inversion of that literal.
Additionally, XOR/XNOR synthesis module 156 may rebuild the XOR/XNOR gates to maximize the amount of reuse of the prior design representation, to in turn minimize the amount of change to the design representation caused by subexpression elimination. Such a criterion may be used as a “tie-breaker” when selecting among arbitrary equal-cost solutions (e.g., if more than 2 “shallowest nodes” exist when using the min-depth creation algorithm above, the present invention could select those whose conjunctions already exist in the original design); or it could be the only criteria. Assume that XOR/XNOR synthesis module 156 has a “queue” of literals to build an XOR tree over, and XOR/XNOR synthesis module 156 is to retain as much similarity with the original gates as possible. Again, this may either be the entire queue that the present invention is designed to synthesize, or may be a subset of the queue to synthesize representing equal-cost solutions for another criteria, such as min-depth above.
XOR/XNOR synthesis module 156 may also employ an instruction set where, for each literal A in the queue XOR/XNOR synthesis module 156 and for each XOR/XNOR gate over A in the original cone-of-influence, XOR/XNOR synthesis module 156 looks at the other XOR/XNOR literal B or NOT B, and XOR/XNOR synthesis module 156 calls the match “C” (which is either B or NOT B). Note that XOR/XNOR synthesis module 156 may readily identify XOR/XNOR gates over A even in a 2-input AND representation. An appropriate algorithm is embodied in the following pseudocode:
(get_xor_type) applied to AND gates which are 2 fanout levels “deeper”
than A
if(B is in queue)
delete A and B from the queue
if the existing gate is an XOR, add that existing XOR gate for
(A XOR B) to the queue
if the existing gate is an XNOR, add the inverse of that existing
XNOR gate for (A XNOR B) to the queue
Cross elimination module 138 executes algorithms to allow subexpression elimination between XOR/XNOR expressions and AND/OR expressions. When building an XOR gate over A and B in a 2-input AND representation, cross elimination module 138 pursues one of two options: NOT(NOT(A & NOT B) & NOT(NOT A & B)) or (NOT(A & B) & NOT(NOT A & NOT B)). Assume that, somewhere in the original design (D) netlist 120 , cross elimination module 138 sees an AND gate for (NOT A & B); and no other AND gates over gates A and B exist (save for those to be fabricated for A XOR B). This condition implies that cross elimination module 138 chooses the former synthesis of the XOR, and cross elimination module 138 may reuse one existing AND gate, thereby adding only two for the XOR, whereas the latter would require three dedicated XORs.
When synthesizing a 2+ input XOR in a 2-input AND representation, Cross elimination module 138 attempts to share the resulting AND gates with those in the original structure using the algorithm embodied in the following pseudocode, in which references to “queue” represent the XOR literals to be synthesized:
// refactor out pairs which have 2 of the 3 AND gates already in the cone for each literal A in the
queue
for each AND gate over A in the cone-of-influence, which is not an xor_internal, look at the
other AND literal B or NOT B; call the match “C” (which is either B or NOT B)
if(B is in queue)
if( (NOT A & NOT C) also exists in the cone-of-influence, and is not an xor_internal)
refactor A and B out of queue
create XOR gate (NOT(A & C) & NOT(NOT A & NOT C)), and add that to the queue
for each AND gate over NOT A in the cone-of-influence, which is not an xor_internal, look
at the other
AND literal B or NOT B; call the match “C” (which is either B or NOT B)
if(B is in queue)
if( (A & NOT C) also exists in the cone-of-influence, and is not an xor_internal) refactor A
and B out of queue
create XOR gate (NOT(NOT A & C) & NOT(A & NOT C)), and add that to the queue
//refactor out pairs which have 1 of the 3 AND gates already in the cone
for each AND gate over A in the cone-of-influence, which is not an xor_internal, look at the
other AND literal B or NOT B; call the match “C” (which is either B or NOT B)
if(B is in queue)
refactor A and B out of queue
create XOR gate (NOT(A & C) & NOT(NOT A & NOT C)), and add that to the queue
for each AND gate over NOT A in the cone-of-influence, which is not an xor_internal, look
at the other AND literal B or NOT B; call the match “C” (which is either B or NOT B)
if(B is in queue)
refactor A and B out of queue
create XOR gate (NOT(NOT A & C) & NOT(A & NOT C)), and add that to the queue
Prevention module 136 executes an algorithm to heuristically prevent logic increases for AND/OR as well as XOR/XNOR refactoring. Though AND/OR elimination module 144 and XOR/XNOR elimination module 154 provide complete elimination of subexpressions, AND/OR elimination module 144 and XOR/XNOR elimination module 154 are heuristic. The order in which common subexpressions including literals “j” and “k” are removed from expressions affects the optimality of the final solution, and may result in an increase in size. Prevention module 136 provides a functionality to attempt to prevent such an increase in size. After building the multi-input AND and XOR representations described above, respectively, and before calling the subexpression elimination code, Prevention module 136 deploys the algorithm embodied in the following pseudocode:
For each AND root “g”
traverse fanin-wise looking for AND roots that were “traversed through”, and queue these up
For each element of the queue “h”, in order of decreasing number of literals in “h”: if the literals queue for “g” includes all the literals in “h”
refactor h literals out of “g” add h as a literal of “g”
Similarly for XOR roots: For each multi-input XOR root “g”: traverse fanin-wise looking for XOR roots that were “traversed through, and queue these up For each element of the queue “h”, in order of decreasing number of literals in “h”: if the literals queue for “g” includes all the literals in “h” refactor “h” literals out of “g” if “h” has its inverted flag as false, add “h” as a literal of “g” else, add the inversion of “h” as a literal of “g”
Prevention module 136 heuristically keeps the final subexpression-eliminated solution closer to that of the original solution, which prevents certain gate increases which may result from the heuristic algorithms AND/OR elimination module 144 and XOR/XNOR elimination module 154 .
Reversal module 148 executes an algorithm to selectively undo portions of the subexpression elimination results in reduced design (D′) netlist 140 , to improve overall reduction capability and/or retain greater similarity with the original design representation in initial design (D) netlist 120 . As described in the discussion of Prevention module 136 , heuristic algorithms can at times increase design size. Such increases may occur for certain cones of logic, though other cones may attain a reduction through the subexpression elimination. Reversal module 148 provides functionality to selectively undo portions of the subexpression elimination, and retain others.
After application of AND/OR elimination module 144 and XOR/XNOR elimination module 154 have generated an intermediate data structure, reversal module 148 may partition the roots which overlap in literals. Assume every root which contains literal ‘A’ is in the same partition. For optimality, reversal module 148 places disjoint roots into different partitions. This may be performed by the algorithm embodied in the following pseudocode:
partition = 1
for each root “g” {
if(labeled(g)) {continue;}
push(queue, g)
while(queue)
{ h = pop(queue)
label(h) = partition;
for each literal “l” in the literals queue of “h”
for each root “r” in the fanout of “l” {
if(labeled(r)) {continue;}
label(r) = partition
push(queue, r)
}
}
partition++
}
Once reversal module 148 has labeled each root in maximally disjoint partitions, reversal module 148 may selectively undo the subexpression elimination results for a given partition. The results of each partition are independent from the others by the construction of the partitioning, hence undoing one partition entails no suboptimality to other partitions.
One significant consideration for undoing the subexpression elimination for a given partition is whether the transformation increases the number of gates necessary to represent the partition. Reversal module 148 may therefore count the number of gates used in the original design to represent the logic of the “traversed through” gates for the given roots in a partition, and compare it to those needed to represent the replacement logic for those roots. If the former is less than, or possibly equal to/within a specific threshold of being equal to (e.g., if the reversal module 148 attempts to retain as much of the original design representation as possible), the latter, reversal module 148 may neglect the replacement of the original gates. Numerous other criteria for neglecting the replacement may be selected, such as choosing based upon gate depth, or any other criteria.
Referring now to FIG. 2 , a high-level logical flowchart of a method for heuristic elimination of sub-expressions instructional design representations is depicted. The process starts at step 200 and then proceeds to step 202 , which depicts verification environment 124 receiving initial design (D) netlist 120 . The process next moves to step 204 . At step 204 , reduction tool package 126 determines whether to use whether to use XOR/XNOR or AND/OR simplification. The choice of what form of simplification is to be used can be based on any number of criteria, ranging from alternating between passes to performing mathematical computations with respect to initial design (D) netlist 120 . If AND/OR simplification is chosen, then the process passes to step 206 , which depicts AND/OR identification module 142 identifying a minimal set of AND/OR roots whose functions must be preserved. The process then moves to step 208 . At step 208 , reduction tool package 126 enqueues AND leaves of each root from initial design (D) netlist 120 .
The process then proceeds to step 210 , which depicts AND/OR elimination module 144 using AND rewriting rules to simplify queues. The process next moves to step 212 . At step 212 , for each root queue of a gate (g 1 ) which is a superset of the queue of another gate (g 2 ), AND/OR elimination module 144 replaces the common leaves in g 1 's queue with leaf g 2 .
The process then proceeds to step 214 , which depicts AND/OR elimination module 144 clustering roots into leaf-disjoint groups. Next, the process proceeds to step 216 . At step 216 , AND/OR elimination module 144 successively eliminates common leaf sets from each corresponding group of roots creating the corresponding AND gates over common leaves and replacing the common leaves in queues with the new AND gate. AND/OR elimination module 144 also adds the new AND gate to the root group. The process then moves to step 218 , which depicts prevention module 136 and cross elimination module 138 building depth-balanced AND trees for each AND root. The process then proceeds to step 220 .
At step 220 , reduction tool package 126 determines whether the new logic created in steps 206 to 218 or steps 226 to 238 is smaller than the original logic of initial design (D) netlist 120 received in step 202 . If the new logic created in steps 206 to 218 or steps 226 to 238 is not smaller than the original logic of initial design (D) netlist 120 received in step 212 , then the process moves to step 222 , which depicts reversal module 148 retaining the original logic or group received in initial design (D) netlist 120 at step 202 . The process returns to step 204 , which is described above. If reduction tool package 126 determines that the new logic created in steps 206 to 218 or steps 226 to 238 is smaller than the original logic received in initial design (D) netlist 120 at step 202 , then the process proceeds to step 224 . Step 224 depicts reduction tool package 126 replacing the original logic received in initial design (D) netlist 120 at step 202 with the new logic created in steps 206 to 218 or steps 226 to 238 . The process then proceeds to step 240 .
At step 240 , reduction tool package 126 determines whether the current solution of initial design (D) netlist 120 as modified through steps 206 to 218 or steps 226 to 238 meets the required size parameters for the current verification problem. If reduction tool package 126 determines that the current solution meets the size parameters for the current verification problem then the process ends at step 242 , at which point results are reported to output table 122 . If reduction tool package 126 determines that the current solution constructed in steps 206 to 218 or steps 226 to 238 does not meet the sized parameters of the current verification problem then the process returns to step 202 which is described above.
Returning to step 226 , which depicts verification environment 124 identifying a minimal set of XOR/XNOR roots whose functions must be preserved. The process then moves to step 228 , at step 228 , reduction tool package 126 enqueues XOR leaves of each root from initial design (D) netlist 120 . The process then proceeds to step 230 , which depicts verification environment 124 using XOR rewriting rules to simplify queues. The process next moves to step 232 . At step 232 , for each root queue of a gate (g 1 ) which is a superset of the queue of another gate (g 2 ), verification environment 124 replaces the common leaves in g 1 's queue with leaf g 2 .
The process then proceeds to step 234 , which depicts XOR/XNOR elimination module 154 clustering roots into leaf-disjoint groups. Next, the process proceeds to step 236 . At step 236 , verification environment 124 successively eliminates common leaf sets from each corresponding group of roots creating the corresponding XOR gates over common leaves and replacing the common leaves in queues with the new XOR gate. Verification environment 124 also adds the new XOR gate to the root group. The process then moves to step 238 , which depicts verification environment 124 building depth-balanced XOR trees for each XOR root. The process then proceeds to step 220 .
While the invention has been particularly shown as described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention. It is also important to note that although the present invention has been described in the context of a fully functional computer system, those skilled in the art will appreciate that the mechanisms of the present invention are capable of being distributed as a program product in a variety of forms, and that the present invention applies equally regardless of the particular type of signal bearing media utilized to actually carry out the distribution. Examples of signal bearing media include, without limitation, recordable type media such as floppy disks or CD ROMs and transmission type media such as analog or digital communication links.
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A method, system and computer program product for reducing XOR/XNOR subexpressions in structural design representations are disclosed. The method includes receiving an initial design, in which the initial design represents an electronic circuit containing an XOR gate. A first simplification mode for the initial design is selected from a set of applicable simplification modes, wherein the first simplification mode is an XOR/XNOR simplification mode, and a simplification of the initial design is performed according to the first simplification mode to generate a reduced design containing a reduced number of XOR gates. Whether a size of the reduced design is less than a size of the initial design is determined, and, in response to determining that the size of the reduced design is less than a the size of the initial design, the initial design is replaced with the reduced design.
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BACKGROUND OF THE INVENTION
The invention pertains to a seed coating compositions and more particularly to a seed coating composition comprising a certain latex binder and/or certain graft polymer dispersant.
Seeds are often treated to reduce yield losses during cultivation and for enhancing the agronomic and nutritional value of the produce. Such treating agents are for example fungicides, insecticides, rodenticides, nematocides, miticides or bird repellents. Furthermore, many varieties of genetically altered crops are coming to the market. Treated and/or genetically modified seeds must be marked in order to distinguish them from the untreated and unmodified seeds. The marking of seeds is particularly beneficial for farmers who then can easily distinguish the chemically treated and modified seeds for plantings from e.g. cereal grains for consumption.
Various seed coating ingredients therefore, have been disclosed. For example, U.S. Pat. No. 4,272,417 discloses a seed coating composition comprising a binding agent selected from the class of vinyl acrylic emulsions, partially hydrolyzed copolymers of vinyl chloride and vinyl acetate, polyvinyl alcohols, polyvinyl acetates, drying oil modified polyurethanes, vinyl toluene copolymer modified drying oils, 23 percent penta soya oil alkyd, pinene polymer hydrocarbon resins, chain stopped alkyds, chlorinated rubber, epoxy esters, acrylics, modified polyacrylamides, self-curing carboxylated styrene butadiene latex, polyvinyl pyrrolidone, poly (methyl vinyl ether/maleic anhydride), vinyl pyrrolidone/dimethylamino ethylmethacrylate copolymer, and vinyl pyrrolidone/vinyl acetate copolymer.
U.S. Pat. No. 5,849,320 discloses an insecticidal coating for a seed comprising one or more binders selected from the group consisting of polymers and copolymers of polyvinyl acetate, methyl cellulose, polyvinyl alcohol, vinylidene chloride, acrylic, cellulose, polyvinylpyrrolidone and polysaccharide and an insecticidally effective amount of an insecticide, wherein the binder forms a matrix for the insecticide.
U.S. Pat. No. 4,249,343 discloses compositions for coating plant seeds comprising a water insoluble polymeric microgel that provides protection for the seeds from mechanical and environmental damages and that may be used as a carrier for materials such as fertilizers, herbicide, pesticides and so forth. Useful monomers for the production of microgels by addition polymerization include acrylic acid; methacrylic acid; hydroxy esters, amino substituted esters and amides of acrylic acid, methacrylic acid and maleic acid; vinylpyridine and derivatives of vinyl pyridine such as 2-methyl-5-vinylpyridine.
U.S. Pat. No. 3,707,807 discloses a composition for treating seeds comprising an aqueous emulsion of a substantially water-soluble neutralized copolymer of an α,β-unsaturated monocarboxylic acid and a lower alkyl acrylate and a crosslinked copolymer of vinyl acetate and a lower alkyl acrylate.
U.S. Patent Publication 2003/0221365 discloses pigment forms and pigment concentrates which can be effectively used for seed coloring.
Seed coating compositions and ingredients are also available commercially from, for example, Becker Underwood (Ames, Iowa) under the SEEDKARE® tradename, Uniqema (New Castle, Del.) under the Atlox™ Semkote tradename, International Specialty Products (Wayne N.J.) under the Agrimer® tradename and Celanese Corp. (Dallas Tex.) under the Celvol® tradename.
There is still a need for, and it is an objective of this invention to provide, seed coating compositions that impart good color to treated seeds, that resist attrition and dust formation on handling and that are non-sticky and allow smooth flow of coated seed in planting equipment.
SUMMARY OF THE INVENTION
In accord with an objective of this invention, there is provided a seed coating composition comprising an aqueous carrier, a pigment colorant, and either one or both of (a) an acrylic latex binder and/or (b) a graft copolymer dispersant.
The acrylic latex binder is an acrylic polymer dispersion containing about 30-40% by weight methyl methacrylate, 10-20% by weight styrene, 35-45% by weight 2-ethylhexyl acrylate, 1-6% by weight methylol methacrylamide, 1-5% by weight hydroxyethyl acrylate and 1-5% by weight methacrylic acid; and, wherein the acid groups of the graft copolymer are neutralized with an inorganic base or an amine.
The dispersant is a graft copolymer having a weight average molecular weight of about 5,000-100,000 and comprising a polymeric backbone and macromonomer side chains attached to the backbone wherein: (1) the polymeric backbone is hydrophobic in comparison to the side chains and contains polymerized ethylenically unsaturated hydrophobic monomers and up to 20% by weight, based on the weight of the graft copolymer, of polymerized ethylenically unsaturated acid containing monomers; and (2) the sidechains are hydrophilic macromonomers that are attached to the backbone at a single terminal point and contain polymerized ethylenically unsaturated monomers and 2-100% by weight, based on the weight of the macromonomer, of polymerized ethylenically unsaturated acid containing monomers and have a weight average molecular weight of about 1,000-30,000; and, wherein the acid groups of the graft copolymer are neutralized with an inorganic base or an amine.
The prescribed acrylic latex binder is particularly advantageous for providing a durable, non-sticky coating that effectively binds colorants and other ingredients to treated seeds.
The prescribed graft copolymer dispersant is particularly effective at stably dispersing a range of pigment colorants in an aqueous seed coating carrier comprising binder. Because of the advantageous dispersion properties of the prescribed graft copolymer dispersant, a given color strength can be achieved with less pigment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Seed Coating Composition
Seed coating compositions comprise an aqueous carrier which can be simply water, or combination of water and other solvent(s), and colorant dispersed or dissolved in the carrier. The composition will typically comprise binder, such as a polymer or resin, dispersed or dissolved in the carrier. The will also typically comprise colorant, especially pigment colorant, and also may comprise a dispersant, such as a polymer or resin dispersant, to stabilize the dispersion of a pigment colorant. Other ingredients known in the art may also be present in the composition including, for example, surfactants, biocides, fungicides, insecticides, fillers and the like.
The seed coating composition according to the present invention will comprise one or both of a prescribed latex binder and/or a prescribed graft copolymer dispersant which species are herein after described. Although not limited to any particular amounts, seed coating compositions will generally contains 0.01 to 10 wt % pigment, and 40 to 98 wt % aqueous carrier. When the prescribed dispersant is present, the pigment to dispersant weight ratio will generally be in the range of about 0.1/100 to 1500/100. When the prescribed acrylic latex binder is present, it will generally be present in an amount of between about 0.5 and 40 wt % (polymer solids basis). All percentages are weight percent (wt %) of the ingredient relative to the final weight of seed coating composition.
Colorant
Seed coatings typically comprise colorant so as to be visually distinguishable. Suitable colorants include charcoal, graphite, iron oxide, tartrazine, titanium dioxide, zinc oxide and organic pigments with C.I. designation Pigment Blue 15, Pigment Green, Pigment Violet 23 and Pigment Red 48. Suitable colorants can also include dyes such as those with C.I. designation Food Red 17, Food Blue 2, Solvent Green, Solvent Red 23, Acid Red 33, Solvent Violet 13, and Basic Blue 9. The “C.I.” designation refers to the nomenclature established by Society Dyers and Colourists, Bradford, Yorkshire, UK and published in The Color Index, Fourth Edition, 2002.
Binder
A binder can be any suitable binder approved for agricultural use, One such list of suitable binders can be found in the U.S. Code of Federal Regulations Title 40, Part 180.960 (referred to hereafter as 40CFR 180.960).
Included in this list approved binders are acrylic polymers composed of one or more of the following monomers: acrylic acid, methyl acrylate, ethyl acrylate, butyl acrylate, hydroxyethyl acrylate hydroxybutyl acrylate, carboxyethyl acrylate, methacrylic acid, methyl methacrylate, hydroxy butyl methacrylate, lauryl methacrylate, and stearyl methacrylate; with none and/or one or more of the following monomers: acrylamide, N-methyl acrylamide, N,N-dimethyl acrylamide, N-octyl acrylamide, maleic anhydride, maleic acid, monoethyl maleate, diethyl maleate, monooctyl maleate, dioctyl maleate; and their corresponding sodium, potassium, ammonium, isopropylamine, triethylamine, monoethanolamine, and/or triethanolamine salts. Other suitable binders from this list include: copolymers of methyl vinyl ether with maleic anhydride or monoalkyl esters of maleic anhydride (e.g. Agrimer® VEMA line of products from ISP); polyvinylpyrrolidone; copolymers of vinyl pyrrolidone with vinyl acetate (e.g., Agrimer VA line of products from ISP); copolymers of vinyl pyrrolidone with vinyl alkyls (e.g. Agrimer® AL line of products from ISP); polyvinyl acetate; ethylene/vinyl acetate copolymers (e.g. Atlox® SemKote E product line from Uniqema); vinyl acetate acrylic copolymers (e.g., Atlox® Semkote V product line from Uniqema); A-B block copolymers of ethylene oxide and propylene oxide; A-B-A triblock copolymers of EO-PO-EO (e.g. Pluronics® line from BASF); and polyvinyl alcohol.
A preferred binder is an acrylic latex polymer comprising N-methylol (meth)acrylamide monomer. The term “latex” as used herein means a dispersion in an aqueous carrier of polymer particles having a particle size of about 0.06-0.20 microns and a weight average molecular weight of greater than 500,000. (typically 500,000 to about 3,000,000)
A particularly preferred acrylic latex binder polymer comprises: an acrylic polymer containing about 30-40% by weight methyl methacrylate, 10-20% by weight styrene, 35-45% by weight 2-ethylhexyl acrylate, 1-6% by weight methylol methacrylamide, 1-5% by weight hydroxyethyl acrylate and 1-5% by weight methacrylic acid which binder is described in U.S. Pat. No. 5,219,916, which disclosure is incorporated by reference herein for all purposes as if fully set forth.
The acrylic latex polymer is formed by conventional emulsion polymerization by emulsifying a mixture of monomers, water, surfactant and polymerization catalyst and charging the resulting emulsion into a conventional polymerization reactor and heating the constituents in the reactor to about 60-95° C. for about 15 minutes to 8 hours and then the resulting polymer is neutralized with ammonia or an amine. The size of the polymeric particles of the latex is about 0.06-0.20 microns. The resulting polymer has a hydroxyl no. of 2-100, a glass transition temperature of −40 to +40° C. and a weight average molecular weight of about 500,000-3,000,000.
All molecular weights herein are measured by gel permeation chromatography using polystyrene as the standard.
Typically useful catalysts are ammonium persulfate, hydrogen peroxide, sodium meta bisulfite, hydrogen peroxide, sodium sulfoxylate and the like.
Typically useful surfactants are nonylphenoxypolyethyleneoxy ethanol sulfate, allyl dodecyl sulfosuccinate, alkyl phenoxy polyethylene oxyethanol, sodium lauryl sulfate and mixtures thereof. One preferred surfactant is a mixture of nonylphenoxy polyethyleneoxy ethanol sulfate and allyl dodecyl sulfosuccinate.
The acrylic latex polymer contains about 1-15% by weight of polymerized methylol methacrylamide, methylol acrylamide or any mixtures thereof.
Dispersant
Pigment dispersion stability in aqueous carrier can be increased by the presence of a polymer dispersant or surfactant. Suitable dispersants and surfactants include those commonly used in agricultural and crop protection applications such as those listed in the Code of Federal Regulations Title 40 Parts 180.900, 180.910, and 180.920 (to be referred to hereafter as 40CFR 180.900; 40CFR 180.910; and 40 CFR 180.920, respectively.) That list includes, for example, A-B block copolymers of ethylene oxide and propylene oxide; A-B-A triblock copolymers of EO-PO-EO (e.g. Pluronics® line from BASF); naphthalenesulfonic acid-formaldehyde condensates, ammonium and sodium salts; styrene-maleic anyhydride copolymers; monobutyl/ethyl Ester of poly(methyl vinyl ether/maleic acid), partial sodium salt (e.g. EasySperse Dispersant available from ISP); methyl methacrylate/polyethylene glycol graft copolymer (e.g. Atlox 4913 from Uniqema); random, water-soluble acrylic copolymers (e.g. Metasperse 100L and Atlox® 4914 from Uniqema); nonyl phenol ethoxylates (e.g. Tergitol nonionic surfactants from Dow Chemical); octyl phenol ethoxylates (e.g. Triton nonionic surfactants from Dow Chemical and Igepal product line from Stepan Chemical).
A preferred dispersant is a graft copolymer having a weight average molecular weight of about 5,000-100,000 and comprising a polymeric backbone and macromonomer side chains attached to the backbone and more specifically a graft copolymer dispersant wherein:
(1) the polymeric backbone is hydrophobic in comparison to the side chains and contains polymerized ethylenically unsaturated hydrophobic monomers and up to 20% by weight, based on the weight of the graft copolymer, of polymerized ethylenically unsaturated acid containing monomers; and
(2) the sidechains are hydrophilic macromonomers that are attached to the backbone at a single terminal point and contain polymerized ethylenically unsaturated monomers and 2-100% by weight, based on the weight of the macromonomer, of polymerized ethylenically unsaturated acid containing monomers and have a weight average molecular weight of about 1,000-30,000 and wherein the acid groups of the graft copolymer are neutralized with an inorganic base or an amine.
The graft copolymer contains about 50-90% by weight of polymeric backbone and correspondingly about 10-50% by weight of sidechains. The graft copolymer has a weight average molecular weight of about 5,000-100,000 and preferably about 10,000-40,000. The side chains of the graft copolymer are formed from hydrophilic macromonomers that have a weight average molecular weight of about 1,000-30,000 and preferably 2,000-5,000 and contain about 2-100% by weight and preferably 20-50% by weight, based on the weight of the macromonomer, of polymerized ethylenically unsaturated acid monomers. These sidechains are hydrophilic and keep the dispersant and pigments uniformly dispersed in the pigment dispersion and in the resulting coating composition.
The backbone of the graft copolymer is hydrophobic relative to the sidechains and may contain up to 20% by weight, preferably 1-10% by weight, based on the weight of the graft copolymer, of polymerized ethylenically unsaturated acid monomers which are listed hereinafter. The backbone contains polymerized hydrophobic monomers such as alkyl methacrylates and acrylates, cycloaliphatic methacrylates and acrylates and aryl methacrylates and acrylates as are listed hereinafter and also may contain up to 30% by weight, based on the weight of the graft copolymer, of polymerized ethylenically unsaturated non-hydrophobic monomers which may contain functional groups. Examples of such monomers are hydroxy ethyl acrylate, hydroxy ethyl methacrylate, t-butylamino ethyl methacrylate, diethyl amino ethyl acrylate, diethyl amino ethyl methacrylate, acrylamide, nitro phenol acrylate, nitro phenol methacrylate, phthalimido methyl acrylate, phthalimido methacrylate, acrylic acid, acryloamido propane sulfonic acid.
The backbone of the graft copolymer has an affinity for the surface of the pigment used in the dispersion and anchors the copolymer to the pigment and keeps the pigment dispersed and prevents the graft copolymer from returning to the aqueous phase. Reactive groups on the backbone can react with the pigment and form a bond with the pigment.
Molecular weights are determined by Gel Permeation Chromatography using polystyrene as a standard.
The macromonomer contains a single terminal ethylenically unsaturated group which is polymerized into the backbone of the graft copolymer and primarily contains polymerized monomers of methacrylic acid, its esters, nitriles, amides or mixtures of these monomers.
Typical alkyl methacrylates that can be used have 1-8 carbon atoms in the alkyl group and are for example methyl methacrylate, ethyl methacrylate, propyl methacrylate, isopropyl methacrylate, butyl methacrylate, pentyl methacrylate, hexyl methacrylate, 2-ethyl hexyl methacrylate and the like. Cycloaliphatic methacrylates also can be used such as trimethylcyclohexyl methacrylate, isobutylcyclohexyl methacrylate, and the like. Aryl methacrylates also can be used such as benzyl methacrylate. Other polymerizable monomers that can be used are styrene, alpha methyl styrene, methacrylamide and methacrylonitrile. The above monomers can also be used in the backbone of the graft copolymer.
The macromonomer can contain 2-100% by weight, preferably about 20-50% by weight, based on the weight of the macromonomer, of polymerized ethylenically unsaturated acid. Methacrylic acid is preferred particularly if it is the sole constituent. Other acids that can be used are ethylenically unsaturated carboxylic acids such as acrylic acid, itaconic acid, maleic acid and the like. Ethylenically unsaturated sulfonic, sulfinic, phosphoric or phosphonic acid and esters thereof also can be used such as styrene sulfonic acid, acrylamido methyl propane sulfonic acid, vinyl phosphonic acid and its esters and the like. The above acids also can be used in the backbone of the graft copolymer.
Up to 40% by weight, based on the weight of the macromonomer, of other polymerized ethylenically unsaturated monomers can be present in the macromonomer. Primarily alkyl acrylates having 1-12 carbons in the alkyl group can be used such as methyl acrylate, ethyl acrylate, propyl acrylate, isopropyl acrylate, butyl acrylate, pentyl acrylate, hexyl acrylate, 2-ethyl acrylate, nonyl acrylate, lauryl acrylate and the like can be used. Cycloaliphatic acrylates can be used such as trimethylcyclohexyl acrylate, t-butyl cyclohexyl acrylate and the like. Aryl acrylates such as benzyl acrylate also can be used. The above monomers also can be used in the backbone of the graft copolymer.
One preferred macromonomer contains about 50-80% by weight of polymerized methyl methacrylate and 20-50% by weight of polymerized methacrylic acid and has a weight average molecular weight of about 2,000-5,000. To ensure the macromonomer only has one terminal ethylenically unsaturated group which will polymerize with the backbone monomers to form the graft copolymer, the macromonomer is preferably polymerized using cobalt chain transfer agents.
Methods of making graft copolymer dispersant are known and described, for example, in U.S. Pat. No. 5,231,131 which disclosure is incorporated by reference herein for all purposes as if fully set forth.
To form a pigment dispersion or a mill base, pigments are added to the aqueous graft copolymer dispersion and then the pigments are dispersed using conventional techniques such as high speed mixing, ball milling, sand grinding, attritor grinding or two or three roll milling. The resulting pigment dispersion has a pigment to dispersant binder weight ratio of about 0.1/100 to 1500/100.
The preferred graft copolymer dispersant is advantageous in seed coatings with pigment colorant because it provides good color strength on the coated seed, therefore less pigment is needed to achieving a given level of coloration. It also has the advantage of being able to disperse a wide range of pigments both organic and inorganic.
Coated Seeds
The seeds prescribed herein are used to grow plants, fruits, or vegetables. The particular type of seed is not critical. The coating composition is applied to the exterior surface of the seeds and the water and other volatile components are allowed to vaporize leaving the non-volatile components bound to the seed by the binder.
Various techniques and equipment known in the seed coating art may be used for applying the coating composition to the seed. The process may be continuous or batch and typically involves tumbling the seed in the presence of the coating composition. Some drying of the coated seed may be required.
It may be advantageous to “overcoat” the coated seeds with additional binder to encase the seed treating agents and further protect them from attrition during handling.
The following examples illustrate the invention without, however, being limited thereto.
EXAMPLES
Preparation of Graft Copolymer Dispersant
Using the methods described in U.S. Pat. No. 5,231,131 a macromonomer was prepared with contained 28.75% methacrylic acid and 71.25% methyl methacrylate and having a weight average molecular weight of about 4000 and a number average molecular weight of about 2000.
Graft Copolymer 1 was prepared by polymerizing the macromonomer above with butyl acrylate, methyl acrylate and acrylic acid, again following the methods described in U.S. Pat. No. 5,231,131 and having the overall approximate composition: 31.8% butyl acrylate, 31.8% methyl acrylate, 6.4% acrylic acid, 21.4% methyl methacrylate, and 8.6% methacrylic acid and had a weight-average molecular weight of about 24000 and a number-average molecular weight of about 9500. Graft copolymer 1 was neutralized with 2-amino-2-methyl-1-propanol and recovered as a 30 wt % solution in water for subsequent use as a dispersant.
Preparation of Latex Binder
Latex Binder 1 was prepared according to methods described in U.S. Pat. No. 5,219,916 having the following monomer composition: MMA/S/2-EHA/MOLMAM/HEA/MAA in a weight ratio of 26.5/15/50/2.5/3/3. It was neutralized with ammonia to form the ammonium salt and had a weight average molecular weight of about 500,000-1,250,000. Latex 1 had a average particle size was 0.095 microns and was recovered as an aqueous slurry with 35.7 wt % polymer solids. The following abbreviations are used for the monomers: MMA is methyl methacrylate; S is styrene; 2-EHA is 2-ethylhexyl acrylate; MOLMAM is N-methylol methacrylamide; HEA is hydroxyethyl acrylate; and MAA is methacrylic acid.
Example 1
Dispersion 1 was prepared from 100 parts of Latex Binder 1 described above, 3 parts of talc and 0.5 parts of Pigment Red 48:2. Ingredients were mixed and milled in a sand mill with 0.8-1.0 mm zirconia media. The milled dispersion had a Brookfield viscosity (Brookfield viscometer, #3 spindle, 100 rpm, 25° C.) of 197 cps and a pH of 5.51. As demonstrated here, low concentration of pigment, about 0.5 wt %, can form an adequately stable dispersion in the latex binder solution without separate dispersant. However, higher concentrations of pigment (2-4 wt %) would not disperse adequately, and dispersant was required.
Coating Composition 1 was prepared by stirring together three fluid oz. of Dispersion 1, 10 fluid oz of Prescribe® insecticide (trademark of Gustafson), 2 additional oz of water and isopropyl alcohol (0.5% wt % based on total weight of the coating composition.
Coating Composition 1 was applied to corn seed at a rate of 3 fluid oz of the coating composition per 100 pounds of seed, whereafter the seed was allowed to dry at ambient temperature. As judged by visual inspection and routine handling, the dried seeds were uniformly coated and the coating felt durable and non-sticky.
Example 2
Dispersion 2 was prepared from 100 parts of Latex Binder 1, one part ethylene glycol monobutyl ether and 0.5 parts of Pigment Violet 23 in the same manner as described for Dispersion 1. This demonstrates a violet colored composition, again with a low concentration of pigment and no dispersant. As with dispersion 1, higher concentrations of pigment required dispersant for adequate dispersion quality.
Example 3
Dispersion 3 was prepared by mixing, in order 198.2 parts of deionized water, 142.2 parts of Graft Copolymer 1 solution, 33.3 parts of Latex Binder 1 and 6.7 parts of Surfynol® 104 DPM (surfactant from Air Products, Allentown, Pa., USA). When these ingredients were thoroughly mixed, 133.4 parts of Pigment Violet 23 was added, slowly, after which the mixture was stirred under high shear with a high speed disperser. Another 20.5 gms deionized water was added and the mixture was transferred to a Eiger mill and milled with 0.6-0.8 mm zirconia grinding media. At the end of the milling cycle another 126.7 parts of deionized water was added, followed by another brief period of milling. After filtration through 5 micron paper, the dispersion had a viscosity (Brookfield viscometer, UL adapter, 25° C.) of 28.3 cps and a pH of 7.5.
Coating Composition 3 (containing 4 wt % PV 23) was prepared by mixing, in order, 199.4 parts of Dispersion 3, 10 parts of butyl cellosolve and 790.6 parts of Latex Binder 1. After straining through a 250 micron paint strainer, the resulting coating composition had a viscosity (Brookfield viscometer, RV#2 Spindle, @100 rpm, 25° C.) of 97 cps, and a pH of 8.56. In the presence of graft copolymer dispersant, stable, high pigment content compositions were achieved.
Example 4
Coating composition 4 was prepared from 43.9 parts of Dispersion 4 from Example 4, 2.2 parts butyl cellosolve, 2.2 parts Surfynol® 104 BC (surfactant from Air Products), and 171.7 parts Latex Binder 1 in a manner a similar Coating Composition 3 in the previous example. This mixture was stirred with Poncho 1250 to make the final composition. Coating composition 5 was applied to hybrid seed corn at a rate of 1.5 fluid oz./100 pounds of seed. The coated seed had very good appearance (even coating, stronger color).
Example 5
Coating Composition 5 was prepared from 43.87 parts of Dispersion 3, 2.2 parts butyl cellosolve, 2.2 parts Surfynol 104 BC, and 171.7 parts Latex Binder 1 in a manner a similar Coating Composition 3 in the Example 3. This mixture was stirred with was mixed with Poncho 1250 to make the final composition. Coating composition 5 was applied to hybrid seed corn at use rates of 1.5 fluid oz./100 pounds of seed. The coated seed had very good appearance (even coating, stronger color).
Example 6
Dispersion 6 was prepared by mixing, under low shear, 255.8 parts of deionized water, 111.2 parts of Graft Copolymer 1, 33.3 parts of Latex Binder and 6.7 parts of Surfynol® 104 DPM (surfactant from Air Products). To the mixture was added, slowly, 133.4 parts of Pigment Red 48:2. After the pigment addition was complete, the mixture was stirred under high shear with a high speed disperser. Another 101.6 parts of deionized water was added and the mixture was transferred a sand mill and milled with 0.6-0.8 mm zirconia grinding media. At the end of the grind cycle another 25.1 parts of deionized water was added, followed another 15 minutes of grinding and discharge of the batch. After filtration through 5 micron filter paper, the resulting dispersion had a viscosity (Brookfield viscometer, 00 Spindle at 100 rpm, 25° C.) of 192 cps and a pH or 7.81
Application of Treated Seed
Coated seeds as disclosed in the examples herein before were planted in test plots and an assessed for germination. The germination of the coated seeds was a good as or better than control samples. Also, the coated seeds handled well in the application equipment in that they resisted dust formation and flowed well without sticking.
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The invention pertains to a seed coating composition comprising a certain latex binder and/or graft polymer dispersant. The seed coating composition imparts good color to treated seeds, has excellent durability, and is non-sticky after application to allow for smooth flow of coated seed in planting equipment.
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BACKGROUND OF THE INVENTION
This invention relates to a resin-molded type ignition coil assembly for internal combustion engines (e.g., U.S. Pat. No. 4,763,094 issued on Aug. 9, 1988 and assigned to the same assignee with this invention, and particularly to one which uses a case molded integral with an external iron core.
FIG. 6 is a partial cross-sectional front view of a conventional ignition coil assembly for internal combustion engines, and FIG. 7 is a partial cross-sectional plan view taken along a line B--B in FIG. 6.
This ignition coil assembly for internal combustion engines is a resin-molded type ignition assembly for internal combustion engines which uses a case molded integral with an external iron core (hereinafter, referred to as the core-case integral-type combustion engine-purpose ignition coil assembly). This core-case integral-type combustion engine-purpose ignition coil assembly comprises a primary coil 1a, a secondary coil 2a coaxially disposed on the outside of the primary coil 1a, an internal iron core 3a inserted through the primary and secondary coils 1a and 2a, an external iron core 4a combined with the internal iron core 3a to constitute a closed magnetic path, a resin case 5a which is made of a resin material to be integral with the external iron core 4a and to have a mold space portion 50a, and a molded resin portion 6a which is formed by injecting a resin material into the mold space portion 50a in which the primary and secondary coils 1a and 2a and the internal iron core 3a are placed.
In this core-case integral-type combustion engine-purpose ignition coil assembly, a central partitioning wall portion 51a of the case 5a which separates a central portion 40a of the external iron core 4a which is parallel to the internal iron core 3a, from the mold space 50a is formed to be thick and to be in intimate contact with the central portion 40a of the external iron core 4a.
This thick wall of the central partitioning wall portion assures the insulation between the low-potential external iron core 4a and the high-potential secondary coil 2a.
When the central partitioning portion 51a of the case 5a which separates the central portion 40a of the external iron core 4a and the mold space portion 50a is molded thick enough to increase the dielectric strength, however, internal defects 100 such as nests and voids may be caused in the central partitioning wall portion 51a of the case 5a. When the internal defects are caused in the central partitioning wall portion 51a of the case 5a, a corona discharge may occur within the internal defects 100 upon operation and it will lead to reduce the insulation ability of the case 5a and finally to make the insulation breakdown.
On the contrary, when the central partitioning wall portion 51a of the case 5a is made thin in order to avoid the problem, the distance between the external iron core 4a and the secondary coil 2a becomes short and thus the strength of the electric field across the central partitioning wall portion 51a of the case 5a increases. As a result, a corona discharge may occur across the very small gap (not shown) of the boundary between the corner 48a, 49a of the external iron core 4a where the electric field strength is the highest, and the central partitioning wall portion 51a of the case 5a. When a corona discharge is caused thereat, the insulation ability of the case 5a is deteriorated as described above and finally the insulation may be broken down. The very small gap is created depending on the difference between the thermal expansion coefficients of the external iron core 4a and the case 5a.
SUMMARY OF THE INVENTION
In view of the foregoing, it is an object of this invention to provide an ignition coil assembly for internal combustion engines which does not easily cause any corona discharge and has high reliability.
According to a typical aspect of this invention, there is provided an ignition coil assembly for internal combustion engines, comprising a primary coil, a secondary coil coaxially disposed around the primary coil, an internal iron core inserted through the primary and secondary coils to form part of a closed magnetic path, an external iron core combined with the internal iron core to constitute the closed magnetic path and which has its central portion extended along the internal iron core with a constant distance kept therebetween, a resin-molded case which has a mold space portion containing the primary and secondary coils and the internal iron core, a withstand voltage air gap of a predetermined shape provided between the mold space portion and the central portion of the external iron core, and a central partitioning wall portion provided between the withstand voltage air gap and the mold space portion, and which resin-molded case is formed to be integral with the external iron core, and a mold resin portion which is formed by injecting a resin material into the mold space portion so as to surround and fix the primary and secondary coils and the internal iron core.
The thickness of the central partitioning wall portion is selected to be preferably, for example, in a range from the lower limit of about 0.5 mm from the molding point of view to the upper limit of about 3.5 mm from the viewpoint of nests, voids and so on to begin occurring, though the values depend on the conditions of molding the case.
The thickness of the withstand voltage air gap is selected to be preferably, for example, in a range from about 0.75 mm to 6 mm. In other words, when the thickness of the withstand voltage air gap is less than about 0.75 mm, the distance between the external iron core and the secondary coil becomes short, and thus the field strength in the withstand voltage air gap is increased. This may cause a corona discharge. Although it is better that the withstand voltage air gap can resist a higher voltage, excessive increase of the dielectric strength will uselessly make the assembly large-sized. As a result, the preferable thickness of the withstand voltage air gap should be in the above range in which at least a corona discharge can be prevented fully.
Since the electric field of interest here is most concentrated at around the corner of the external iron core, it is desired to provide the withstand voltage air gap at least between the corner of the external iron core and the secondary coil. In order to prevent the peculiar concentration of the field within the withstand voltage air gap, the thickness of the withstand voltage air gap should be made substantially constant and the inner surface of the withstand voltage air gap should be smooth.
The internal defects such as nests and voids which are easy to occur in the central partitioning wall portion of a thick wall of the prior art can be considered as a kind of air gap. These internal defects are irregular in the shape and size, thus causing the concentration of field which is not predictable, and hence a corona discharge.
In the ignition coil assembly for internal combustion engines of this invention, a withstand voltage air gap of a predetermined shape and a central partitioning wall portion which makes part of the case and separates the withstand voltage air gap from the mold space are provided between the mold space in which the secondary coil is placed and a mold resin is filled, and the external iron core. Therefore, part of the thickness of the central partitioning wall portion is, in a sense, replaced by the withstand voltage air gap so that the central partitioning wall portion is made thin enough not to cause within itself the nest and the void.
Thus, the electric field strength between the secondary coil and the external iron core is divided by the mold resin portion within the nold space, the central partitioning wall portion and the withstand voltage air gap.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially cross-sectional plan view of a first embodiment of an ignition coil assembly for internal combustion engines of this invention;
FIG. 2 is a partially cross-sectional front view taken along a line A--A' in FIG. 1;
FIGS. 3, 4 and 5 are partially cross-sectional front views of other embodiments of an ignition coil assembly for internal combustion engines of this invention;
FIG. 6 is a partially cross-sectional plan view of a conventional ignition coil assembly for internal combustion engines; and
FIG. 7 is a partially cross-sectional front view of the ignition coil assembly for internal combustion engines of FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
EMBODIMENT 1
One embodiment of an ignition coil assembly for internal combustion engines according to this invention will be described with reference to FIGS. 1 and 2. FIG. 1 is a partial cross-sectional plan view of the one embodiment, and FIG. 2 is a partial cross-sectional front view taken along a line A--A' in FIG. 1.
This ignition coil assembly for internal combustion engines comprises a primary coil 1, a secondary coil 2 coaxially disposed around the outside of the primary coil 1, an internal iron core 3 which is inserted through the primary and secondary coils 1 and 2, an external iron core 4 which is combined with the internal iron core 3 to constitute a closed magnetic path, a case 5 which is molded integral with the external iron core 4 and has a mold space 50, and a molded resin portion 6 which is formed by injecting a resin material into the mold space 50.
The internal iron core 3 is an I-shaped core of a cylindrical shape and of a rectangular shape in cross-section which is produced by stacking a great number of silicon steel laminas of the same shape. Around the outside of the internal iron core 3 is provided a primary spool 10 of a prism shape and of a predetermined wall thickness which is integrally molded with a thermoplastic resin. The internal iron core 3 has flux penetration surfaces 31, 32 at the opposite ends of the internal iron core 3. The flux penetration surfaces coincide with the ends 11, 12 of the primary spool 10, respectively. Ribs 10a are projected from near the ends 11, 12 of the primary spool 10. The primary coil 1 is wound around the outside of the primary spool 10. Also, the primary spool 10 is coaxially inserted in a secondary spool 20 substantially of a prism shape and the opposite ends of the inner peripheral surface of the secondary spool 20 are supported by the ribs 10a of the primary spool 10. The secondary spool 20 has a great number of ribs 20a with a predetermined spacing provided to project from its outer peripheral surface in the direction perpendicular to the axis of the core 3. Moreover, a large rib 20b is projected from each of the opposite ends of the outer peripheral surface of the secondary spool 20, and the secondary coil 2 is wound on the secondary spool 20.
The external iron core 4 is formed of a great number of silicon steel laminas of the same shape to be substantially U-shaped with its cross-section being rectangular. Moreover, this U-shaped external iron core has a central portion 40, and arms 42, 43 extending from both ends of the central portion 40 at right angles to the central portion 40. The arms 42, 43 have provided at their ends opposite magnetic flux penetration surfaces 44, 45 of a square shape, between which the internal iron core 3 is fitted so that the flux penetration surfaces 44, 45 of the external iron core 4, respectively oppose the flux penetration surfaces 31, 32 of the internal iron core 3 through a slight gap. The central portion 40 of the external iron core 4 has apertures 47a, 47b for insertion of clamping bolts bored at its opposite ends in the direction of stacking the silicon steel laminas.
The resin case 5 has a thin wall of a cup-like shape with its upper end opened and forms the mold space 50 of a substantially rectangular parallel-piped shape. In other words, the case 5 has a flat bottom portion 52 of a substantially rectangular shape, from the respective sides of which are integrally extended upwards a first side wall portion 53, a second side wall portion 54, a third side wall portion 55 and a fourth side wall portion (not shown). The second and third side wall portions 54, 55 are parallel and the first and fourth side wall portions 53 are parallel.
Moreover, slightly below the outer surface of the first side wall portion 53 is formed an external iron core cover 58 which is made of a resin (see FIG. 2). The wall thickness of the cover which covers the surface of the external iron core 4 is substantially constant. In this embodiment, the lower surface 46 of the external iron core 4 and the inner peripheral surface of the apertures 47a, 47b are not covered by this external iron core cover 58 but exposed to the external. The ends of the arms 42, 43 of the external iron core 4 reach the outsides of the second and third side wall portions 54, 55 of the case 5, and the flux penetration surfaces 44, 45 of the external iron core 4 are exposed to the mold space 50. In the mold space 50 are enclosed the primary coil 1, the secondary coil 2, the internal iron core 3, the primary spool 10 and the secondary spool 20. As described above, the flux penetration surfaces 44, 45 of the external iron core 4 are respectively opposed to the flux penetration surfaces 31, 32 of the internal iron core 3 through a slight gap.
The inside portion, 58a of the cover 58 of the case 5 which covers the central portion 40 of the external iron core 4 is opposed to the first side wall portion 53 of the case 5 through a withstand voltage air gap 57 about 2.5 mm wide. The upper and lower ends of the withstand voltage portion 57, as shown in FIG. 2, have openings 57a, 57b for communicating to the external space.
The molded resin portion 6 is formed by injecting a thermoplastic resin such as epoxy resin into the mold space 50 of the case 5 and fixes and protects the primary coil 1, the secondary coil 2 and the internal iron core 3 enclosed in the mold space 50. As described above, between the first side wall portion 53 of the case 5 and the external iron core 4 are located the inner side portion 58a of the external iron core cover 58 of which the wall thickness is about 1.5 mm, and the withstand voltage air gap 57 about 2.5 mm thick.
Upon operation of the ignition coil assembly for internal combustion engines, the external iron core 4 is grounded and the secondary coil 2 is at a high potential. The potential difference between the external iron core 4 and the secondary coil 2 is divided by the inner side portion 58a of the external iron core cover 58, the withstand voltage air gap 57, the first side wall portion 53 and the mold resin 6 in the mold space portion.
Thus, the strength of electric field between the external iron core 4 and the secondary coil 2 is decreased by the withstand voltage air gap 57. Therefore, even if the first side wall portion 53 of the case 5 and the inside portion 58a of the external iron core cover 58 thereof are decreased in the wall thickness, no corona discharge occurs between the external iron core 4 and the secondary coil 2. Particularly, the electric field flux between the external iron core 4 and the secondary coil 2 is normally collected at the corners 48, 49 of the external iron core 4, but in this embodiment, since the withstand voltage air gap 57 is larger than the total height h (see FIG. 2) of the external iron core 4, the electric field flux is fully prevented from being collected at around the corners 48, 49 of the external iron core 4.
Moreover, since the first side wall portion 53 of the case 5 and the wall of the external iron core cover 58 thereof are thin, internal defects such as nests and voids are difficult to occur.
EMBODIMENT 2
FIG. 3 is a partial cross-sectional front view of a second embodiment of an ignition coil assembly for internal combustion engines of this invention. In this figure, like elements corresponding to those in the first embodiment are identified by the same reference numerals.
This ignition coil assembly for internal combustion engines comprises the first coil 1, the second coil 2, the internal iron core 3, the external iron core 4, the case 5 and the molded resin portion 6. The second embodiment is different from the first embodiment only in the shape of part of the case 5.
In other words, in the case 5, the external iron core cover 58 and the first side wall portion 53 are connected at the upper end of the withstand voltage air gap 57, and as a result the withstand voltage air gap 57 and the external space are not communicated with each other at the upper side.
In this embodiment, since the withstand voltage air gap 57 is extended above the corner 48 of the external iron core 4, the electric field flux is fully prevented from being collected at near the corner 48 of the external iron core 4.
EMBODIMENT 3
FIG. 4 is a partial cross-sectional front diagram of a third embodiment of an ignition coil assembly for internal combustion engines of this invention. In FIG. 4, like elements corresponding to those in the second embodiment are identified by the same reference numerals.
This ignition coil assembly for internal combustion engines comprises the first coil 1, the secondary coil 2, the internal iron core 3, the external iron core 4, the case 5 and the molded resin portion 6. The third embodiment is different from the second embodiment only in the shape of part of the case 5.
In other words, in this case 5, the inside portion 58a (see FIG. 3) of the external iron core cover 58 in the embodiment 2 is replaced by the withstand voltage air gap 57, so that the dielectric strength of the withstand voltage air gap 57 can be further increased.
EMBODIMENT 4
FIG. 5 is a partially cross-sectional front view of a fourth embodiment of an ignition coil assembly for internal combustion engines of this invention. In FIG. 5, like elements corresponding to those in the first embodiment are identified by the same reference numerals.
This ignition coil assembly for internal combustion engines comprises the first coil 1, the secondary coil 2, the internal iron core 3, the external iron core 4, the case 5 and the molded resin portion 6. This embodiment is different from the embodiment 3 only in the shape of part of the case 5.
In this embodiment, the external iron core cover 58 has large recesses 48m, 48n provided at the positions close to the corners 48, 49 of the case 5, which prevent a discharge from being caused along the surface of the external iron core cover 58.
According to the ignition coil assembly for internal combustion engines of this invention, as described above, since the withstand voltage air gap of a predetermined shape is provided between the central partitioning wall portion of the case having the mold space portion in which the primary coil, the secondary coil and the internal iron core are enclosed, and the central portion of the external iron core close to this central partitioning wall portion, no corona discharge is difficult to occur, and thus the insulation ability of the case can be prevented from deteriorating even if the central partitioning wall portion of the case is decreased in its thickness.
Moreover, since the central partitioning wall portion of the case can be decreased in its thickness, internal defects such as nests and voids of irregular shapes through which a corona discharge is easy to occur can be suppressed from being caused.
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An ignition coil assembly for internal combustion engine has a voltage withstanding air gap of a predetermined shape and an insulating resin cover for covering the external iron core provided in addition to resin mold and partitioning wall in order to electrically insulate from the secondary coil the external iron core constituting a magnetic path together with the internal iron core.
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FIELD OF THE INVENTION
[0001] The present invention addresses novel polycarboxylic ligand molecules and chelated complexes of said ligands with metals; the metals are for instance transition metals, e.g. paramagnetic metals for generating responses in the field of magnetic resonance imaging (MRI)
[0002] The present polycarboxylic ligands exhibit outstanding tensioactive properties which make them particularly useful in the form of paramagnetic chelates for making formulations and compositions useful as MRI contrast media of controllable and long lasting activity in the blood pool.
BACKGROUND ART
[0003] U.S. Pat. No. 5,466,438 (WO 92/231017) discloses compounds of formulae
[0004] in which formulae I-III:
[0005] R 1 is independently a substituted or unsubstituted C 7-30 straight chain or cyclic compound;
[0006] R 2 is independently a substituted or unsubstituted C 1 -C 30 straight chain or cyclic compound which may be internally interrupted by O, NH, NR 3 or S, where R 3 is a C 1 -C 3 alkyl;
[0007] n is 0-1 in formula I and 1-20 in formula III;
[0008] m is 1-2;
[0009] B is a substituted or unsubstituted C 1 -C 30 straight chain or cyclic compound which may be internally interrupted by O, NH, NR 3 or S.
[0010] In formula IV:
[0011] R 1 , R 2 are independently H or a substituted or unsubstituted C 7 -C 30 straight chain or cyclic compound;
[0012] R 3 , R 4 are independently H or a substituted or unsubstituted C 1 -C 30 straight chain or cyclic compound which may be internally interrupted by O, NH, NR 5 or S, where R 5 is a C 1 -C 3 alkyl;
[0013] and in formula V:
[0014] R 1 is independently a substituted or unsubstituted C 7 -C 30 straight chain or cyclic compound
[0015] R 2 is independently a substituted or unsubstituted C 1 -C 30 straight chain or cyclic compound which may be internally interrupted by O, NH, NR 4 or S, where R 4 is a C 1 -C 3 alkyl;
[0016] R 3 is independently a substituted or unsubstituted C 1 -C 30 straight chain or cyclic compound which may be internally interrupted by O, NH, NR 4 or S, where R 4 is a C 1 -C 3 alkyl and
[0017] m is 0-12.
[0018] The reference also discloses contrast agents obtained with the compounds of the above formulae (I-V), the latter further comprising lipids; the lipids are in the form of emulsions, liposomes or micelles.
[0019] U.S. Pat. No. 5,312,617 dicloses a method of imaging comprising administering to patients a contrast agent comprising a complex of a paramagnetic metal and a ligand selected from formulae IV and V disclosed in the foregoing U.S. Pat. No. 5,466,438.
[0020] Liposomes incorporating the above chelates are also disclosed as well as the possibility of having the compounds in the form of emulsions or micelles.
[0021] The micelles can be prepared by a variety of conventional liposome preparatory techniques; suitable lipids include, for example, monomyristoyl-phosphatidyl-choline, monopalmitoyl-phosphatidylcholine, dibutyroyl-phosphatidylcholine and the like, linoleic acid, oleic acid, palmitic acid, and the like.
[0022] Lipid emulsions can be prepared by conventional techniques, for instance a typical method is as follows:
[0023] 1. In a suitable flask, the lipids are dissolved in ethanol or chloroform or any other suitable organic solvent.
[0024] 2. The solvent is evaporated leaving a thin layer of lipid at the bottom of the flask.
[0025] 3. The lipids are resuspended in an aqueous medium, such as phosphate buffered saline, this producing an emulsion
[0026] 4. Sonication or microfluidization can then be applied to improve homogeneity.
[0027] 5. The contrast agents can be added to the lipids during preparation of the emulsion, or they may be added to the emulsion afterwards.
[0028] 6. Useful additives include, for example, soybean lecithin, glucose, Pluronic F-68 and D,L-α-tocopherol; these additives are particularly useful where injectable intravenous formulations are desired.
[0029] The foregoing contrast agents may further comprise suspension stabilizers such as polyethyleneglycol, lactose, mannitol, sorbitol, ethyl alcohol, glycerin, lecithin, polyoxyethylene sorbitan monoleate, sorbitan monoleate and albumin. Various sugars and other polymers may also be added, such as polyethylene glycol, polyvinylpyrrolidone, polypropylene glycol and polyoxyethylene.
[0030] The contrast agents of this reference have high T 1 and T 2 relaxivity, especially when lipids are also present. Because of the high relaxivity, these contrast media are particularly useful for imaging the blood pool.
SUMMARY OF THE INVENTION
[0031] Despite the merit of the paramagnetic polycarboxylic chelates of the prior art as contrast agents for MRI, there was a need for a new range of chelating compounds of further improved properties designed to provide blood-pool contrast agents of outstanding long life in the circulation. In view of their structure including strongly hydrophobic and hydrophilic moieties, the compounds of the present invention achieve a significant step in the right direction.
[0032] The novel compounds of the present invention, either racemic or enantiomeric, have the following formulae (\) and (IV)
[0033] in which n and m are 1 or 0 but not simultaneously 1, and
[0034] when n=m=0, R′ is H, and R* is a C 12-25 linear or ramified, saturated or unsaturated, hydrocarbon radical;
[0035] when n=1 and m=0, R* is H or a C 1-3 alkyl or alkylene substituent; and R′ is selected from —NHR 3 , —NR 4 R 5 and —OR 6 where the R 3 to R 6 are independently C 1-25 linear or ramified, saturated or unsaturated, hydrocarbon radicals optionally interrupted by —CO—and/or —O—and optionally terminated by —NR 7 R 8 in which R 7 and R 8 are independently H or C 12-25 hydrocarbon radicals;
[0036] when n=0 and m=1, R* is H or a C 1-3 alkyl or alkylene substituent; and R′ is selected from R 9 and —CH 2 —O—CO—R 9 in which R 9 is a C 10-30 linear or ramified, saturated or unsaturated, hydrocarbon radical optionally interrupted by —NH—, —NR 10 —, —CO— or —O—, R 10 being a lower aliphatic hydrocarbon; and
[0037] R 12 is H or a C 12-30 hydrocarbon radical optionally interrupted by —NH—, —NR 10 —, —CO—or —O—and optionally terminated by a cholesteryl residue, and the R 13 are —OH; or one or two R 13 are a —NH—R 14 group in which R 14 is a C 2-30 linear or ramified, saturated or unsaturated, hydrocarbon radical optionally interrupted by —NH—, -NR 10 —, —CO—, —O—, and/or —OPO(OH)O—, the remaining R 13 being —OH.
[0038] The compounds of formulae (\) and (IV) can be used as chelates of paramagnetic metals, preferably Gd(III), Mn(II), Cr(III), Cu(II), Fe(III), Pr(III), Nd(III), Sm(III), Tb(III), Yb(III), Dy(III), Ho(III) and Er(III) in the preparation of MRI contrast formulations and compositions of outstanding long life in the blood which makes them ideal agents for investigating the circulation in appended organs.
DETAILED DESCRIPTION OF THE INVENTION
[0039] Preferred are the compounds encompassed by formula (\), in which n and m are 1 or 0 but not simultaneously 1, and when n=1 and m=0, R* is an alkylene group, and the other variable groups are the meanings defined above.
[0040] Equally preferred are the compounds, encompassed by formula (\), in which n and m are 1 or 0 but not simultaneously 1, and when n=1 and m=0, R* is H or a C 1-3 alkyl; and R′ is selected from —NHR 3, or —NR 4 R 5 , where the R 3 to R 5 groups are independently C 12-25 linear or ramified, saturated or unsaturated, hydrocarbon radicals, optionally interrupted by —CO—and/or —O—and optionally terminated by —NR 7 R 8 in which R 7 and R 8 are independently H or C 12-25 hydrocarbon radicals with the same meaning just above defined.
[0041] Equally preferred are the compounds encompassed by formula (\), in which n and m are 1 or 0 but not simultaneously 1, and when n=0 and m=1, R* is an alkylene group, and the other variable groups are the meaning defined above.
[0042] Equally preferred are the compounds encompassed by formula (\), in which n and m are 1 or 0 but not simultaneously 1, and when n=1 and m=0, R* is H or a C 1-3 alkyl;and R′ is selected from R 9 and —CH 2 —O—CO—R 9 in which R 9 is a C 12-25 linear or ramified, saturated or unsaturated, hydrocarbon radical optionally interrupted by —NH—, —NR 10 —, —CO—or —O—, R 10 being a C 1-4 linear or ramified, saturated or unsaturated, hydrocarbon radical.
[0043] Furthermore are prefered the compounds of general formula (IV) in which R 12 is H, and two R 13 are a —NH—R 14 group in which R 1 4 is a C 12-25 linear or ramified, saturated or unsaturated, hydrocarbon radical optionally interrupted by —NH—, —NR 10 —, —CO—, —O—, and/or —OPO(OH)O—, the remaining R 13 being —OH.
[0044] The compounds of formula (\) are preferably selected among compounds of the following formulae (I), (II) or (III)
[0045] wherein R* is as defined heretofore;
[0046] R is H or a C 1-3 alkyl or alkylene substituent;
[0047] R 1 is selected from —NHR 3 , —NR 4 R 5 and —OR 6 where the R 3 to R 6 are independently C 1-25 linear or ramified, saturated or unsaturated, hydrocarbon radicals optionally interrupted by —CO—and/or —O—and optionally terminated by —NR 7 R 8 in which R 7 and R 8 are independently H or C 12-25 hydrocarbon radicals;
[0048] R 2 is selected from R 9 and —CH 2 —O—CO—R 9 in which R 9 is a C 10-60 linear or ramified, saturated or unsaturated, hydrocarbon radical optionally interrupted by one or more —NH—, —NR 10 —, —CO—or —O—, R 10 being a lower aliphatic hydrocarbon.
[0049] For instance, the compounds of formula (II) can have formula (IIa)
[0050] in which R 3 is a C 12-25 linear or ramified, saturated or unsaturated, hydrocarbon radical.
[0051] Particularly preferred are the compounds of formula (IIa) in which R 3 is a C 16-20 linear or ramified, saturated or unsaturated, hydrocarbon radical.
[0052] Or they can have formula (IIb)
[0053] in which R 4 and R 5 are independently C 12-25 linear or ramified, saturated or unsaturated, hydrocarbon radicals optionally interrupted by —CO—and/or —O—.
[0054] Particularly preferred are the compounds of formula (IIb) in which R 4 and R 5 are independently C 16-20 linear or ramified, saturated or unsaturated, hydrocarbon radicals interrupted by —CO—and —O—.
[0055] Furthermore, they can have formula (IIc)
[0056] in which A is —NH—or —O—, A 1 is a C 1-20 linear or ramified, saturated or unsaturated, hydrocarbon radicals optionally interrupted by —CO—and/or —O—and R 7 and R 8 are defined as above.
[0057] Particularly preferred are the compounds of formula (IIc) in which R is an alkylene substituent.
[0058] Equally preferred are the compounds of formula (IIc) in which A is —NH—, A 1 is a C 1-20 linear or ramified, saturated or unsaturated, hydrocarbon radicals interrupted by —CO—and —O—and R 7 and R 8 are defined as above. Also the compounds of formula (IIc) are preferred in which A is —O—and A 1 is a C 1-20 linear or ramified, saturated or unsaturated, hydrocarbon radicals interrupted by —CO—and —O—and R 7 and R 8 are defined as above.
[0059] Compounds of formula (III) can have formula (IIIa)
[0060] in which R is H and R 2 is is a C 10-30 linear or ramified, saturated or unsaturated, hydrocarbon radical optionally interrupted by one or more —NH—, —N—, —CO—or —O. Otherwise, they can have formula (IIIb) below
[0061] in which R is H and R 9 is a C 10-25 linear alkyl, or a C 10-50 linear or ramified, saturated or unsaturated, hydrocarbon radical optionally interrupted by one or more —N—, —CO—and/or —O—.
[0062] Some preferred compounds of formula (IV) are those in which all the R 13 are —OH and R 12 is defined as mentioned above. Otherwise, compounds of formula (IV) can be selected from the compounds of formulae (IVa) and (IVb) below. In Formula (IVa),
[0063] the R 14 are independently as defined above for formula (IV).
[0064] Particularly preferred are the compounds of formula (Iva) in which R 14 is C 12-25 linear or ramified, saturated or unsaturated, hydrocarbon radical optionally interrupted by —CO—and/or—O—, and/or -OPO(OH)O—.
[0065] In formula (IVb) shown below,
[0066] R 14 is a C 12-25 linear or ramified, saturated or unsaturated, hydrocarbon radical.
[0067] The compounds of this invention of formulae (\) and (IV) can be as represented in the formulae, or they can be in the form of complex chelates with paramagnetic metal ions (as indicated heretofore) and the salts thereof with physiologically acceptable bases selected from primary, secondary, tertiary amines and basic aminoacids, or inorganic hydroxides of sodium, potassium, magnesium, calcium or mixtures thereof;
[0068] or with physiologically acceptable anions of organic acids selected from acetate, succinate, citrate, fumarate, maleate, oxalate, or inorganic acids selected from hydrogen halides, sulphates, phosphates, phosphonates and the like;
[0069] or with cations or anions of aminoacids selected from lysine, arginine, ornithine, aspartic and glutamic acids, and the like;
[0070] For preparing the compounds of formula (I) in the form of complexes with metals (ME), one can proceed as in the following Scheme 1
[0071] Where Pg is a protecting group;
[0072] R* is as defined for formula (I);
[0073] ME n+ is a metal ion;
[0074] n=2 or 3.
[0075] In step al the compound 1A, i.e. 1,4,7,10-tetraazacyclododecane-1,4,7-triacetic acid, whose carboxylic groups are suitably protected by groups such as benzyl or t-butyl, is reacted with R*—X, where R* is a substituent residue and X is a leaving group such as Cl, Br, I. The reaction product is then deprotected by known methods (e.g. with CF 3 COOH) to give the free ligand 1B. The ligand is then complexed with a suitable metal ion oxide or salt (preferably paramagnetic), such as Gd oxide, chloride or acetate, in order to obtain the desired metal complex chelate 1C. Depending on the value of n, 1C may be salified with a suitable counter-ion.
[0076] For the complexes of the compounds of formula (IIa), one may proceed according to the scheme 2 below:
[0077] in which Pg is a protecting group as in Scheme 1;
[0078] R and R 3 have been defined above; and ME and n are as in Scheme 1.
[0079] According to the method of Scheme 2, one prepares compound 2C by the reaction of a halogenated halide (or equivalent) with a primary amine R 3 NH 2 in a suitable solvent, such as CH 2 Cl 2 , CHCl 3 or H 2 O/CH 2 Cl 2 mixtures, in the presnce of a base (e.g. K 2 CO 3 ). Then, Compound 2C is reacted with compound 2D and the product is deprotected (b2) to furnish the desired free ligand 2E. The latter is finally complexed according to the general procedure disclosed in Scheme 1. If required, i.e. depending on whether n has an appropriate value, compound 2F may be salified with a suitable counter-ion.
[0080] For preparing the metal complexes of the compounds of formula (IIb), one may proceed according to the Scheme 3 below:
[0081] in which n=1-6; p=0-5; m=2 or 3; Y=halogen; Pg is a protecting group and Alk is a lipophilic alkyl chain.
[0082] In step a3 compound 3A is reacted with a suitable long-chain carboxylic acid halide 3B in a suitable aprotic dipolar solvent to obtain compound 3C. The latter is reacted (step b3) with compound 3D, i.e. 1,4,7,10-tetraazα-cyclododecane-1,4,7,10-tetraacetic acid of which three acetic groups are protected with, for example, benzyl or t-butyl groups, in the presence of 1-propanephosphonic acid cyclic anhydride (PPAA) and a base (e.g. Et 3 N) in a suitable solvent such as CH 2 Cl 2 .
[0083] Compound 3E obtained in step C 3 is deprotected by known methods (e.g. by catalytic hydrogenation) which provides the free ligand 3F, which is then complexed with a metal (step d3), according to the procedure described earlier. This affords the desired complex chelate 3G. Then, compound 3G may be salified with a suitable counter-ion if the value of m permits.
[0084] For preparing the compounds of formula (Iic) in which A is —NH—, one can proceed like in the previous scheme, the first step (condensation of triprotected 1,4,7,10-tetraazacyclododecane-1,4,7,10-tetraacetic acid (4A) with an amine H 2 N—A 1 —NR 7 R 8 (4B) being effected in the presence, as condensing a agent, of (benzotriazo-1-yloxy)-tris(dimethylamino)-phosphonium hexafluorophosphate and a sterically hindered tertiary amine such as diisopropylethylamine (DIEA) when 4B is an α-aminoacid derivative, or N,N′-bis(2-oxo-3-oxazolidyl)-phosphoro-diamidic chloride (BOP). This is illustrated in Scheme 4.
[0085] A similar method can be applied for compounds (IIc) in which A is —O—, i.e. the esterification of triprotected 1,4,7,10-tetraazacyclododecane-1,4,7,10-tetraacetic acid with a halogenated compound X—A 1 —NR 7 R 8 in the presence of 1,8-diazabicyclo[5.4.0]undecene. Then the resulting intermediate 5C is deprotected, complexed and salified as in the previous schemes (Scheme 5).
[0086] The compounds of formula (IIIa) can be obtained as illustrated in Scheme 6. The protected 1,4,7,10-tetraazacyclododecane-1,4,7-triacetic acid 6A is reacted with an alkyl epoxide
[0087] in a solvent such as ethanol and the resulting product is deprotected and treated as described in the previous schemes
[0088] A possible technique for making the compounds (IIIb) and the corresponding metal chelates and salts is illustrated in Scheme 7. Here the initial reactant to be condensed with the triprotected 1,4,7,10-tetraaza-cyclododecane-1,4,7-triaacetic acid is 2,3-epoxypropanol 7B which provides the vic-diol 7C, the primary —OH of which is thereafter esterified with an acid R 9 —COOH, the remaining steps being as described previously.
[0089] The following preparative methods are applicable regarding the compounds of formula (IV) in which R 12 is H. For instance, for the compounds (IVa), one may operate as illustrated in Scheme 8, by reacting in DMF the DTPA cyclic dianhydride (N,N-bis[2-(2,6-dioxo-4-morpholinyl)ethyl]gly-cine) 8A with an amine H 2 NR 14 , the remaining step being that of complexation with a metal and possible salification as discussed earlier.
[0090] Otherwise, one may first effect protection of up to four of the —COOH's groups in DTPA, the unprotected group being thereafter amidated in DMF with an amine H 2 NR 14 according to usual means (see Scheme 9).
[0091] One preparative route for the compounds of formula (IV) with a substituent R 12 in α- to the central carboxylic function is to first attach in the said position, a carbon chain functionalized with, for example, a —NH 2 or —COOH group (Scheme 10). For example, compound 10A can be prepared, according to Rapoport et al. in J. Org. Chem. 58 (1993), 1151-1158, or using a method disclosed in WO 98/05626. The synthon is then reacted with, for example, a chloride of a carboxylic acid having the desired chain length, or with a suitable amine, depending on the nature of the said functional group. Then, the resulting compound 10B is deprotected and complexed as already shown in the previous Schemes.
[0092] This technique is exemplified in the synthesis of the compound of Example 16 involving reaction with cholesteryl chloroformate.
[0093] The injectable compositions and formulations according to the invention which are usable as contrast agents for MRI investigations will preferably contain further additives, in addition to one or more of the afore discussed novel paramagnetic chelates and a carrier liquid. The additives include non-ionic and/or ionic surfactants and mixtures thereof, as well as other amphipatic compounds. Due to their physiological suitability, the non-ionic surfactants are preferred. The non-ionic surfactants are preferably block-copolymers having polyoxyethylene and polyoxypropylene sequences, polyethyleneglycol-alkylethers such as, for example, polyethyleneglycol-octadecylether, or polyoxyethylene fatty acid esters or polyoxyethylene sorbitan fatty acid esters, or n-alkyl glycopyranoside and n-alkyl maltotrioside. The non-ionic surfactant in the compositions of the invention is conveniently selected from the commercially available products, such as Pluronic®, Poloxamer®, Poloxamine®, Synperonic®, BRIJ®, Myrj®, Tween®s (polysorbates) and their mixtures. The weight proportion of the surfactant relative to the amount of the paramagnetic imaging agent is from 1:50 to 50:1, preferably 1:10 to 10:1, and even more preferably 1:1. The ionic surfactants preferably include biliary acid salts such as sodium deoxycholate.
[0094] The amphipatic compounds suitable in the present compositions are phospholipids which may be selected from phosphatidic acid (PA), phosphatidylcholine (PC), phosphatidylethanolamine (PE), phosphatidylserine (PS), phosphatidylglycerol (PG), phosphatidylinositol (PI), cardiolipin (CL) and sphyngomielin (SM). The amphipatic compound may also consists of a monophosphate ester of a substituted or partially substituted glycerol, at least one functional group of said glycerol being esterified by saturated or unsaturated aliphatic fatty acid, or etherified by saturated or unsaturated alcohol, the other two acidic functions of the phosphoric acid being either free or salified with alkali or earth-alkali metals. Preferably the phosphate esters will include monophosphates of fatty acid glycerides selected from dimiristoylphosphatidic acid, dipalmitoylphosphatidic acid, or distearoylphosphatidic acid.
[0095] The phospholipids may also include diacyl and dialkyl glycerophospholipids in which the aliphatic chains have at least twelve carbon atoms, as well as one or more compounds selected from ionic and neutral phospholipids, monoalkyl or alkenyl esters of phosphoric acid and/or cholesterol, ergosterol, phytosterol, sitosterol, lanosterol, tocopherol. In the compositions containing phospholipids, the weight proportion of the phospholipids to the amphiphilic chelate seems not critical and it may vary, for example, from 1:50 to 50:1. The practical range will be between 10:1 and 1:10, preferably between 1:5 and 5:1 and even more preferably between 1:3 and 3:1. In the compositions in which phospholipids are used the weight ratio of the phospholipid to the surfactant may vary as above, however the ranges from 1:10 to 10:1 and, preferably, between 1:2 and 2:1 are considered optimal.
[0096] The compositions of the present invention may exist in micellar form, in which case they can be prepared using known techniques, namely as described in WO 97/00087; Polym. Prepr. 1997, 38(1), 545-546; Acad. Radiol. 1996, 3, 232-238. These documents describe micelles of amphiphilic Gd chelates useful in percutaneous lymphography. The micelles have particle size between 10 and 500 nm, preferably between 50 and 200 nm.
[0097] The micelles can be prepared in any physiologically acceptable aqueous liquid carrier, such as water or saline, neat or bufferd, according to usual practice. Depending upon the choice of the components, the dispersion can be achieved by gentle mixing or by more energetic means, such as homogenisation, microfluidization or sonication.
[0098] In an advantageous mode of preparing the micelles of the invention, one part by weight of the paramagnetic chelate contrast component is admixed with one to two parts each of surfactants and of lipids, and with 100 to 200 parts of liquid carrier, for example Tris/Glycerol buffer.
[0099] The compositions can be stored and used as such, or may be lyophilized dry, according to known methods, e.g. by freeze-drying. This dry form (porous lumps or free flowing powder) is particularly convenient for long-term storage. The formulations can be reconstituted before usage by dispersion of the lyophilizate in a physiologically acceptable liquid carrier, thus obtaining a suspension corresponding to the early formulation and directly usable as NMR imaging contrast agent.
[0100] For practically applying the compositions of the invention in the medical field, the lyophilized components and the carrier liquid can be marketed separately in a kit form. The lyophilized components may be stored under a dry, inert atmosphere ant the carrier liquid may further contain isotonic additives and other physiologically acceptable ingredients, such as various mineral salts, vitamins, etc.
[0101] The compositions of the invention are particularly useful as magnetic resonance contrast agents for the imaging of the blood pool. They have shown to possess a sufficiently high relaxivity effect on the blood after injection in the rat and an exceptionally favourable elimination kinetic profile from the blood circulation, as demonstrated by pharmacokinetic and biodistribution data. These two combined characteristics make them very suitable for angiographic magnetic resonance imaging in general. The compositions of the invention can therefore facilitate MR angiography and help to assess myocardial and cerebral ischemia, pulmonary embolism, vascularization of tumours and tumour perfusion.
[0102] The following examples further illustrate the invention in more detail.
EXAMPLE 1
[10-Hexadecyl-1,4,7,10-tetraazacyclododecane-1,4,7-triacetato(3-)]gadolinium
[0103] [0103]
[0104] A) 10-Hexadecyl-1,4,7,10-tetraazacyclododecane-1,4,7-triacetic acid
[0105] A mixture of 1,4,7,10-tetraazacyclododecane-1,4,7-triacetic acid tris(1,1-dimethylethyl) ester (prepared according to EP-A-299795) (20.6 g; 40 mmol) and 1-bromohexadecane (12.4 g; 40.6 mmol) in CH 3 CN (500 mL) was heated to reflux for 2 h. Then, the reaction mixture was evaporated and the residue was flash chromatographed (CH 2 Cl 2 /MeOH=9/1 (v/v) to give a solid. This product was dissolved in CHCl 3 and an excess CF 3 COOH was added. After 2 h the reaction mixture was evaporated and the oily residue redissolved in CF 3 COOH. After 16 h at room temperature the solution was evaporated and the residue was purified by flash chromatography (CH 2 Cl 2 /MeOH/NH 4 OH 25% (w/w)=12/4/1 (v/v/v)). The product was dissolved in H 2 O and acidified with 6N HCl; the solution was loaded onto an Amberlite □ XAD-8 resin column and eluted with a CH 3 CN/H 2 O gradient.
[0106] The fractions containing the product were evaporated and dried under reduced pressure to give the desired product (8.1 g; 14 mmol). Yield 35%. HPLC: 98% (area %). Karl Fisher (K. F.): 4.05%. The 13 C—NMR, MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Calcd. 63.13 10.24 9.82 Found 63.16 10.53 9.84 anhydrous
[0107] B) [10-Hexadecyl-1,4,7,10-tetraazacyclododecane-1,4,7-triacetato (3-)]gadolinium
[0108] A solution of GdCl 3 .6H 2 O (3.9 g; 10.5 mmol) in H 2 O (40 mL) was added to a solution of the product from the previous preparation (6 g; 10.5 mmol) in H 2 O; the pH was maintained at 6.8 by addition of a solution of NaOH 1N (30 mL) . The solution was treated with n-BuOH and the organic phase was evaporated to give a solid that was extracted at reflux with CHCl 3 in a Soxhlet apparatus. The solution was evaporated to give a solid. The product was dissolved in H 2 O and i-PrOH, loaded onto a mixed bed of Amberlite □ IRA 400 (250 mL) and Duolite □ C20 MB resin (250 mL); then, it was and eluted with H 2 O/i-PrOH 1:1. The fractions containing the product were evaporated to give the title compound (2 g; 2.7 mmol).Yield 26%.
[0109] HPLC: 99% (area %); K.F.:2.49%; Weight loss: (120° C.): 10.45%. The MS and IR spectra were consistent with the structure postulated.
Elemental analysis (%): C H N Gd Calcd. 49.70 7.65 7.73 21.69 Found 49.80 7.95 7.69 21.49
EXAMPLE 2
[10—Octadecyl-1,4,7,10-tetraazacyclododecane-1,4,7-triacetato(3-)]godolinium
[0110] [0110]
[0111] A) 10-Octadecyl-1,4,7,10-tetraazacyclododecane-1,4,7-triacetic acid
[0112] A mixture of 1,4,7,10-tetraazacyclododecane-1,4,7-triacetic acid tris(1,1-dimethylethyl)ester (37.5 g; 72.8 mmol) and 1-bromooctadecane (24.5 g; 73.5 mmol) in CH 3 CN (500 mL) was heated to reflux. After 2 h the reaction mixture was evaporated and the residue was dissolved in CHCl3 and a portion of CF 3 COOH was added. After 16 h at room temperature the reaction mixture was evaporated and the oily residue dissolved in CF 3 COOH. After 3 days at room temperature, the solution was evaporated, the residue taken up in CHCl 3 and the solution evaporated. This operation was repeated three times. The oily residue was purified by flash chromatography as follows:
[0113] Eluents:
[0114] (a) CH 2 Cl 2 /MeOH=3/1 (v/v) 3 liters
[0115] (b) CH 2 Cl 2 /MeOH/NH 4 OH 25% (w/w)=12/4/1 (v/v/v) 12 liters
[0116] (c) CH 2 Cl 2 /MeOH/NH 4 OH 25% (w/w)=6/3/1 (v/v/v) 2 liters
[0117] The product was dissolved in H 2 O and acidified with 6N HCl; then, the solution was loaded onto an Amberlite □ XAD-8 resin column and eluted with a CH 3 CN/H 2 O gradient. The product started eluting with 20% CH 3 CN.
[0118] The fractions containing the product were evaporated and dried under reduced pressure to give the desired product (24.2 g; 40.4 mmol). Yield 55%.
[0119] HPLC: 91% (area %); K.F.: 8.01%; the 13 C—NMR, MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Calcd. 64.18 10.44 9.36 Found 64.17 10.48 9.33 anhydrous
[0120] B) [10-Octadecyl-1,4,7,10-tetraazacyclododecane-1,4,7-triacetato(3-)]gadolinium
[0121] (CH 3 COO) 3 Gd (7.05 g; 17.3 mmol) was added to a suspension of the free ligand issued from the previous preparation (10.4 g; 17.3 mmol) in MeOH (400 mL) at 50° C. The reaction mixture was kept at 50° C. for 1 h, after which the clear solution was evaporated and dried under reduced pressure to give the title compound (11 g; 14.6 mmol). Yield 84%. HPLC: 100% (area %); K.F.: 1.83%; Weight loss (120° C.) : 5.04%. The MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Gd Calcd. 51.04 7.90 7.44 20.88 Found 50.84 7.96 7.19 20.39
EXAMPLE 3
[10-(2-Hydroxyoctadecyl)-1,4,7,10-tetraazacyclo-dodecane-1,4,7-triacetato-(3-)]gadolinium
[0122] [0122]
[0123] A) 10-(2-Hydroxyoctadecyl)-1,4,7,10-tetraazacyclodode-cane-1,4,7-triacetic acid
[0124] A solution of 1,2-epoxyoctadecane (17.4 g; 65 mmol) in abs. EtOH (100 mL) was added dropwise to a solution of 1,4,7,10-tetraazacyclododecane-1,4,7-triacetic acid tris-(1,1-dimethylethyl)ester (33.3 g; 65 mmol) in abs. EtOH and the mixture was heated to reflux. After 3 h, the reaction mixture was evaporated and the residue was dissolved in EtOAc and washed with brine. The organic phase was separated, dried over Na 2 SO 4 and evaporated under reduced pressure. The residue was flash-chromatographed, (Eluent: CH 2 Cl 2 /MeOH=9/1 (v/v))
[0125] The obtained product was dissolved in 5N HCl (500 mL) and the solution was heated to reflux. After 1.5 h, the mixture was evaporated and the residue purified by flash chromatography CH 2 Cl 2 /MeOH/NH 4 OH 25% (w/w)=12/4/1 (v/v/v))
[0126] The product was dissolved in H 2 O and 6N HCl, the solution was loaded onto an Amberlite® XAD-8 resin column (800 mL) and eluted with a CH 3 CN/H 2 O gradient.
[0127] The fractions containing the product were evaporated and dried under reduced pressure to give the desired product (18 g; 29 mmol) Yield 45%. Acidic titer (0.1 N NaOH): 95% HPLC: 94% (area %); K.F.: 7.10%. The 13 C-NMR, MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Calcd. 62.51 10.16 9.11 Found 62.93 10.26 9.14 anhydrous
[0128] B) [10-(2-Hydroxyoctadecyl)-1,4,7,10-tetraazacyclodode-cane-1,4,7-triacetato-(3-)]qadolinium
[0129] Gd 2 O 3 (3.62 g.; 10 mmol) was added to a solution of the free ligand issued from the previous preparation (12.3 g; 20 mmol) in H 2 O (150 mL) and the resulting suspension was heated at 50° C. for 40 h. The reaction mixture was filtered through a Millipore □ apparatus (HA 0.45 μm filter); the filtrate (pH 6.7) was evaporated under reduced pressure and dried to give the title compound (14.2 g.; 18 mmol). Yield 92%. Free ligand: 0.7%; HPLC 95% (area %); K.F.: 7.94%. The MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Gd Calcd. 49.97 7.73 7.28 20.45 Found 49.98 7.88 7.29 20.57 Anhydrous
EXAMPLE 4
[ 10 -[2-(Octadecylamino)-2-oxoethyl]-1,4,7,10-tetraazacyclo)dodecane-1,4,7-triacetato(3-)]gadolinium
[0130] [0130]
[0131] A) 2-Bromo-N-octadecylacetamide (C.A.S. registry number 15491-43-7)
[0132] A solution of bromoacetyl bromide (44.4 g; 0.22 mol) in CH 2 Cl 2 (50 mL) was added dropwise in 2.5 h at 20° C. to a mixture of octadecylamine (59.3 g; 0.22 mol) and K 2 CO 3 (30.4 g; 0.22 mol) in CH 2 Cl 2 (600 mL) and H 2 O (600 mL). After 16 h at room temperature the organic layer was separated, washed with H 2 O, dried over Na 2 SO 4 and evaporated. The crude product was purified by flash chromatography (CH 2 Cl 2 /MeOH=100/1 (v/v)) to give the desired product (60 g; 0.154 mol). Yield 70%. GC: 96% (area %), K.F.: <0.1%; 1 H-NMR, 13 C-NMR and MS spectra were consistent with the postulated structure.
Elemental analysis (%): C H N Br O Calcd. 61.52 10.33 3.59 20.46 4.09 Found 61.75 10.71 3.58 20.14 4.01
[0133] B) 10-[2-(Octadecylamino)-2-oxoethyl]-1,4,7,10-tetraazacyclododecane-1,4,7-triacetic acid
[0134] A mixture of 1,4,7,10-tetraazacyclododecane-1,4,7-triacetic acid tris(1,1-dimethylethyl) ester (24 g; 46.6 mmol) and 2-bromo-N-octadecylacetamide (18.2 g; 46.6 mmol) in EtOH (500 mL) was heated to reflux. After 2.5 h, the reaction mixture was evaporated, the residue was dissolved in CH 2 Cl 2 and CF 3 COOH was added. After 15 min, the solvent was evaporated and the oily residue dissolved in CF 3 COOH. After 16 h at room temperature the solution was evaporated and the oily residue was purified by flash chromatography (CH 2 Cl 2 /MeOH=3/1 (v/v); then CH 2 Cl 2 /MeOH/NH 4 OH 25% (w/w)=12/4/1 (v/v/v)).
[0135] The product was dissolved in H 2 O and 6N HCl, the solution was loaded onto an Amberlite® XAD-8 resin column and eluted with a CH 3 CN/H 2 O gradient. The product elutes with 50% CH 3 CN.
[0136] The fractions containing the product were evaporated and dried under reduced pressure to give the desired product (12 g; 18 mmol) Yield 39%. Acidic titer (0.1 N NaOH): 91%; HPLC: 95% (area %); K.F.: 8.82%. The 13 C-NMR, MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Calcd. 62.26 9.99 10.68 Found 62.28 9.63 10.64 anhydrous
[0137] C) [10-[2-(Octadecylamino)-2-oxoethyl]-1,4,7,10-tetraazacyclododecane-1,4,7-triacetato(3-)]gadolinium
[0138] Gd 2 O 3 (1.97 g; 5.4 mmol) was added to a solution of the free ligand from the previous preparation (7.12 g; 9.7 mmol) in H 2 O (310 mL) and the resulting suspension was heated to 50° C. for 9.5 h. The reaction mixture was filtered through a Millipore □ membrane (HA 0.45 μm filter) and the solution was evaporated to give the title compound (8.6 g; 9.5 mmol). Yield 98%. HPLC: 98% (area %); K.F.: 9.98%; MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Gd Calcd. 50.41 7.71 8.64 19.41 Found 50.52 7.78 8.65 19.32 anhydrous
EXAMPLE 5
[10-[2-(Dioctadecylamino)-2-oxoethyl]-1,4,7,10-tetraazacyclododecane-1,4,7-triacetato(3-)]gadolinium
[0139] [0139]
[0140] A) 2-Bromo-N,N-dioctadecylacetamide
[0141] This novel compound was prepared as follows: Bromoacetyl bromide (4.25 g; 21 mmol) was added dropwise to a solution of dioctadecylamine (10 g; 19 mmol) and Et 3 N (2.13 g; 21 mmol) in CHCl 3 (400 mL). After 4 h at room temperature the reaction solution was washed with H 2 O, dried over Na 2 SO 4 and evaporated. The residue was purified by flash chromatography (n-hexane/Et 2 O=8/2 (v/v) to give the desired product (7.5 g; 11.5 mmol). Yield 61%. K.F.: <0.1%; The 1 H-NMR, 13 C-NMR, MS and IR spectra were consistent with the postulated structure
Elemental analysis (%): C H N Br Calcd. 70.99 11.91 2.18 12.43 Found 71.05 12.18 2.11 12.27
[0142] B) 10-[2-(Dioctadecylamino)-2-oxoethyl]-1,4,7,10-tetraazacyclododecane-1,4,7-triacetic acid trihydrochloride
[0143] A mixture of 1,4,7,10-tetraazacyclododecane-1,4,7-triacetic acid tris(1,1-dimethylethyl)ester (14.4 g; 28 mmol) and 2-bromo—N,N-dioctadecylamide (18.1 g; 28 mmol) in EtOH (800 mL) was heated to reflux. After 3 h the reaction mixture was evaporated and the residue was dissolved in CH 2 Cl 2 . The solution was washed with brine, dried over Na 2 SO 4 and evaporated to give the crude alkylated ester. This product was suspended in 5N HCl and refluxed. After 2 h the suspension was filtered, the solid was washed with 5N HCl and dried under reduced pressure to give the desired compound (21.5 g; 21 mmol). Yield 75%. HPLC: 95.7% (area %). Argentometric titer (0.1 N AgNO 3 ): 98.5%; K.F.: 4.79%. The 1 H-NMR, 13 C-NMR, MS and IR spectra were consistent with the desired structure.
Elemental analysis (%): C H Cl N Calcd. 61.37 10.29 10.45 6.88 Found 61.30 10.08 10.71 6.44 Anhydrous
[0144] C) [10-[2-(Dioctadecylamino)-2-oxoethyl]-1,4,7,10-tetraazacyclododecane-1,4,7-triacetato(3-)]gadolinium
[0145] A solution of GdCl 3 .6H 2 O (5.8 g; 15.7 mmol) in H 2 O (50 mL) was added dropwise to a refluxing solution of the product from the previous preparation (16 g; 15.7 mmol) and 1 N NaOH (94.3 mL; 94.3 mmol) in abs. EtOH (1 L) . After 1.5 h the mixture was cooled to room temperature, filtered and concentrated to half its volume, thus causing the precipitation of a solid which was filtered, washed with H 2 O and dried under reduced pressure. The solid was purified by flash chromatography (CH 2 Cl 2 /MeOH/Et 3 N=16/4/1 (v/v/v)) and then suspended in H 2 O at 50° C. for 3 h. The suspension was drained and the solid was washed with H 2 O and dried under reduced pressure to give the title compound (11.5 g; 10.8 mmol). Yield 69%. HPLC: 96% (area %); K.F.: 3.93%. The MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Gd Calcd. 58.78 9.30 6.59 14.80 Found 58.59 9.14 6.36 14.26 anhydrous
EXAMPLE 6
[10-[2-Hydroxy-3-[(1-oxooctadecyl)oxy]propyl]-1,4,7,10-tetraazacyclododecane-1,4,7-triacetato(3-)]gadolinium
[0146] [0146]
[0147] A) 10-(2,3-Dihydroxypropyl)-1,4,7,10-tetraazacyclodo-decane-1,4,7-triacetic acid tris(1,1-dimethylethyl)ester adduct with NaCl
[0148] A solution of 2,3-epoxypropanol (3.7 g; 50 mmol) in abs. EtOH (80 mL) was added dropwise in 30 min to a refluxing solution of 1,4,7,10-tetraazacyclododecane-1,4,7-triacetic acid tris(1,1-dimethylethyl)ester (25.7 g; 50 mmol) in abs. EtOH (250 mL). After 2.5 h the solution was evaporated, the residue taken up with EtOAc and washed with brine. The organic phase was separated, dried (Na 2 SO 4 ) and evaporated. The crude was purified by flash chromatography (CH 2 Cl 2 /MeOH—9/1 (v/v)) to give the desired compound (24 g; 37 mmol). Yield 74%. K.F.: 1.30%; The 13 C-NMR, MS and IR spectra were consistent with the desired structure.
Elemental analysis (%): C H N Cl Na Calcd. 53.82 8.72 8.66 5.48 3.55 Found 53.95 8.97 8.72 5.47 3.48 anhydrous
[0149] B) 10-[2-Hydroxy-3-[(1-oxooctadecyl)oxy]propyl]-1,4,7,10-tetraazacyclododecane-1,4,7-triacetic acid tris-(1,1-dimethylethyl)ester adduct with NaCl
[0150] A solution of dicyclohexylcarbodiimide (0.43 g; 2.1 mmol) in CHCl 3 (10 mL) was added dropwise in 10 min to a solution of stearic acid (0.44 g; 1.5 mmol) (commercial product), 10-(2,3-dihydroxypropyl)-1,4,7,10-tetraazacyclo-dodecane-1,4,7-triacetic acid tris(1,1-dimethylethyl)ester adduct with NaCl (1 g; 1.5 mmol) and 4-(dimethylamino)pyridine (0.06 g; 0.5 mmol) (commercial product) in CHCl 3 (40 mL) at 0° C. The temperature of the reaction mixture was allowed to come back to normal. After 16 h, the mixture was concentrated to half its volume, the precipitate was filtered off and the solution evaporated. The crude was purified by flash chromatography (CH 2 Cl 2 /MeOH =10/1 (v/v)) to give the desired compound (0.95 g; 1.04 mmol). Yield 67%. The 1 H-NMR, 13 C-NMR, MS and IR spectra were consistent with the structure.
[0151] C) [10-[2-Hydroxy-3-[(1-oxooctadecyl)oxy]propyl]-1,4,7,10-tetraazacyclo-dodecane-1,4,7-triacetato(3-)]qadolinium
[0152] CF 3 COOH (20 mL) was added to a solution of the product from the previous preparation (13.9 g; 15.2 mmol) in CH 2 Cl 2 (5 mL). After 24 h the solution was evaporated and the residue takes up with more CF 3 COOH (15 mL). After 6 h the mixture was evaporated and the crude desalted by dialysis (Spectra/Por® CE(Cellulose Ester) membrane MWCO 500) to afford a white solid (4 g). A portion of this solid (2.9 g) was dissolved in 2-propanol (100 mL) and H 2 O (25 mL) at 80° C. then (CH 3 COO) 3 Gd (1.7 g) was added and the solution kept at 80° C. for 3 h. The reaction mixture was evaporated and the residue was purified by flash chromatography (CH 2 Cl 2 /MeOH/H 2 O=5/5/1 (v/v/v)) to give the title compound (1.53 g; 1.8 mmol). Yield 12%.HPLC: 100% (area %); Weight loss (120° C.): 4.96%. The MS and IR spectra were consistent with the postulated structure.
Elemental analysis (%): C H N Gd Calcd. 49.98 7.55 6.66 18.69 Found 50.24 7.63 6.61 18.39
EXAMPLE 7
[10-[2-Hydroxy-3-[[[2-(Octadecyloxy)-1-[(octadecyloxy)methyl]-ethoxy]-acetyl]oxy]propyl]-1,4,7,10-tetraazacyclododecane-1,4,7-triacetato(3-)]gadolinium
[0153] [0153]
[0154] A) 1,3-Bis(octadecyloxy)-2-propanol (C.A.S. Registry No. 18794-74-6)
[0155] Epichlorohydrin (4.6 g; 50 mmol) was added in 5 min to excess stearyl alcohol (117 g; 433 mmol) at 70° C. in the presence of 80% NaH mineral oil dispersion (1.65 g; 55 mmol) (commercial product). The mixture was stirred for 6 h, then cooled to room temperature and treated with Et 2 O (2 L). The mixture was filtered and the solution evaporated. The crude product was crystallized four times from acetone to give the desired compound(16.5 g; 27.6 mmol). Yield 55%. K.F.: −0.1%. The 1 H-NMR, 13 C-NMR, MS and IR spectra were consistent with the above structure.
Elemental analysis (%): C H Calcd. 78.46 13.51 Found 78.63 13.61
[0156] B) (2-(Octadecyloxy)-1-[(octadecyloxy)methyl]ethoxy)-acetic acid (C.A.S. Registry No. 79979-56-9)
[0157] 80% NaH mineral oil dispersion (2.65 g; 88 mmol) was added under nitrogen atmosphere to a solution of 1,3-bis(octadecyloxy)-2-propanol (6.92 g; 11.6 mmol) in THF (200 mL). The mixture was heated to reflux and a solution of BrCH 2 COOH (8.1 g; 58 mmol) in THF (50 mL) was added dropwise in 30 min. After another 30 min, MeOH was added, then the solvent was evaporated. The residue was dissolved in Et 2 O, washed with 0.1 N HCl, dried and evaporated. The crude product was crystallized twice from EtOAc to give the desired compound (5.7 g; 8.7 mmol). Yield 75%. K.F.: 0.47%; the 1 H-NMR, 13 C-NMR, MS and IR spectra were consistent with the foregoing structure.
Elemental analysis (%): C H Calcd. 75.17 12.62 Found 75.13 13.01 anhydrous
[0158] C) The title compound was then prepared, starting from [2-(octadecyloxy)-1-[(octadecyloxy)methyl]ethoxy]acetic acid and the intermediate (A) of Example 6, according to the synthetic method reported in Example 6.
EXAMPLE 8
[6,9-Bis(carboxymethyl)-3-[2-(octadecylamino)-2-oxoet-hyl]-11-oxo-3,6,9,12-tetraazatriacontanoato(3-)]gadolinium
[0159] [0159]
[0160] A) 6,9-Bis(carboxymethyl)-3-[2-(octadecylamino)-2-oxoethyl]-11-oxo-3,6,9,12-tetraazatriacontanoic acid (C.A.S. Registry Number 135546-68-8)
[0161] The product was synthesized following the procedure F. Jasanada and F. Nepveu in Tetrahedron Lett. 33 (1992), 5745-5748. KF: 0.54%. The 1 H-NNR, 13 C-NMR, MS and IR spectra were consistent with the foregoing structure.
Elemental analysis (%): C H N Calcd. 67.0 10.91 7.81 Found 67.1 11.31 7.78 anhydrous
[0162] B) [6,9-Bis(carboxymethyl)-3-[2-(octadecylamino)-2-oxoethyl]-11-oxo-3,6,9,12-tetraazatriacontanoato(3-)]qadolinium
[0163] This product was synthetized according to G. W. Kabalka et al. Magn. Reson. Med. 19 (1991), 406-415. Yield 82%. Weight loss (130° C.): 5.95%. The MS and IR spectra were consistent with the desired structure.
Elemental analysis (%): C H N Gd Calcd. 57.16 9.02 6.67 14.97 Found 57.09 9.37 6.57 14.85
EXAMPLE 9
6,9-Bis(carboxymethyl)-3-(2-oxo-6,9,12,15,18,21,24-hep-taoxa-3-azapentacosyl)-11-oxo-15,18,21,24,27,30,33-heptaoxa-3,6,9,12-tetraaza tetratriacontanoato(3-)]gadolinium
[0164] [0164]
[0165] A) 6,9-Bis(carboxymethyl)-3-(2-oxo-6,9,12,15,18,21,24-heptaoxa-3-azapentacosyl)-11-oxo-15,18,21,24,27,30,33-heptaoxa-3,6,9,12-tetraaza tetratriacontanoic acid
[0166] N,N-Bis[2-(2,6-dioxo-4-morpholinyl)ethyl]glycine (commercial product) (8.93 g; 25 mmol) was added to a solution of 2,5,8,11,14,17,20-heptaoxadocosan-22-amine (prepared according to WO 95/17380) (16.97 g; 50 mmol) in DMF (250 mL) at room temperature. After 2 h, the reaction mixture was evaporated and the residue was dissolved in H 2 O and 6N HCl. The solution (pH 2) was loaded onto an Amberlite 58 XAD-1600 resin column and eluted with a CH 3 CN/H 2 O gradient. The product starts eluting with 10% CH 3 CN.
[0167] The fractions containing the product were evaporated and dried under reduced pressure to give the desired product (14 g; 13.5 mmol). Yield 54%. HPLC: 96% (area %). K.F.: 1.22%. The 1 H-NMR, 13 C-NMR, MS and IR spectra were consistent with the above structure.
Elemental analysis (%): C H N Calcd. 51.00 8.27 6.76 Found 51.55 8.35 6.81 anhydrous
[0168] B) 6,9-Bis(carboxymethyl)-3-(2-oxo-6,9,12,15,18,21,24-heptaoxa-3-azapentacosyl)-11-oxo-15,18,21,24,27,30,33-hepta-oxa-3,6,9,12-tetraaza tetratriacontanoato(3-)]gadolinium
[0169] Gd 2 O 3 (1.86 g; 5.1 mmol) was added to a solution of the free ligand from the previous preparation (10.62 g; 10.2 mmol) in H 2 O (200 mL) and the resulting suspension was heated at 50° C. for 7 h. The reaction mixture was filtered through a Millipore® apparatus (HA 0.45 μm filter); the filtrate was evaporated and dried under reduced pressure to give the title compound (11.9 g; 10 mmol). Yield 98%/. Free ligand (0.001 M GdCl 3 ): 0.05% (w/w). HPLC: 98% (area %). K.F.: 1.69%. Weight loss (120° C.): 1.58%. The MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Gd Calcd. 44.40 6.94 5.88 13.21 Found 44.45 7.13 5.91 13.23 anhydrous
EXAMPLE 10
[6,9-Bis(carboxymethyl)-3-(2,16-dioxo-6,9,12-trioxa-3,15-diazaririacontanyl)-11,25-dioxo-15,18,21-trioxa-3,6,9,12,24-pentaazadoetraontanoato(3-)]gadolinium
[0170] [0170]
[0171] A) 1-[(1-Oxooctadecyl)oxy]-2,5-pyrrolidinedione (C.A.S. Registry Number 14464-32-5)
[0172] This compound was synthetized according to M. Shinitzky and R. Haimovitz in J. Am. Chem. Soc. 115 (1993), 12545-12549, and Y. Lapidot, S. Rappoport and Y. Wolman in J. Lipid Res. 8 (1967), 142-145. Yield: 86%. K.F.: <0.1%. The 1 H-NMR, 13 C-NMR and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Calcd. 69.25 10.30 3.67 Found 69.46 10.77 3.85
[0173] B) 3,6,9-Trioxaundecane-1,11-diamine (C.A.S. Registry No. 929-75-9)
[0174] This compound was prepared according to the method disclosed in Liebigs Ann. Chem. 2 (1990), 129-143.
Elemental analysis (%): C N Calcd. 49.98 14.57 Found 49.68 14.23
[0175] C) 13-Oxo-3,6,9-trioxa-12-azatriacontanylamine H 35 C 17 -CONH-[(CH 2 ) 2 -O] 3 -(CH 2 ) 2 -NH 2
[0176] 1-[(1-Oxooctadecyl)oxy]-2,5-pyrrolidinedione (3.87 g; 10.1 mmol) in CHCl 3 (600 mL) was added dropwise in 6 h to a solution of 3,6,9-trioxaundecane-1,11-diamine (19.8 g; 103 mmol) in CHCl 3 (100 mL) at 20° C. The reaction mixture was evaporated, the residue treated with CH 2 Cl 2 (50 mL) and the suspended solid filtered off. The solution was evaporated, the residue treated with H 2 O and extracted with EtOAc. The organic phases were combined and dried. Concentration to small volume led to the precipitation of the desired compound (4.04 g; 8.8 mmol) which was collected by filtration. Yield 87%. The 1 H-NMR, 13 C-NMR, MS and IR spectra were consistent with the proposed structure.
Elemental analysis (%): C H N Calcd. 68.08 11.87 6.11 Found 67.94 11.91 5.92 anhydrous
[0177] D) 6,9-Bis(carboxymethyl)-3-(2,16-dioxo-6,9,12-trioxa-3,15-diazatritriacontanyl)-11,25-dioxo-15,18,21-trioxa-3,6,9,12,24-pentaazadotetracontanoic acid
[0178] N,N-Bis[2-(2,6-dioxo-4-morpholinyl)ethyl]glycine (commercial product) (6.45 g; 18 mmol) was added to a solution of 12-aza-13-oxo-3,6,9-trioxatriacontanylamine (16.57 g; 36 mmol) in DMF (300 mL) at 70° C. After 2 h the mixture was cooled to room temperature to give a precipitate that was filtered and washed with acetone. The crude was crystallized twice from acetone. The solid was filtered, washed with acetone and dried under reduced pressure to give the desired compound (17.35 g; 13.6 mmol). Yield 75%. HPLC: 98% (area %); K.F.: 0.99%. Weigth loss (120° C.): 0.95%. The 1 H-NMR, 13 C-NMR, MS and IR spectra were consistent with the above structure.
Elemental analysis (%): C H N Calcd. 62.19 10.04 7.69 Found 62.36 10.00 7.55 anhydrous
[0179] E) [6,9-Bis(carboxymethyl)-3-(2,16-dioxo-6,9,12-trioxa-3,15-diazatritriacontanyl)-11,25-dioxo-15,18,21-trioxa-3,6,9,12,24-pentaazadotetracontanoato(3-)]gadolinium
[0180] (CH 3 COO) 3 Gd.4H 2 O (4.06 g; 10 mmol) was added to a solution of the product from the previous preparation (12.75 g; 10 mmol) in MeOH (600 mL) at 50° C. After 2 h the clear solution was evaporated and dried under reduced pressure to give the title compound (12.3 g; 8.6 mmol). Yield 86%. Free ligand (0.001 M GdCl 3 ): 0.02 (w/w). HPLC: 100% (area %); K.F.: 1.90%. Weight loss (120° C.) 3.02%. The MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Gd Calcd. 55.47 8.75 6.86 11.00 Found 55.49 8.88 6.73 10.66 anhydrous
EXAMPLE 11
[6,9-Bis(carboxymethyl)-3-(2,14-dioxo-18,21,24,27,30,33,36-heptaoxa-3,15-diazaheptatriacontanyl)-11,23-dioxo-27,30,33,36,39,-42,45-heptaoxa-3,6,9,12,24-pentaazahexatetracontanoato(3-)]gadolinium
[0181] [0181]
[0182] A) 11-[[(1,1-Dimethylethoxy)carbonyl]amino]undecanoic acid (C.A.S. Registry No. 10436-25-6)
[0183] 11-Aminoundecanoic acid (3 g; 14.9 mmol) was suspended in a 10% solution of Et 3 N in MeOH (200 mL); dicarbonic acid bis(1,1-dimethylethyl)ester (Boc 2 O) (3.58 g; 16.4 mmol) was added and the mixture was heated to 50° C. for 15 min. As soon as the aminoacid dissolved, reaction was complete. After evaporation of the solvent under reduced pressure, the triethylammonium salt of the product was treated with a 20% solution of citric acid in H 2 O and the free acid was extracted with EtOAc. The organic phase was separated, dried over Na 2 SO 4 and then evaporated under reduced pressure to give the desired compound (4.45 g; 14.1 mmol). Yield 95%. HPLC: 97% (area %); K.F.: <0.1%. Weight loss (60° C.): 0.83%. The 13 C-NMR, MS and IR spectra were consistent with the proposed structure.
Elemental analysis (%): C H N Calcd. 63.76 10.37 4.65 Found 63.73 10.38 4.63
[0184] B) 11-Amino-N-(3,6,9,12,15,18,21-heptaoxadocosyl)-undecanamide
[0185] To a stirred mixture of 11-[[(1,1-dimethyl-ethoxy)carbonyl]amino]undecanoic acid (8.8 g; 29.2 mmol), 2,5,8,11,14,17,20-heptaoxadocosan-22-amine (prepared accor-ding to WO 95/17380) (10.9 g; 32.1 mmol) and diethyl cyanophosphonate (DEPC) (5.2 g; 32.1 mmol; 4.9 mL) in DMF (200 mL), maintained at 0° C., Et 3 N (3.3 g; 32.1 mmol; 4.5 mL) was added over 1 h. The reaction mixture was stirred at 0° C. for 30 min and then at room temperature for 1 h. The solvent was evaporated under reduced pressure, the crude was dissolved in 1.2 N HCl in MeOH and the resulting solution was stirred overnight.
[0186] (In an analogous preparation the above-mentioned crude was purified by washing the solution of the product in EtOAc with 5% aq. NaHCO 3 and identified as 11-[[(1,1-dimethylethoxy)carbonyl]amino]-N-(3,6,9,12,15,18,21-heptaoxadocosyl)undecanamide: HPLC: 91% (area %). Weight loss (120° C.): 0.71%; K.F.: 0.64%
Elemental analysis (%): C H N Calcd. 59.78 10.03 4.50 Found 59.59 10.48 4.51 Anhydrous
[0187] The 13 C-NMR, MS and IR spectra were consistent with the structure).
[0188] After evaporation of the solvent under reduced pressure, the residue was dissolved in a saturated solution of NaHCO 3 and then washed with EtOAc. The aqueous phase was separated and acidified with 1N HCl until precipitation of the product occurred; the latter was filtered to give 11-amino-N-(3,6,9,12,15,18,21-heptaoxadocosyl)undecanamide salified with 1/3 HCl (11.9 g; 22.3 mmol). Yield 76%. HPLC: 95% (area %). K.F.: 0.30%. The 13 C-NMR, MS and IR spectra were consistent with the foregoing structure.
Elemental analysis (%): C H N Cl Calcd. 58.38 10.24 5.24 2.09 Found 58.05 10.13 5.15 2.12 anhydrous
[0189] C) 6,9-Bis(carboxymethyl)-3-(2,14-dioxo-18,21,24,27,30,33,36-heptaoxa-3,15-diazaheptatriacontanyl)-11,23-dioxo-27,30,33,36,39,42,45-heptaoxa-3,6,9,12,24-pentaazahexatetracontanoic acid
[0190] N,N-Bis[2-(2,6-dioxo-4-morpholinyl)ethyl]glycine (3.8 g; 10.6 mmol) (commercial product) was added to a suspension of 11-amino-N-(3,6,9,12,15,18,21-heptaoxadocosyl) undecan-amide (11.1 g; 21.1 mmol) in DMF (200 mL). After 15 min the reaction mixture became clear and the conversion was complete. The solvent was evaporated under reduced pressure, the residue was dissolved in CHCl 3 and washed with H 2 O. The organic phase was separated, dried over Na 2 SO 4 and then evaporated under reduced pressure. The solid was dissolved in H 2 O and loaded onto an Amberlite® XAD-7 HP resin column (700 mL) and eluted with a CH 3 CN/H 2 O gradient. The fraction containing the product was evaporated to give the desired compound (11 g; 7.8 mmol). Yield 74%. HPLC: 85% (area %); K.F. 0.49%. Weight loss (120° C.): 0.45%. The 13 C-NMR, MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Calcd. 56.51 9.13 6.99 Found 56.36 9.12 7.02
[0191] D) [6,9-Bis(carboxymethyl)-3-(2,14-dioxo-18,21,24,27,30,33,36-heptaoxa-3,15-diazaheptatriacontanyl)-11,23-dioxo-27,30,33,36,39,-42,45-heptaoxa-3,6,9,12,24-pentaazahexatetracontanoato(3-)]gadolinium
[0192] Gd 2 O 3 (0.9 g; 2.5 mmol) was added to a solution of the free ligand from the previous preparation (7 g; 5 mmol) in EtOH (100 mL) and H 2 O (150 mL), the resulting suspension was heated at 65° C. for 1 h. The reaction mixture was filtered through a Millipore® apparatus (HVLP type; 0.45 μm filter); the filtrate was evaporated under reduced pressure to give the title compound (7.5 g; 4.74 mmol). Yield 95%. Free gadolinium (0.001 M Na 2 EDTA): <0.01% (w/w). HPLC: 96% (area %); K.F.: 1.69%. The MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Gd Calcd. 50.91 8.03 6.30 10.10 Found 51.06 7.98 6.52 9.94 anhydrous
EXAMPLE 12
[[6,9-Bis(carboxymethyl)-16-hydroxy-3-(7-hydroxy-2,7-dioxo-6,8-dioxa-3-aza-7-phosphatetracosanyl)-11,16-dioxo-15,17-dioxa-3,6,9,12-tetraaza-16-phosphatritriacontanoato(5-)]gadolinate(2-)]disodium salt
[0193] [0193]
[0194] A) Phosphoric acid mono(2-aminoethyl) monohexadecyl ester [C.A.S. Registry Number 57303-02-3]
[0195] A solution of hexadecyl alcohol (26.2 g; 108 mmol) in THF (100 mL) was added dropwise in 30 min to a solution of POCl 3 (16.56 g; 108 mmol) and Et 3 N (12.35 g; 122 mmol) in THF (200 mL) at 0° C. After 5 min a solution of ethanolamine (7.2 g; 118 mmol) and Et 3 N (43.51 g; 430 mmol) in THF (60 mL) was added dropwise in 60 min. at 0° C. The reaction mixture was allowed to reach room temperature in 3 h; then it was heated at 40° C. and HCl 10% (100 mL) was added. After 2 h the mixture was cooled to room temperature and addition of H 2 O (200 mL) afforded a precipitate that was filtered, washed with H 2 O and dried under reduced pressure to give the desired product (33.4 g; 91 mmol). Yield 85%. K.F.: 0.53%. The 1 H-NMR, 13 C-NMR, MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N P Calcd. 59.15 11.03 3.83 8.47 Found 59.07 11.41 3.76 8.02 anhydrous
[0196] B) 6,9-Bis(carboxymethyl)-16-hydroxy-3-(7-hydroxy-2,7-dioxo-6,8-dioxa-3-aza-7-phosphatetracosanyl)-11,16-dioxo-15,17-dioxa-3,6,9,12-tetraaza-16-phosphatritriacontanoic acid
[0197] N,N-Bis[2-(2,6-dioxo-4-morpholinyl)ethyl]glycine (7.15 g; 20 mmol) (commercial product) was added to a suspension of phosphoric acid mono(2-aminoethyl) monohexadecyl ester (14.62 g; 40 mmol) in DMF (700 mL) at 75° C. to afford a solution after 15 min. After 5 h the reaction mixture was evaporated and the crude was treated with H 2 O and 2N HCl to give a solid that was filtered, washed with H 2 O and acetone. The solid was purified by flash chromatography (CH 2 Cl 2 /MeOH/NH 4 OH 25% (w/w)=6/3/1 (v/v/v)).
[0198] The fractions containing the product were combined and concentrated to 200 mL. Acidification with 2N HCl down to pH 1 led to the formation of a precipitate that was filtered, washed with H 2 O and acetone and dried under reduced pressure to give the desired compound (17 g; 15.6 mmol). Yield 78%. Acidic titer (0.1 N NaOH): 95%. HPLC: 99% (area %). Weight loss (120° C.): 3.45%; K.F.: 3.06%. The 1 H-NMR, 13 C-NMR, MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N P Calcd. 55.18 9.17 6.43 5.69 Found 55.03 8.97 6.25 5.44 anhydrous
[0199] C) [[6,9-Bis(carboxymethyl)-16-hydroxy-3-(7-hydroxy-2,7-dioxo-6,8-dioxa-3-aza-7-phosphatetracosanyl)-11,16-dioxo-15,17-dioxa-3,6,9,12-tetraaza-16-phosphatritriacontanoato(5-)]gadolinate(2-)]disodium salt
[0200] (CH 3 COO) 3 Gd.4H 2 O (4.06 g; 10 mmol) was added to a solution of the free ligand from the previous preparation (10.88 g; 10 mmol) in MeOH (500 mL) and 1 N NaOH (20 mL; 20 mmol). After 24 h the clear solution was evaporated, the residue dissolved in H 2 O (200 mL) and the solution nanofiltered for 16 h.
[0201] The retentate was evaporated and dried under reduced pressure to give the title compound (11 g; 8.6 mmol). Yield 86%. HPLC: 99% (area %). Weight loss (120° C.): 4.33% K.F.: 4.23%. The MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Gd Na P Calcd. 46.68 7.36 5.44 12.22 3.57 4.82 Found 46.50 7.66 5.44 11.99 3.48 4.47 anhydrous
EXAMPLE 13
[6,9-Bis(carboxymethyl)-11,19-dioxo-3-[2-[[2-[2-[(1-oxooctadecyl)oxylethoxy]ethyl]amino]-2-oxoethyl]-15,18-dioxa-3,6,9,12-tetraazahexatriacontanoato(3-)]gadolinium
[0202] [0202]
[0203] A) Octadecanoic acid 2-(2-aminoethoxy)ethyl ester hydrochloride
[0204] 1.2 M HCl in CH 3 OH (30 mL) was added to a solution of 2-(2-aminoethoxy)ethanol (2.1 g; 20 mmol) (commercial product) in CH 3 OH (30 mL); after 30 min the solution was evaporated and dried under reduced pressure to give 2-(2-aminoethoxy)ethanol hydrochloride (2.9 g; 20 mmol).
[0205] Stearoyl chloride (6.4 g; 21 mmol) (commercial product) was added dropwise in 5 min to a solution of 2-(2-aminoethoxy)ethanol hydrochloride (2.9 g; 20 mmol) in DMF (50 mL) at room temperature to afford a suspension. After 16 h, the suspension was diluted with acetone and the precipitated solid filtered and washed with acetone. The crude was crystallized from EtOAc; the solid was filtered, washed with EtOAc and dried under reduced pressure to give the desired compound (3.3 g; 8 mmol). Yield 40%. Acidic titer (0.1 N NaCH): 93%. K.F.: 1.06%. The 1 H-NMR, 13 C-NMR, MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Cl Calcd. 64.75 11.36 3.43 8.69 Found 64.82 11.41 3.52 8.90 anhydrous
[0206] B) 6,9-Bis(carboxymethyl)-11,19-dioxo-3-[2-[[2-[2-[(1-oxooctadecyl)oxy]ethoxy]ethyl]amino]-2-oxoethyl]-15,18-dioxa-3,6,9,12-tetraaza-hexatriacontanoic acid
[0207] N,N-Bis[2-(2,6-dioxo-4-morpholinyl)ethyl]glycine (1.9 g; 5.5 mmol) (commercial product) was added to a solution of octadecanoic acid 2-(2-aminoethoxy)ethyl ester hydrochloride (4.5 g; 11 mmol) and Et 3 N (1.5 g; 14 mmol) in DMF (150 mL) at 60° C. After 5 min the temperature was decreased to 45° C. After 2.5 h the mixture was cooled to room temperature to give a precipitate that was filtered, washed with acetone/H 2 O 15/5, then with acetone. The crude was dissolved in acetone and 0.1 N HCl and the solution heated at 50° C. After 10 min the solution was cooled to room temperature to afford a precipitate which was filtered, washed with acetone/H 2 O 15/5 then with acetone and dried under reduced pressure to give the desired compound (1.7 g; 1.5 mmol). Yield 27%. HPLC: 100% (area %). HPCE: 100% (area). K.F.: 3.11%. Weight loss (120° C.): 4.49%. The 1 H-NMR, 13 C-NMR, MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Calcd. 63.30 9.98 6.36 Found 63.29 9.95 6.50
[0208] C) [6,9-Bis(carboxymethyl)-11,19-dioxo-3-[2-[[2-[2-[(1-oxooctadecyl)oxy]ethoxy]ethyl]amino]-2-oxoethyl]-15,18-dioxa-3,6,9,12-tetraazahexatriacontanoato(3-)]gadolinium
[0209] (CH 3 COO) 3 Gd.4H 2 O (1.11 g; 2.7 mmol) was added to a solution of the free ligand from the previous preparation (3 g; 2.7 mmol) in MeOH (150 mL) at 40° C. After 1 h the clear solution was evaporated and dried under reduced pressure. The crude was purified by flash chromatography (CH 3 OH) to give the title compound (3.2 g; 2.5 mmol). Yield 94%. HPCE: 100% (area %). K.F.: 4.07%. Weight loss (120° C.): 4.08%. the MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Gd Calcd. 55.52 8.52 5.58 12.53 Found 55.50 8.52 5.58 12.62 anhydrous
EXAMPLE 14
[[N,N′-[[[2-(Octadecylamino)-2-oxoethyl]imino]di-2,1-ethanediyl]bis[N-(carboxymethyl)glycinato(4-)]]gadolin-ate(1-)]sodium salt
[0210] [0210]
[0211] A) N,N-bis [2-[bis[2-(1,1-dimethylethoxy)-2-oxoethyl]amino]-ethyl]glycine
[0212] The compound was prepared according to the method disclosed in patent application WO-A-95/32741.
[0213] B) N,N′-[[[2-(Octadecylamino)-2-oxoethyl]imino]di-2,1-ethanediyl]bis[N-[2-(1,1-dimethylethoxy)-2-oxoethyl]glycine 1,1-dimethylethyl ester]
[0214] Isobutyl chloroformate (205 mg; 1.65 mmol; 215 μL) was added dropwise to a solution of the product from the previous preparation (950 mg; 1.54 mmol) and Et 3 N (165 mg; 1.65 mmol; 230 μL) in THF (50 mL) at −5° C. and under nitrogen. After 15 min a suspension of octadecylamine (450 mg; 1.65 mmol) in THF (50 mL) was added to the reaction mixture at −5° C. After 20 min the reaction mixture was allowed to rise to room temperature and stirred overnight. The suspension was filtered to remove the residual octadecylamine and the solution was evaporated under reduced pressure. The residue was dissolved in Et 2 O and the solution washed with 5% aq. NaHCO 3 . The organic phase was dried over Na 2 SO 4 and then evaporated under reduced pressure. The crude product was purified by flash chromatography (CH 2 Cl 2 /MeOH=100/2 (v/v)) to give the desired compound (1.1 g; 1.26 mmol). Yield 80%. HPLC: 94% (area %). The 13 C-NMR, MS and IR spectra were consistent with the structure.
[0215] C) N,N′-[[[2-(Octadecylamino)-2-oxoethyl]imino]di-2,1-ethanediyl]bis[N-(carboxymethyl)glycine]
[0216] 0.5 M H 2 SO 4 (100 mL; 50 mmol) was added dropwise to a solution of the tetraester from the previous preparation (21 g; 24.3 mmol) in dioxane (150 mL) and the resulting mixture was heated at 90° C. for 4 h. The pH of the solution was adjusted to 5 with 2 N NaOH (10 mL) and the solvent was evaporated under reduced pressure. The residue was dissolved in CHCl 3 /MeOH (4:1) and the resulting suspension was filtered and evaporated under reduced pressure. The crude product was purified by flash chromatography (CH 2 Cl 2 /MeOH/NH 4 OH 25% (w/w)=6/3/1 (v/v/v)). The product was dissolved in H 2 O (150 mL) and 12 N HCl (7 mL) and desalted by elution through an Amberlite □ XAD 7-HP resin column with a CH 3 CN/H 2 O gradient. The fractions containing the product were evaporated to give the desired compound (4 g; 6.2 mmol). Yield 25%. HPLC 99% (area %). K.F.: 3.77%. The 13 C-NMR, MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Calcd. 59.60 9.38 8.69 Found 58.70 9.21 8.51 anhydrous
[0217] D) [[N,N′-[[[2-(Octadecylamino)-2-oxoethyl]imino]di-2,1-ethanediyl]bis[N-(carboxymethyl)glycinato(4-)]]gadoli-nate(1-)]sodium salt
[0218] 1 N NaOH (4.5 mL) was added to a suspension of the free ligand from the previous preparation (2.9 g; 4.5 mmol) in 1:1 H 2 O/CH 3 CN (600 mL). A solution of GdCl 3 .6H 2 O (1.66 g; 4.48 mmol) in H 2 O (50 mL) was added dropwise to the reaction mixture mantained at pH 6.8 by the addition of 1 N NaOH (13.5 mL). After 2 h the solution was evaporated; the residue was dissolved in H 2 O and desalted by elution through an Amberlite® XAD 7-HP resin column (250 mL) with a H 2 O/CH 3 CN gradient.
[0219] The fractions containing the product were evaporated. The solid residue was dissolved in H 2 O and the solution eluted through a Dowex® CCR 3LB weak cation exchange resin column (Na + form, 20 mL). The eluate was evaporated and dried under reduced pressure to give the title compound (1.35 g; 1.64 mmol). Yield 35%. HPLC: 100% (area %). K.F.: 8.85%. Weight loss (120 ° C.): 8.15%. The MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Gd Na Calcd. 46.81 6.87 6.82 19.15 2.80 Found 46.79 7.03 6.74 18.96 2.68
EXAMPLE 15
[N 2 ,N 2 -Bis[2-[bis(carboxymethyl)amino]ethyl]-N 6 -(1-oxooctadecyl)-L-lysinato(5-)]gadolinate(2-)]disodium salt
[0220] [0220]
[0221] A) N 2 ,N 2 -Bis[2-[bis[2-(1,1-dimethylethoxy)-2-oxoethyl]-amino]-ethyl]-L-lysine 1,1-dimethylethyl ester
[0222] This product was prepared according to Example 2 of WO 98/05626. The 13 C-NMR, 1 H-NMR, MS and IR spectra were consistent with the disclosed structure.
Elemental analysis (%): C H N Calcd. 61.26 9.74 7.52 Found 61.43 10.25 7.48
[0223] B) N 2 ,N 2 -Bis[2-[bis[2-(1,1-dimethylethoxy)-2-oxoethyl]amino]-ethyl]-N 6 -(1-oxooctadecyl)-L-lysine-(1,1-dimethylethyl)-ester
[0224] Stearoyl chloride (5.45 g; 18 mmol) dissolved in CHCl 3 (60 mL) was added dropwise in 1 h to a solution of N 2 ,N 2 -bis[2-[bis[2-(1,1-dimethylethoxy)-2-oxoethyl]amino]ethyl]-L-lysine 1,1-dimethylethyl ester (13.5 g; 18 mmol) in CHCl 3 (300 mL) at 0° C. After 10 min the reaction mixture was allowed to rise to room temperature and TLC analysis showed the complete conversion of the starting materials. The solution was washed with 5% aq. NaHCO 3 , the organic phase was separated, dried over Na 2 SO 4 and then evaporated under reduced pressure. The crude product was purified by flash chromatography (n-hexane/EtOAc=6/4 (v/v)) to give the desired product (11.3 g; 11.2 mmol). Yield 62%. HPLC: 95% (area %). the 13 C-NMR, MS and IR spectra were consistent with the structure.
[0225] C) N 2 ,N 2 -Bis[2-(bis(carboxymethyl)amino]ethyl]-N 6 -(1-oxooctadecyl)-L-lysine
[0226] N 2 , N 2 -Bis [2-[bis[2-(1,1-dimethylethoxy)-2-oxoethyl]-amino]ethyl]-N 6 -(1-oxooctadecyl)-L-lysine 1,1-dimethylethyl ester (9 g, 8.9 mmol) was dissolved in 6 N HCl (200 mL) and the solution was stirred for 3 days. The reaction mixture was directly loaded onto an Amberlite □ XAD 7-HP resin column and desalted by elution with a CH 3 CN/H 2 O gradient.
[0227] The solid obtained from the column was completely converted into the expected acid by treatment with neat CF 3 COOH for 2 h. CF 3 COOH was eliminated by repeated dilution with CH 2 Cl 2 and Et 2 O followed each time by evaporation under reduced pressure. The residue was dried to give the desired product (3.1 g; 4.06 mmol). Yield 45%. HPLC: 94.4% (area %). Weight loss (120° C.): 4.22%. The 13 C-NMR, MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Calcd. 59.16 9.10 7.67 Found 59.02 9.38 7.63
[0228] D) [N 2 ,N 2 -Bis[2-[bis(carboxymethyl)amino]ethyl]-N 6 -(1-oxooctadecyl)-L-lysinato(5-)]gadolinate(2-)]disodium salt
[0229] The free ligand from the previous preparation (2.16 g; 2.96 mmol) was suspended in H 2 O (50 mL) and dissolved by addition of 1 N NaOH (5.9 mL). Dropwise addition of a 1 M aq. solution of (CH 3 COO) 3 Gd (2.96 mL) led to the precipitation of a solid, which was dissolved by addition of EtOH (150 mL). The solvent was evaporated under reduced pressure to give the title compound (2.57 g; 2.66 mmol). Yield 90%. HPLC: 99% (area %). K.F.: 3.81%. Weight loss (120° C.) 3.84%. The MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Gd Na Calcd. 46.54 6.62 6.03 16.92 4.95 Found 46.17 6.38 5.67 16.93 5.42
EXAMPLE 16
[[N 2 ,N 2 -Bis[2-[bis(carboxymethyl)amino]ethyl]-N 6 -[[[(3β-cholest-5-en-3-yl]oxy]carbonyl]-L-lysinato(5-)]gadolinate(2-)]disodium salt
[0230] [0230]
[0231] A) N 2 ,N 2 -Bis[2-[bis[2-(1,1-dimethylethoxy)-2-oxoethyl]-amino]-ethyl]-N -[([(3,8)-cholest-5-en-3-yl]oxy]carbonyl]-L-lysine 1,1-dimethylethyl ester
[0232] A solution of cholesteryl chloroformate (11 g; 22 mmol) (commercial product) in CHCl 3 (60 mL) was added in 1 h to a solution of N 2 ,N 2 -bis[2-[bis[2-(1,1-dimethylethoxy)-2-oxoethyl]amino]ethyl]-L-lysine 1,1-dimethyl ethyl ester (14.9 g; 20 mmol) (prepared according to Example 2 of WO 98/05626) in CHCl 3 (150 mL). The reaction mixture was stirred overnight. The solution was then washed with 5% aq. NaHCO 3 , the organic phase was separated, dried over Na 2 SO 4 and then evaporated under reduced pressure The crude product was purified by flash chromatography (n-Hexane/EtOAc=85/15 (v/v)) to give the desired compound (18.2 g; 15.7 mmol). Yield 78%. HPLC: 94% (area %). Weight loss (100° C.): 1.23%. The 13 C-NMR, MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Calcd. 68.48 10.10 4.84 Found 68.89 10.08 4.75
[0233] B) N 2 ,N 2 -Bis[2-[bis(carboxymethyl)amino]ethyl]-N 6 -[[[(3β)-cholest-5-en-3-yl]oxy]carbonyl]-L-lysine
[0234] 12.6 g of the product from the previous preparation (10.88 mmol) were dissolved in formic acid (250 mL) and refluxed for 1.5 h. The solution was evaporated under reduced pressure, the crude was suspended in water, stirred for 30 min and filtered to give the desired compound (7.8 g; 8.5 mmol). Yield 79%. HPLC: >91% (area %). K.F.: 3.73%. The 13 C-NMR, MS and IR spectra were consistent with this structure
Elemental analysis (%): C H N Calcd. 62.99 8.73 6.39 Found 62.70 8.89 6.31
[0235] C) [[N 2 ,N 2 -Bis[2-[bis(carboxymethyl)amino]ethyl]-N 6 -[[[(3β)-cholest-5-en-3-yl]oxy]carbonyl]-L-lysinato(5-)]gadolinate(2-)]disodium salt
[0236] 5.3 g of the free ligand from the previous preparation (5.8 mmol) were suspended in H 2 O (300 mL) and dissolved by the addition of 2 N NaOH (5.8 mL). A solution of GdCl 3 .6H 2 O (2.16 g; 5.8 mmol) in H 2 O (10 mL) was added dropwise to the reaction mixture mantained at pH 6.8 by the addition of 2 N NaOH (8.7 mL). After 1 h the solution was concentrated to 50 mL, the addition of CH 3 CN led to the precipitation of the title compound, which was filtered and dried (4.94 g; 4.60 mmol). Yield 79%. HPLC: >89% (area %). K.F.: 10.12%. Weight loss (120° C.): 11.89%. The MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Gd Na Calcd 51.38 6.66 5.21 14.62 4.28 Found 51.47 6.83 5.17 14.51 4.02
EXAMPLE 17
[10-[[2-[2-[2-(Dioctadecylamino)-2-oxoethoxy]-2-oxoethyl]amino]-2-oxoethyl]-1,4,7,10-tetraazacyclododecane-1,4,7-triacetato(3-)]gadolinium
[0237] [0237]
[0238] A) N-Octadecyl-1-octadecanamine (dioctadecylamine) (C.A.S. Registry No. 112-99-2.
[0239] A1) Dioctadecylcyanamide (C.A.S. Registry No. 113576-09-3)
[0240] Cyanamide (5 g; 119 mmol) was added to stirred 50% aq. NaOH (100 g). The mixture was cooled to 25° C., then a solution of Aliquat □ 336 (trioctylmethylammonium chloride) (2.42 g; 6 mmol) (commercial product) and 1-bromooctadecane (40.37 g; 121 mmol) in toluene (50 mL) was added. The mixture was vigorously stirred at 55° C. for 6 h. The organic phase was separated and evaporated to give the desired compound (38 g). The crude product was used in the hydrolysis step without any further purification. K.F.: <0.1%. The 1H-NMR, 13 C-NMR, MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Calcd. 81.24 13.64 5.12 Found 80.86 13.91 5.19
[0241] A2) N-Octadecyl-1-octadecanamine (dioctadecylamine)
[0242] The crude dioctadecylcyanamide (38 g) was suspended in 2.75 M H 2 SO 4 (150 mL) and the mixture was refluxed for 2.5 h. After cooling to room temperature H 2 O (100 mL), 30% NaOH (100 mL) and CHCl 3 (300 mL) were added. The organic phase was separated, dried and evaporated. The solid residue was suspended in Et 2 O and stirred for 1 h. The solid was filtered and washed with to give the desired compound (15.3 g; 29.3 mmol). Yield 48%. K.F.: 0.20%. The 1 H-NMR, 13 C-NMR, MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Calcd. 82.83 14.48 2.68 Found 82.61 14.65 2.69 anhydrous
[0243] B) 2-Hydroxy-N,N-dioctadecylacetamide
[0244] (Acetyloxy)acetyl chloride (3.8 g; 28.1 mmol) (commercial product) dissolved in CHCl 3 (150 mL) was added dropwise to a solution of dioctadecylamine (13.3 g; 25.5 mmol) and Et 3 N (3.9 mL; 28.1 mmol) in CHCl 3 (350 mL) and the solution was stirred at room temperature overnight. MeOH (250 mL) and 2 N NaOH (50 mL) were added to the solution. H 2 O was added to the reaction mixture and a two phase system was obtained. The lower organic layer was separated and evaporated. The solid residue was suspended in n-hexane and filtered to give the desired compound (12.1 g;20.9 mmol). Yield 82%. HPLC: 96% (area %). K.F.: <0.1%. The 13 C-NMR, MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Calcd. 78.69 13.38 2.41 Found 78.56 13.44 2.44
[0245] C) N-[(Phenylmethoxy)carbonyl]glycine [2-(dioctadecylamino)-2-oxoethyl]ester
[0246] A solution of DCC (2.1 g; 10.3 mmol) in CHCl 3 (50 mL) was added dropwise to a solution of 2-hydroxy-N,N-dioctadecylacetamide (5 g; 8.6 mmol) and Z-glycine (2 g; 9.5 mmol) in CHCl 3 (250 mL). DMAP (0.1 g; 0.9 mmol) was added to the resulting solution. After 1 h the reaction mixture was filtered and the solvent was evaporated. The crude was purified by flash chromatography (n-Hexane/EtOAc=7/3 (v/v)) to give the desired compound (5.6 g; 7.3 mmol). Yield 84%. HPLC: 99% (area %). K.F.: <0.1%. The 13 C-NMR, MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Calcd. 74.76 11.24 3.63 Found 75.45 11.47 3.68
[0247] D) Glycine [2-(dioctadecylamino)-2-oxoethyl]ester hydrochloride
[0248] 10% Pd/C (150 mg) was added to a solution of N-[(phenylmethoxy)-carbonyl]glycine [2-(dioctadecylamino)-2-oxoethyl]ester (1.2 g; 1.4 mmol) in EtOAc (100 mL) and the suspension was stirred for 3 h under hydrogen atmosphere at room temperature. After filtration (through a Millipore® filter FT 0.45 μm) 1.2 M HCl in MeOH (1.3 mL; 1.6 mmol) was added dropwise to the resulting solution obtaining the precipitation of a white solid that was filtered to give the desired compound (830 mg; 1.2 mmol).Yield 86%. HPLC: 100% (area %). K.F.: 0.22%. The MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Cl Calcd. 71.33 12.48 4.16 5.26 Found 71.72 12.48 4.30 5.30 anhydrous
[0249] E) 1,4,7,10-tetraazacyclododecane-1,4,7,10-tetraacetic acid tris(phenylmethyl)ester
[0250] E1) 1,4,7,10-Tetraazacyclododecane-1-acetic acid (1,1dimethylethyl)ester
[0251] A solution of t-butyl bromoacetate (25.3 g; 130 mmol) in CHCl 3 (500 mL) (commercial product) was added dropwise in 7 h to a solution of 1,4,7,10-tetraazacyclododecane (112.3 g; 650 mmol) (commercial product) in CHCl 3 (2 L) maintained under nitrogen at room temperature. After 14 h the solution was concentrated to 800 mL, washed with H 2 O, dried and evaporated to give the desired compound (39 g; 129 mmol). Yield 99%. GC: 92% (area %). K.F.: 0.42%. The 13 C-NMR, MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Na Cl Calcd. 56.20 10.06 18.56 = = Found 56.36 10.34 18.84 <0.1 4.56 anhydrous
[0252] E2) 1,4,7,10-Tetraazacyclododecane-1,4,7-tetraacetic acid -(1,1-dimethyl-ethyl)tris(phenylmethyl)ester
[0253] A solution of 1,4,7,10-tetraazacyclododecane-1-acetic acid (1,1-dimethylethyl)ester (36 g; 126 mmol) in DMF (200 mL) was added dropwise in 7 h to a suspension of benzyl bromoacetate (94.96 g; 414 mmol) and K2CO 3 (86.8 g; 628 mmol) in DMF (250 mL) maintained under nitrogen at room temperature. After 14 h the suspension was filtered *i and the solution evaporated to dryness. The residue was dissolved in EtOAc, washed with H 2 O, then with brine. The organic phase was i* separated, dried over Na 2 SO 4 and evaporated. The residue was purified by flash chromatography (CH 2 Cl 2 /MeOH=15/1 (v/v)) to give the desired compound (51 g; 65 mmol). Yield 51%. HPLC: 90% (area %). K.F.: 0.48%. The 13 C-NMR, MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Na Cl Calcd. 62.38 6.91 7.10 2.91 4.49 Found 61.77 6.74 6.90 2.90 4.95 anhydrous
[0254] E3) 1,4,7,10-Tetraazacyclododecane-1,4,7-tetraacetic acid tris(phenyl-methyl)ester
[0255] 1,4,7,10-Tetraazacyclododecane-1,4,7,10-tetraacetic acid (1,1-dimethyl-ethyl)tris(phenylmethyl)ester adduct with NaCl (47.11 g; 60 mmol) was dissolved in dioxane (500 mL). The solution was treated with 12 N HCl (500 mL) under nitrogen at room temperature, obtaining a precipitate. After 16 h the suspension was evaporated and the residue dissolved in H 2 O by ultrasound sonication. The solution (pH 2) was loaded onto an Amberlite® XAD-1600 resin column (900 mL) and eluted with a CH 3 CN/H 2 O gradient. The fractions containing the product were concentrated to remove CH 3 CN, then extracted with EtOAc. The organic phase was dried over Na 2 SO 4 and evaporated. The residue was triturated with EtOAc to give the desired compound (21 g; 31 mmol). Yield 52%. HPLC: 99% (area %). K.F.: <0.1%. The 13 C-NMR, MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Calcd. 65.86 6.87 8.30 Found 66.00 7.03 8.33
[0256] F) 10-[[2-[2-[2-(Dioctadecylamino)-2-oxoethoxy]-2-oxoethyl]-amino]-2-oxoethyl]-1,4,7,10-tetraazacyclododecane-1,4,7-triacetic acid tris(phenylmethyl)ester
[0257] To a suspension of 1,4,7,10-tetraazacyclododecane-1,4,7,10-tetraacetic acid tris(phenylmethyl)ester (2.7 g; 4 mmol) and glycine [2-(dioctadecylamino)-2-oxoethyl]ester hydrochloride (3 g; 4.4 mmol) in CHCl 3 (250 mL) was added DIEA (diisopropylethylamine) (1.5 mL; 8.8 mmol). BOP ((benzotriazol-1-yloxy)tris(dimethylamino)phosphonium hexafluorophosphate, commercial product) (2.2 g; 4.8 mmol) was added to the resulting solution, which was stirred at room temperature for 2 h. The solvent was evaporated and the solid residue was suspended in 9:1 i-PrOH/H 2 O and filtered to obtain the desired compound (4.9 g; 3.8 mmol). Yield 95%. The 13 C-NMR, MS and IR spectra were consistent with the given structure.
Elemental analysis (%): C H N Calcd. 71.48 9.66 6.50 Found 71.23 9.54 6.38
[0258] G) 10-[(2-[2-[2-(Dioctadecylamino)-2-oxoethoxy]-2-oxoethyl]-amino]-2-oxoethyl]-1,4,7,10-tetraazacyclododecane-1,4,7-triacetic acid
[0259] 10% Pd/C (150 mg) was added to a solution of 10-[[2-[2-[2-(dioctadecylamino)-2-oxoethoxy]-2-oxoethyl]amino]-2-oxoethyl]-1,4,7-10-tetraazacyclododecane-1,4,7-triacetic acid tris(phenylmethyl)ester (1.5 g; 1.2 mmol) in CH 3 COOH (150 mL) and the suspension was stirred for 8 h under hydrogen atmosphere at room temperature. After filtration (through a Millipore® filter FT 0.45 m) the solvent was evaporated and the residue was dried under reduced pressure to give the desired compound (3 g; 1 mmol). Yield 83%. HPLC: 97% (area %) The 13 C-NMR, MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Calcd. 65.72 10.44 8.21 Found 65.54 10.22 8.07
[0260] H) [10-[[2-[2-[2-(Dioctadecylamino)-2-oxoethoxy]-2-oxoethyl]-amino]-2-oxoethyl]-1,4,7,10-tetraazacyclododecane-1,4,7-triacetato(3-)]gadolinium
[0261] The free ligand from the previous preparation (2.2 g; 2.2 mmol) was dissolved in 3:1 EtOH/H 2 O (120 mL); a 0.5 M aq. solution of (CH 3 COO) 3 Gd (4.4 mL) was added dropwise. The resulting solution was heated at 50° C. for 4 h. The solvent was evaporated to give the-title compound (2.2 g; 1.9 mmol). Yield 86%. HPLC: 95% (area %). The MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Gd Calcd. 57.11 8.82 7.14 13.35 Found 56.98 8.74 6.98 13.23
EXAMPLE 18
[10-[1-Methylene-14-octadecyl-2,10,13-trioxo-6,9-dioxa-3,14-diazadotriacontanyl]-1,4,7,10-tetraazacyclododecane-1,4,7-triacetato(3-)]gadolinium
[0262] [0262]
[0263] A) 4-(Dioctadecylamino)-4-oxobutanoic acid (C.A.S. Registry No. 37519-63-4)
[0264] A suspension of dioctadecylamine (24.5 g; 47 mmol) (prepared according to Example 17, Step A) and succinic anhydride (4.7 g; 47 mmol) in THF (100 mL) was stirred at room temperature for 18 h. Solvent was removed by evaporation and the residue was dissolved in CH 2 Cl 2. The solution was washed with 1 N HCl, dried and evaporated. The crude was crystallized from CH 3 CN to give the desired compound (21.8 g; 35 mmol). Yield 75%. K.F.: 0.37%. The 13 C-NMR, MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Calcd. 77.23 12.80 2.25 Found 77.52 13.38 2.36 anhydrous
[0265] B) [10-[1-Methylene-14-octadecyl-2,10,13-trioxo-6,9-dioxa-3,14-diazadotriacontanyl]-1,4,7,10-tetraazacyclo-dodecane-1,4,7-triacetato(3-)]gadolinium
[0266] 4-(Dioctadecylamino)-4-oxobutanoic acid (7.6 g; 12.3 mmol) in CHCl 3 (100 mL) was added to a solution of 10-[2-[[2-(2-hydroxyethoxy)ethyl]amino]-1-(methylene)-2-oxoethyl]-1,4,7,10-tetraazacyclododecane-1,4,7-triacetato(3-)]gadolinium (8.1 g; 12.3 mmol) (prepared according to Example 2 of WO 96/04259) in DMSO (100 mL), then 1-(3-dimethylaminopropyl)-3-ethylcarbodiimmide hydrochloride (EDCI) (2.6 g; 13.4 mmol) and 4-dimethylaminopyridine (DMAP) (0.75 g; 6.1 mmol) were added and the clear solution was stirred at room temperature. After 24 h more EDCI (2.6 g; 13.4 mmol) was added. After another 24 h CH 3 CN and H 2 O were added to obtain the precipitation of a solid, which was filtered with a paper filter. The solid was dissolved in 1/1 CH 2 Cl 2 /MeOH and the solution loaded onto a silica gel flash column (CH 2 Cl 2 /MeOH=1/1 (v/v) (5 L); CH 2 Cl 2 /MeOH/H 2 O=5/5/1 (v/v/v) (4 L)). The fractions containing the product were evaporated to give the title compound (6 g; 4.7 mmol). Yield 38%. HPLC: 98% (area %). K.F.: 3.02%. The MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Gd Calcd. 58.06 8.87 6.66 12.46 Found 58.25 8.92 6.66 12.38 anhydrous
EXAMPLE 19
[10-[2-[2-(Dioctadecylamino)-2-oxoethoxy]-2-oxoethyl]-1,4,7,10-tetraazacyclododecane-1,4,7-triacetato(3-)]gadolinium
[0267] [0267]
[0268] A) 10-[2-[2-(Dioctadecylamino)-2-oxoethoxy]-2-oxoethyl]-1,4,7,10-tetraazacyclododecane-1,4,7-triacetic acid tris-(phenylmethyl)ester
[0269] DBU (820 μL; 5.5 mmol) was added to a suspension of 1,4,7,10-tetraazacyclododecane-1,4,7,10-tetraacetic acid tris(phenylmethyl)ester (prepared according to Step E3 of Example 17) (3.71 g; 5.5 mmol) in toluene (350 mL) obtaining a clear solution, then 2-bromo-N,N-dioctadecylacetamide (prepared according to Example 5, Step A) (3.9 g; 6.05 mmol) dissolved in toluene (50 mL) was added dropwise. After 2 h the reaction mixture was filtered and the solvent was evaporated. The crude was suspended in CH 3 CN (50 mL) and the insoluble was filtered off with a paper filter. The solution was evaporated obtaining the desired product (4.63 g; 3.74 mmol). Yield 68%. The 13 C-NMR, MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Calcd. 72.83 9.86 5.66 Found 72.67 9.58 5.71 anhydrous
[0270] B) 10-[2-[2-(Dioctadecylamino)-2-oxoethoxy]-2-oxoethyl]-1,4,7,10-tetraazacyclododecane-1,4,7-triacetic acid
[0271] 10% Pd/C (0.4 g) was added to a solution of the product from the previous preparation (4.9 g; 4 mmol) in CH 3 COOH (400 mL) and the suspension was stirred for 6 h under hydrogen atmosphere (consumed H 2 : 270 mL; 12 mmol) at room temperature. After filtration through a Millipore® filter FT 0.45 μm the solvent was evaporated under reduced pressure and the residue was dried (1.3 kPa; NaOH pellets; 35° C.) to give the desired compound (3.1 g; 3.2 mmol). Yield 80%. The 13 C-NMR, MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Calcd. 67.11 10.74 7.25 Found 67.15 10.67 7.11 anhydrous
[0272] C) [10-[2-[2-(Dioctadecylamino)-2-oxoethoxy]-2-oxoethyl]-1,4,7,10-tetraazacyclododecane-1,4,7-triacetato(3-)]gadolinium
[0273] The free ligand from the previous preparation (3.6 g; 3.7 mmol) was dissolved in 2:1 i-PrOH/H 2 O (250 mL) and a 0.5 M aq. solution of (CH 3 COO) 3 Gd (7.4 mL) was added dropwise. The resulting solution was heated at 50° C. for 6 h. The solvent was evaporated to give the title compound (3.6 g; 3.2 mmol). Yield 87%.
[0274] MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Gd Calcd. 57.88 8.99 6.25 14.03 Found 57.69 8.88 6.31 13.95 anhydrous
EXAMPLE 20
[10-[2-[Bis[2-[(1-oxohexadecyl)oxy]ethyl]amino]-2-oxoethyl]-1,4,7,10tetraazacyclododecane-1,4,7-triacetato(3-)]gadolinium
[0275] [0275]
[0276] A) Hexadecanoic acid iminodi-2,1-ethanediyl ester hydrochloride (C.A.S. Registry No. 84454-85-3)
[0277] Palmitoyl chloride (29.8 g; 108.4 mmol) (commercial product) was added dropwise in 30 min to a solution of diethanolamine hydrochloride (7 g; 49.4 mmol) (commercial product) in DMF (100 mL). After standing for 1.5 h a white solid crystallized. MeOH (350 mL) was added and the reaction mixture heated to reflux. After cooling to room temperature the recrystallized product was filtered to give as a white solid hexadecanoic acid iminodi-2,1-ethanediyl ester hydrochloride (15 g; 24.2 mmol). Yield 49%. K.F.: 0.4%. The 13 C-NMR, MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Cl Calcd. 69.92 11.73 2.26 5.73 Found 69.79 11.74 2.33 5.82 anhydrous
[0278] B) 10-(2-[Bis[2-[(1-oxohexadecyl)oxy]ethyl]amino]-2-oxoethyl]-1,4,7,10-tetraazacyclododecane-1,4,7-triaceticacidtris(phenylmethyl)ester
[0279] A 50% solution of 1-propanephosphonic acid cyclic anhydride (14.4 g; 22.6 mmol) in EtOAc (commercial product) was added to a solution of 1,4,7,10-tetraazacyclododecane-1,4,7,10-tetraacetic acid tris(phenyl-methyl)ester (15 g; 22.2 mmol) (prepared according to Step E3 of Example 17), hexadecanoic acid iminodi-2,1-ethanediyl ester hydrochloride (14 g; 22.6 mmol) and Et 3 N (6.5 mL; 46.6 mmol) in CH 2 Cl 2 (200 mL). The reaction mixture was stirred at room temperature for 24 h, then more 1-propanephosphonic acid cyclic anhydride (14.4 g; 22.6 mmol) was added. After another 24 h the mixture was washed with brine, dried and evaporated. The residue was purified by flash chromatography (CH 2 Cl 2 /MeOH=9/1 (v/v)) to give the desired compound (17 g; 13.7 mmol). Yield 62%. HPLC: 96% (area %). The 13 C-NMR, MS and IR spectra were consistent with the proposed structure.
Elemental analysis (%): C H N Calcd. 70.78 9.36 5.65 Found 70.57 9.38 5.48 anhydrous
[0280] C) 10-[2-[Bis[2-[(1-oxohexadecyl)oxy]ethyl]amino]-2-oxoethyl]-1,4,7,10-tetraazacyclododecane-1,4,7-triacetic acid
[0281] 10% Pd/C (1.6 g) was added to a solution of 10-[2-[bis[2-[(1-oxohexadecyl)oxy]ethyl]amino]-2-oxoethyl]-1,4,7,10-tetraazacyclo-dodecane-1,4,7-triacetic acid tris(phenylmethyl)ester (16 g; 12.9 mmol) in EtOH (500 mL) and the suspension was stirred for 12 h under hydrogen atmosphere at room temperature. After filtration through a Millipore® filter FT 0.45 μm the solution was evaporated under reduced pressure to give the desired compound. Yield 93%. HPLC: 98% (area %). The 13 C-NMR, MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Calcd. 64.50 10.10 7.23 Found 64.38 10.01 7.15 anhydrous
[0282] D) [10-[2-[Bis[2-[(1-oxohexadecyl)oxy]ethyl]amino]-2-oxoethyl]-1,4,7,10-tetraazacyclododecane-1,4,7-triacetato-(3)]gadolinium
[0283] (CH 3 COO) 3 Gd.4H 2 O (4.63 g; 11.4 mmol) was added to a solution of the free ligand from the previous preparation (11 g; 11.4 mmol) in EtOH (500 mL) at 50° C. After 6 h the solution was evaporated and dried under reduced pressure to give the title compound (12.3 g; 11 mmol). Yield 96%. HPLC: 99% (area %). The MS and IR spectra were consistent with the structure.
Elemental analysis (%): C H N Gd Calcd. 55.64 8.44 6.24 14.01 Found 55.57 8.41 6.12 13.92
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Substituted polycarboxylic ligand molecules and corresponding metal complexes of said ligands, preferably paramagnetic metals complexes for generating responses in the field of magnetic resonance imaging (MRI)
The paramagnetic complexes of the polycarboxylic ligands possess advantageous tensioactive properties and are useful as MRI contrast media in formulations for investigating the blood pool.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. Ser. No. 09/857,337, filed Jun. 4, 2001, now U.S. Pat. No. 6,689,366. which is a 371 of PCT/US99/29577, international filing date of Dec. 14, 1999, which claims priority to U.S. Ser. No. 60/112,610, filed Dec. 17, 1998, now abandoned.
FIELD OF THE INVENTION
The present invention is directed to recombinant papillomavirus virus-like particles (VLPs) comprising heterologous neutralizing conformational epitopes. This invention also includes nucleic acids encoding these VLPs and assays employing these synthetic VLPs.
BACKGROUND OF THE INVENTION
Human papillomavirus (HPV) types 6 and 11 are the causative agents for more than 90% of all genital condyloma and laryngeal papillomas. HPV is a DNA virus which is enclosed in a capsid which is made up principally of L1 protein. The L1 proteins of HPV types 6 and 11 are very similar at both the amino acid and nucleotide level. Consequently, it has been difficult to develop assays which reliably distinguish between these two types of infection.
HPV 11 L1 residues Gly 131 -Tyr 132 were previously identified as responsible for the type-specific binding of several HPV 11 neutralizing monoclonal antibodies (Ludmerer et. al. 1996. “Two Amino Acid Residues Confer Type Specificity to a Neutralizing, Conformationally Dependent Epitope on Human Papillomavirus Type 11 ”. J. Virol. 70:4791–4794). Within this same work, it was further demonstrated that a substitution at Ser 346 of the HPV 11 L1 sequence dramatically reduced binding of neutralizing monoclonal antibody H11.H3, and that the effect was specific for this antibody. Additional studies demonstrated that several HPV 11 neutralizing antibodies bound to a stretch of the HPV 11 L1 sequence between residues 120–140, whereas H11.H3 bound to a completely distinct site (Ludmerer et al. 1997. “A Neutralizing Epitope of Human Papillomavirus Type 11 is Principally Described by a Continuous Set of Residues Which Overlap a Distinct Linear, Surface-Exposed Epitope”. J. Virol. 71:3834–3839).
However, these studies did not define which amino acid residues confer type specificity of binding for antibody H11.H3 completely. Furthermore, there may be other regions of HPV 11 VLPs, not described in these studies, which can elicit important HPV 11-specific, conformationally dependent responses. In addition, VLP-dependent antibodies specific for HPV 6 have also been generated (Christensen et al. 1996 “Monoclonal Antibodies to HPV-6 L1 Virus-Like Particles Identify Conformational and Linear Neutralizing Epitopes on HPV-11 in Addition to Type-Specific Epitopes on HPV-6 ”. Virology 224(2):477–486). These antibodies could be useful in evaluation of infectivity by HPV 6. It would be desirable to determine the exact amino acids involved in the specificity of HPV type 6- and additional type 11-specific conformational epitope formations so that improved assays and vaccines may be developed.
DETAILED DESCRIPTION OF THE INVENTION
This invention is directed to a recombinant papillomavirus L1 protein of a first subtype which comprises a conformational epitope of a papillomavirus L1 protein of a second subtype. Preferably, the L1 protein is part of a virus-like particle (VLP). In some embodiments, the papillomavirus is a human papillomavirus (HPV). In a specific embodiment of this invention, a human papillomavirus L1 protein comprises a heterologous conformational epitope from HPV 6. In another specific embodiment of this invention, a human papillomavirus L1 protein comprises a heterologous conformation epitope from HPV 11.
Another aspect of this invention are nucleic acids encoding these heterologous L1 proteins, particularly DNA.
Another aspect of this invention are assays employing the synthetic virus-like particles.
Another aspect of this invention are vaccines comprising nucleic acids and/or proteins encoded by the nucleic acids, wherein the proteins comprise a heterologous conformational epitope.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the amino acid sequences for the L1 protein of HPV 6 and HPV 11 mutants utilized in these studies.
FIG. 2 are graphs which show that amino acid substitutions at critical positions within the HPV 6 L1 sequence eliminate binding of monoclonal antibodies H6.B10.5, H6.M48, and H6.N8. In the first graph, the left most bar is H6.B10.5; the second bar is H6,.M48; the third bar is H6.C6 and the right most bar is H6.J54. In the second graph the left bar is H6.N8 and the right bar is H6.C6.
FIG. 3 shows substitutions into the HPV 11 L1 sequence which confer binding of HPV 6 specific monoclonal antibodies H6.B10.5, H6.M48, and H6.N8. The left most bar is H6.B10.5; the next bar is H6.M48; the next bar is H6.N8 and the right most bar is H6.C6.
FIG. 4 shows that three amino acid substitutions into the HPV 6 L1 sequence between residues 345 and 348 confer binding of HPV 11 monoclonal antibodies H11.G3 and H11.H3. It also shows that seven substitutions between residues 262 and 289 also confer binding of HPV11 monoclonal H11.G3. The left most bar is H11.H3; the second bar is H11.B2; the third bar is H11.G3; and the right most bar is H11.C6.
FIG. 5 shows that three substitutions into the HPV 6 sequence between residues 49 and 54, or four substitutions into the HPV 6 sequence between residues 169 and 178 confer binding of HPV 11 monoclonal antibody H11.A3.2. The left most bar is H11.A3.2; the middle bar is H11.B2 and the right bar is H11.C6.
As used throughout this specification and claims, amino acid residues (wild-type) are referred to by a two-part designation which is (i) the one-letter standard amino acid abbreviation of the wild-type residue, followed by (ii) the position of the amino acid in the L1 protein. Residues specified in this format would also be for a particular HPV type. For example, “HPV 6 K53” means the lysine residue at position 53 of HPV 6 L1.
As used throughout this specification and claims, mutated amino acids are referred to by a three-part designation which is (i) the one-letter standard amino acid abbreviation of the wild-type amino acid (ii) the position of the amino acid in the L1 protein of a particular HPV type, and (iii) the one letter abbreviation for the amino acid which is now present. For example, HPV 6 “T345S” means that the threonine residue, normally present at position 345 of HPV 6 L1, has been changed to serine.
Monoclonal antibodies referred to throughout this specification are listed below (all were obtained from Dr. Neil Christensen of Pennsylvania State University, Hershey, Pa.).
H6.B10.5—this antibody is specific to HPV 6 L1 protein in VLPs.
H6.M48—this antibody is similar to H6.B10.5 in that it binds to HPV 6 L1 protein in VLPs.
H6.N8—this antibody is similar to H6.B10.5 in that it binds to HPV 6 L1 protein in VLPs.
H11.G3—this antibody is specific for HPV 11 VLPs and its binding is conformationally dependent.
H11.H3—this antibody is specific for HPV 11 VLPs, and is neutralizing. It is known that HPV 11 L1 residue S346 is critically important for the binding of H11.H3, and that a substitution at this position does not affect binding of HPV 11-specific VLP-dependent antibodies demonstrated to bind elsewhere.
H6.J54—this antibody binds VLPs of both HPV 6 and HPV 11, but not other HPV types.
H6.C6—this antibody binds both HPV 6 and 11 VLPs; it also binds both native and denatured material. It can be used to determine total L1 production.
H11.A3—this antibody specifically binds HPV 11 VLPs, but at a different region than either H11.B2 or H11.H3.
H11.B2—similar to H11.A3 in that it specifically binds HPV 11 VLPs, but at a different region than either H11.H3 or H11.A3.
In order to develop an assay which would distinguish between HPV 6 and HPV 11 responses, the amino acids residues that confer antigenic type-specificity on HPV subtypes had to be determined. Therefore we focused on regions of HPV 6 which have multiple divergences from HPV 11 within a short stretch. To streamline the process of analyses, mutants of HPV 6 which were multiply mutated at these regions were synthesized and the VLPs produced from them were analyzed for effects on antibody binding.
In order to construct the VLPs of this invention, the amino acid residues which make up the conformational epitopes where type specific, VLP-dependent monoclonal antibodies bind had to be determined. This was accomplished by mapping the binding sites of monoclonal antibodies which bind specifically to either HPV 6 or HPV 11 VLPs. L1 of either HPV 6 or HPV 11 was modified by introducing amino acid substitutions at various positions, then determining if the mutant protein would bind either HPV 6- or HPV 11-specific monoclonal antibodies. Mapping was confirmed by demonstrating transfer of binding of a monoclonal to one of these types to the other type which had been minimally modified. Modified VLPs used for these transfers were demonstrated to retain binding of other type-specific antibodies.
In accordance with this invention it has been found that HPV 6 L1 with three HPV 11 L1-like substitutions, at T345, T346 and S348 produce VLPs that bind HPV 11-specific monoclonal antibodies H11.G3 and H11.H3. These two antibodies can be distinguished in that H11.G3, but not H11.H3, can also bind HPV 6 VLPs which contain seven substitutions between residues 262 and 290. In specific embodiments of this invention, the substitutions are T345S, T346K, and S348A.
Furthermore, we show that HPV 6 L1 with either three HPV 11 L1-like substitutions between amino acids 49 and 54 (at F49, R53, and A54), or four HPV 11 L1-like substitutions between residues 169 and 178 (at K169, T172, P175, and A178), can bind HPV 11-specific, VLP dependent monoclonal antibody H11.A3.2. In specific embodiments of these class of mutants, the substitutions are (i) the combination of F49Y, R53K, and A54V; and (ii) K169T, T172S, P175S, and A178N.
Thus one aspect of this invention is a recombinant HPV 6 L1 protein which also presents a major neutralizing, conformational epitope of HPV 11. In a preferred embodiment, the conformational epitope comprises T345S, T346K and S348A. These whole regions may be transferred to other HPV types through alignment, generating more refined tools for serological analysis. Thus this invention comprises any papillomavirus type which comprises a heterologous neutralizing conformational epitope of HPV 11 mapped in these studies.
This invention also includes HPV 6 L1 proteins with HPV 11-like substitutions between residues 49–54, 169–178, and 261–290, specifically at (i) F49, R53, and A54; (ii) K169, T273, P175 and A178; and (iii) E262, T270, S276, G277, T280, G283, and N289. In specific embodiments of this class of mutants, the substitutions are: (i) F49Y, R53K, and A54V; (ii) K169T, T273S, P175S, and A178N; and (iii), E262T, T270D, S276G, G277N, T280S, G283A, and N289H. These portions of the protein comprise part of the epitope for HPV 11-specific VLP dependent monoclonal antibodies H11.A3.2, and H11.G3.
A further aspect of this invention is nucleic acids encoding the L1 proteins comprising the heterologous conformational epitopes discussed above, including HPV 11 conformational epitope T345S, T346K and S348A. As L1 protein and nucleic acid sequences are generally well known, it is within the skill of the ordinary artisian to insert the mutations described herein using conventional genetic engineering/protein engineering techniques. In a preferred embodiment the nucleic acid is a DNA, and codons may be optimized for increased viral expression for a given host cell.
Other aspects of this invention include vectors such as plasmids which contain the nucleic acids encoding L1 proteins comprising a heterologous HPV 11 conformational epitope. Also included in this invention are host cells, particularly yeast, bacterial, insect, and mammalian cells containing a nucleic acid encoding an L1 protein comprising an HPV 11 conformational epitope, whether or not present in a vector.
In another aspect of this invention, HPV 6 epitopes were transferred to HPV 11. In this embodiment, HPV 11 L1 modified with either one (at K53) or two ( at Y49 and K53) substitutions show approximately a 10-fold increase in binding of HPV 6-specific monoclonal antibody H6.N8. In the case of H6.N8, the level of binding was comparable to that observed with prototype HPV 6 VLPs. This demonstrates that part of the epitope, including its type 6 specificity, is defined by these and neighboring residues. Preferred substitutions are K53R, and the combinantion of Y49F and K53R.
Another HPV 11 heterologous L1 protein comprises three changes: at Y49, K53, and V54. HPV 11 L1 modified with these three changes show approximately four-fold binding above background to HPV 6-specific monoclonal antibodies H6.B10.5 and H6.M48, in addition to binding monoclonal antibody H6.N8 as discussed above. In specific embodiments of this class of mutants, the substitutions are Y49F, K53R, and V54A.
Another HPV 11 L1 mutant encompasses seven changes in two regions (49–54 and 170–179). These changes are at positions Y49, K53, V54, T170, S173, S176, and N179. HPV 11 L1 modified with these seven substitutions show binding to antibodies H6.B10.5, H6.M48, and H6.N8 comparable to that observed with prototype HPV 6 VLPs. These HPV 6 epitopes can be moved to any desired PV type. In preferred embodiments the substitutions are HPV 6 residues F49, R53, A54, K169, T172, P175, and A178, placed into equivalent positions of the selected PV L1 type by alignment.
Another aspect of this invention is nucleic acids encoding the L1 proteins comprising a heterologous conformational epitope, including (i) HPV 6 conformational epitope K53R, (ii) the combination of Y49F and K53R, (iii) the combination of Y49F, K53R, and V54A, (iv) the combination of Y49F, K53R, V54A, T170K, S173T, S276P and N179A; and (v) combinations of (i), (ii), (iii) and/or (iv). As L1 protein and nucleic acid sequences are generally well known, it is within the skill of the ordinary artisian to insert the mutations described herein using conventional genetic engineering/protein engineering techniques. In a preferred embodiment the nucleic acid is a DNA, and codons may be optimized for increased viral expression for a given host cell. Other aspects of this invention include vectors such as plasmids which contain the nucleic acids encoding L1 proteins comprising a heterologous HPV 6 conformational epitope. Also included in this invention are host cells, particularly yeast, bacterial, insect, and mammalian cells containing a nucleic acid encoding an L1 protein comprising an HPV 6 conformational epitope, whether or not present in a vector.
In another aspect of this invention is the transfer of conformational epitopes to a more distantly-related PV type. Almost every species of animal studied to date has a PV, including cottontail rabbit, bovine, canine, and the like. This discussion and the examples focus on the use of cottontail rabbit papillomavirus (CRPV) comprising heterologous conformational epitopes to produce serological reagents of higher specificity to monitor HPV 6 and HPV 11 responses and infectivity. However, it is intended that any PV can substitute for CRPV for these uses, and the present invention is specifically directed to this broad usage. Thus, this invention specifically includes a recombinant CRPV L1 protein comprising at least one heterologous conformational epitope. In specific embodiments, the heterologous conformational epitope is selected from the groups consisting of human HPV 6 and HPV 11 epitopes, and placed into CRPV L1 by amino acid alignment. This invention also includes nucleic acids encoding the recombinant protein, vectors comprising the nucleic acids, and host cells which comprise the vectors.
A further aspect of the invention is the generation of VLPs which can elicit both HPV 6 and HPV 11 responses. HPV 6 VLPs which contain HPV 11 substitutions T345S, T346K, and S348A will present a major HPV 11 neutralizing epitope alongside all HPV 6 responses. HPV 11 VLPs modified to contain HPV 6 substitutions, such as the combination of Y49F and K53R; the combination of Y49F, K53R, and V54A; or the combinantion of Y49F, K53R, V54A, T170K, S173T, S176P and N179A will present the one known HPV 6 specific conformational epitope alongside most HPV 11 epitopes, including the major neutralizing epitopes. The latter is significant in that all known neutralizing epitopes are conformationally dependent, and conformational dependence is believed to be a necessary property of such epitopes.
Because of the high identity between wild-type HPV 6 and HPV 11 L1 sequences, present serological assays cannot distinguish responses between these two types very well. The modified VLPs of this invention will identify HPV 6 and HPV 11 immune responses upon infectivity or immunization. VLPs which elicit neutralizing responses to both types can simplify vaccine manufacturing, and lower costs for the consumer.
Another aspect of this invention is the use of these derivatized HPV 6 and HPV 11 VLPs as reagents in serological assays. Because most epitopes are shared between HPV 6 and HPV 11 VLPs, polyclonal sera to one competes with the binding of a type-specific monoclonal antibody to the other due to steric hindrance from the binding of antibodies to neighboring sites. In accordance with this invention, HPV 6 and HPV 11 epitopes can be moved to a more distant VLP type, such as CRPV, where there are no cross-reactive epitopes between CRPV and either HPV 6 or HPV 11. Therefore, presentation of HPV 6- and HPV 11-specific epitopes on a CRPV VLP eliminates the problem of steric competition from neighboring epitopes. Only the presence of antibody in a polyclonal response to the specifically transferred epitope should compete with monoclonal antibody binding.
One assay of this invention distinguishes between the presence of HPV 6 and HPV 11 antibodies in a sample suspected of containing either or both types of antibodies comprising the steps of:
a) contacting the sample with recombinant PV protein comprising either a heterologous HPV conformational epitope or a heterologous HPV 11 conformational epitope; and
b) detecting binding between the antibodies present in the sample and the recombinant PV protein;
wherein binding to a heterologous HPV 11 conformational epitope indicates the presence of HPV 11 antibodies in the sample, and binding to a HPV 6 conformational epitope indicates the presence of HPV 6 antibodies in the sample.
Yet another aspect of this invention comprises an assay for discrimination between HPV 6 and HPV 11 in a subject suspected of being infected with either HPV 6 or HPV 11, or vaccinated for protection against HPV 6 and/or HPV 11 infection, comprising the steps of:
a) obtaining a blood sample from the subject, wherein said blood sample comprises either HPV 6 or HPV 11 antibodies;
b) contacting the sample with a recombinant VLP comprising either a heterologous HPV 6 conformational epitope or a heterologous HPV 11 conformational epitope; and
c) detecting binding between the antibodies present in the sample and the heterologous VLP;
wherein binding a VLP comprising a heterologous HPV 11 conformational epitope indicates an HPV 11 infection, and binding to a VLP comprising a heterologous HPV 6 conformational epitope indicates an HPV 6 infection. In preferred embodiments, the VLP is from a distantly related PV, such as a CRPV VLP.
Another aspect of this invention are vaccines which comprise either L1 protein comprising a heterologous conformational epitope, or the nucleic acid which encode these proteins. In specific embodiments, the protein comprises both an HPV 6 and an HPV 11 epitope; either or both may be heterologous. This vaccine will confer protection against both types of HPV infection, as neutralizing antibodies to both viral epitopes are produced. The protein-based vaccine may be formulated according to conventional vaccine formulation techniques, and include such well known, traditional components as adjuvants, and pharmaceutically acceptable carriers. This vaccine may be administered intranasally, intravenously, intramuscularly, or subcutaneously, either with or without a booster dose. Likewise, nucleic-acid based vaccines, or specifically, DNA vaccines may be similarly formulated and administered.
The following examples are provided to further define the invention without, however, limiting the invention to the particulars of these examples.
EXAMPLE 1
Generation of Test Expression Constructs
The HPV 6 and HPV 11 L1 structural genes were cloned from clinical isolates using PCR with primers designed from the published L1 sequence. The L1 genes subsequently were subcloned both into BlueScript (Pharmacia) for mutagenesis, and pVL1393 (Stratagene) for expression in Sf9 cells.
Mutations were introduced into the L1 gene using Amersham Sculptor in vitro mutagenesis kit according to the manufacturer's recommendations. The appearance of the desired mutation was confirmed by sequencing, and the mutated gene subcloned into pVL1393 for expression in Sf9 cells.
EXAMPLE 2
Transient Expression of L1 VLPs in SF9 Cells
SF9 cells were transfected using BaculoGold Transfection kit (Pharmingen). Transfections were done essentially according to the manufacturer's instructions with the following modifications. 8×10 8 Sf9 cells were transfected in a 100 mM dish, with 4 μg of BaculoGold DNA and 6 μg of test DNA. Cells were harvested after 6 days and assayed for VLP production.
EXAMPLE 3
Preparation of SF9 Extracts and ELISA Assays
Cells were harvested six days after transfection, by scraping followed by low speed centrifugation. Cells were resuspended in 300 ml of breaking buffer (1 M NaCl, 0.2 M Tris pH 7.6) and homogenized for 30 minutes on ice using a Polytron PT 1200 B with a PT-DA 1205/2-A probe (Brinkman) in a Falcon 1259 tube. Samples were spun at 2500 rpm for 3 minutes to pellet debris. Tubes were washed with an additional 150 ml of breaking buffer, supernatants collected in a 1.5 ml microfuge tube, and respun for 5 minutes in an Eppendorf microfuge (Brinkman). Supernatants were collected and stored at 4 C. until use. ELISA assays typically were performed the same day, although samples may be frozen on dry ice, stored at −80 C., thawed and assayed at convenience.
5 ml of extract was diluted into 50 ml of 1% BSA in PBS (phosphate buffered saline; 20 mM NaPO 4 , pH 7.0, 150 mM NaCl) and plated onto a polystyrene plate. The plate was incubated overnight at 4 C. Extracts were removed and the plate blocked with 5% powdered milk in PBS. All subsequent wash steps were performed with 1% BSA in PBS. The plate was incubated at room temperature with primary antibody for 1 hour. Primary antibodies (monoclonal antibodies generated against HPV 11 virions, HPV 11 VLPs, or HPV 6 VLPs) were obtained as ascites stock from Dr. Neil Christensen (Pennsylvania State University). They were diluted 10 5 -fold in 1% BSA PBS before use. After washing, plates were incubated for 1 hour with secondary antibody. The secondary antibody, peroxidase labeled Goat anti-Mouse IgG (γ), was purchased from Kirkegaard & Perry Laboratories, Inc. and used at 10 3 dilution in 1% BSA in PBS. After a final washing, a horse radish peroxidase assay was performed and absorbance read at 450 nm.
EXAMPLE 4
Two Near Adjacent Substitutions into the HPV 6 L1 Sequence Eliminates Binding of HPV 6-specific, VLP-dependent Monoclonal Antibodies
We predicted that an HPV 6-specific monoclonal antibody (one which does not bind to closely related HPV 11 VLPs) would bind a region where there are several adjacent or near adjacent residues between types 6 and 11 L1 genes. Excluding the C-terminus (it has been shown that the C-terminus is non-essential for VLP formation), there are five such regions. Using standard procedures, we generated test clones which had multiple 11-like substitutions in each of these five regions. Only clone 1393:6:49–53, which harbors substitutions at L1 residues 49 and 53 (F49Y, R53K) produced VLPs which had an effect on H6.B10.5, H6.M48, and H6.N8 binding. Binding of HPV 11-cross-reactive antibody H6.J54, also VLP-dependent, was not disturbed, demonstrating the presence of VLPs.
EXAMPLE 5
Transfer of Binding of H6.B10.5, H6.M48 and H6.N8 to Modified HPV 11 VLPs
Based upon the studies in Example 4, we generated mutants of HPV 11 L1 with HPV 6-like substitutions at positions within the first 60 residues where the two L1 sequences differ. We also generated HPV 11 mutants with single substitutions at either Y49F or K53R. A third HPV 11 clone harbored three HPV 6-like substitutions between residues 49 to 54 (Y49F, K53R, and V54A), and a fourth clone harbored three HPV 6-like substitutions between residues 49 to 54 and 4 substitutions between residues 170 to 180 (Y49F, K53R, V54A and T170K, S173T, S176P, N179A).
Clones 1393:11:K53R and 1393:11:Y49F,K53R both generated VLPs which produced approximately ten-fold binding above background of HPV 6-specific monoclonal antibody H6.N8. An additional clone, 1393:11:Y49F,K53R,V54A, generated VLPs which showed approximately four-fold binding above background of monoclonal antibodies H6.B10.5 and H6.M48.
Antibody H6.C6 is cross-reactive between types 6 and 11 L1 , and binds both native and denatured material. Thus it is a measure of total L1 production. Normalized to L1 production, the level of H6.N8 binding was comparable to that observed with prototype HPV 6 VLPs. VLPs produced from clone 1393:11:49–54, 170–180, which harbored seven HPV 6-like substitutions over two distinct areas of L1 (Y49F, K53R, V54V; and T170K, S173T, S176P, N179A) showed a level of binding to antibodies H6.B10.5, H6.M48, and H6.N8 which was comparable to that observed with prototype HPV 6 VLPs.
Antibodies H11.B2 and H11.H3, both type 11-specific and VLP-dependent, are known to bind other regions of the L1 sequence. Hence these substitutions at the N-terminus should not impact their binding. They bound these N-terminally mutated constructs, thus demonstrating that these N-terminal substitutions had no effect on VLP assembly, or on the presentation of critical HPV 11 neutralizing epitopes.
This result is especially significant in light of the fact that the binding site of antibody H11.B2 previously was mapped to a stretch of residues between Y123 and V142, a region which lies in between the two multiply mutated regions discussed in the present example. This demonstrates that the structural perturbations generated by the mutations discussed in this work are quite localized.
EXAMPLE 6
Three Substitutions into HPV 6 L1 Sequence Confer H11.G3 and H11.H3 Binding
HPV 6 L1 was modified with HPV 11-like substitutions to generate 1393:6:T345S,T346K, and A348S. This clone was expressed transiently in Sf9 cells, and VLPs were produced and tested for binding for both antibodies H11.G3 and H11.H3. We observed binding 10-fold above background levels, commensurate with binding to prototype HPV 11 VLPs. Binding of HPV 6-specific antibodies H6.B10.5 and H6.M48 was not perturbed, demonstrating that the VLPs retained HPV 6-like character. Furthermore, binding of HPV 11-specific antibodies H11.A3 and H11.B2, antibodies known to bind elsewhere, was not observed, thus demonstrating that the transfer was specific to H11.G3 and H11.H3.
EXAMPLE 7
Seven Substitutions into HPV 6 L1 Sequence Confer H11.G3 Binding
HPV 6 L1 was modified with seven HPV 11-like substitutions between residues 262 and 289 (E262T, T270D, S276G, G277N, T280S, G283A, N289H) to generate clone 1393:6:262–289. This clone was expressed transiently in Sf9 cells, and VLPs were produced and tested for binding. We observed binding 10-fold above background levels of antibody H11.G3. Binding of HPV 6 specific antibodies H6.B10.5 and H6.M48 was not perturbed, demonstrating that the VLPs retained HPV 6-like character. Furthermore, binding of HPV 11-specific antibodies H11.A3 and H11.B2, antibodies known to bind elsewhere, was not observed, thus demonstrating that the transfer was specific to H11.G3.
EXAMPLE 8
Three Substitutions into HPV 6 L1 Sequence Between Residues 49 and 54, or Four Substitutions Between Residues 169 and 178, confer H11.A3.2 Binding
HPV 6 L1 was modified with three HPV 11-like substitutions between residues 49 and 54 (F49Y, R53K, and A54V and four HPV 11-like substitutions between residues 169 and 178 (K169T, T172S, P175S, and A178N), or four HPV 11-like substitutions between residues 169 and 178 (K169T, T172S, P175S, and A178N) to generate clones 1393:6:49–54, 169–178 and 1393:6:169–178 respectively. These clones were expressed transiently in Sf9 cells, and VLPs were produced and tested for binding. We observed binding three-fold above background for antibody H11.A3.2 with either clone. Binding of HPV 6-specific antibodies H6.B10.5 and H6.M48 was not perturbed by clone 1393:6:169–178, demonstrating that these VLPs retained HPV 6-like character. Work described in this document demonstrates that HPV 6- specific antibodies target region 49–54, therefore it is expected that VLPs produced from clone 1393:6:49–54 will not bind these antibodies. The binding of HPV 11-specific antibody H11.B2, known to bind elsewhere, was not observed, thus demonstrating that the transfer was specific to H11.A3.2.
EXAMPLE 9
Monitoring Serological Responses to HPV 11 Infection or Immunization
HPV 6-modified VLPs are used to determine the presence of an immune response to HPV 11 following viral infection or immunization with HPV 11 VLPs. HPV 6-modified VLPs which present the HPV 11 neutralizing epitope to H11.G3 and/or H11.H3 are coated onto the well of a microtitre plate in native form. Following blocking, HPV 11 monoclonal antibody H11.G3 and/or H11.H3 is incubated in ELISA format with increasing amounts of HPV 11 polyclonal sera, HPV 6 polyclonal sera, and test polyclonal sera. Binding of the HPV 11 monoclonal antibody is visualized using a rabbit anti-mouse IgG secondary antibody. Alternatively, it is labeled with I 125 , or coupled directly to horseradish peroxidase or alkaline phosphatase, or another standard ELISA visualization protocol. An increasing amount of polyclonal HPV 11 sera competes with binding until the signal eventually is reduced to background level. Polyclonal HPV 6 sera does not compete, or the competition is significantly reduced from that observed with HPV 11 polyclonal sera. Competition with the test sera at levels comparable to HPV 11 polyclonal sera demonstrates an immune response to HPV 11. Lack of, or a significant reduction of competition demonstrates lack of or a weak immune response to HPV 11.
EXAMPLE 10
Monitoring Serological Responses to HPV 6 Infection or Immunization
HPV 11-modified VLPs are used to determine the presence of an immune response to HPV 6 following viral infection or immunization with HPV 6 VLPs. HPV 11 modified VLPs which present the HPV 6 epitope to H6.N8 and/or H6.M48 are coated onto the well of a microtitre plate in native form. Following blocking, HPV 6 monoclonal antibody H6.N8 and/or H6.M48 is incubated in ELISA format with increasing amounts of HPV 11 polyclonal sera, HPV 6 polyclonal sera, and test polyclonal sera. Binding of the HPV 6 monoclonal antibodies H6.N8 and/or H6.M48 is visualized using a rabbit anti-mouse IgG secondary antibody. Alternatively, they are labeled with I 125 , or coupled directly to horseradish peroxidase or alkaline phosphatase, or another standard ELISA visualization protocol. Increasing amounts of polyclonal HPV 6 sera should compete with binding until the signal eventually is reduced to background level. Polyclonal HPV 11 sera does not compete. Competition with the test sera at levels comparable to HPV 6 polyclonal sera demonstrates an immune response to HPV 6. Lack of or significant reduction of competition demonstrates lack of or a weak immune response to HPV 11.
EXAMPLE 11
Generation of Chimeric VLPs Which Stimulate Both Type 6 and Type 11 Specific Responses
HPV 6 VLPs modified to contain substitutions, S131G and Y132, T345S, T346S, and S348A, produce VLPs which present i) the HPV 6-specific and VLP dependent epitope and ii) all known HPV 11 specific and neutralizing epitopes. Alternatively, HPV 11 VLPs modified to contain substitution K53R, or Y49F and K53R, or Y49F, K53R, V54A, T170K, S173T, S176P, N179A produce VLPs which present i) the HPV 6-specific and VLP dependent epitope and ii) the major HPV 11 specific and neutralizing epitopes. These latter chimeric VLPs present the one type 6 specific epitope known, the two neutralizing type 11 epitopes known, and the 6/11 common epitopes. Chimeric 6/11 VLPs are able to replace double immunization with type 6 and type 11 VLPs to stimulate immune responses, with reduced productivity costs.
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The invention is a series of synthetic virus-like particles comprising a heterologous conformational epitope useful in the characterization of human papillomavirus infection, and useful to vaccinate individual for protection against HPV 6 and HPV 11 infections, and assays employing the synthetic virus-like particles.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of Korean Patent Application No. 2007-0107256, filed on Oct. 24, 2007 in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference.
BACKGROUND
1. Field
The present invention relates to a method for manufacturing a polyimide carbon nanofiber electrode and/or a carbon nanotube composite electrode, and a CDI apparatus using the electrode. More specifically, the present invention relates to a method for manufacturing a flat plate electrode from polyimide carbon nanofibers without using any binder and a CDI apparatus using the flat plate electrode.
2. Description of the Related Art
Generally, carbon fibers and activated carbon fibers are classified into polyacrylonitrile (PAN)-based, acryl-based, pitch-based, phenol-based carbon fibers, etc., depending on the starting material to make the fibers.
Carbon fibers are prepared using wet-, melt- or dry-spinning that employs melting PAN-based, acryl-based, pitch-based, or phenol-based polymers, etc., at ambient temperature or a high temperature and then drawing or pulling out fibers from the molten polymers at a physical pressure.
Meanwhile, activated carbon fibers are prepared by activating carbon fibers with water vapor, carbon dioxide, KOH, ZnCl 2 , etc.
The carbon fibers prepared by these traditional spinning methods almost have a relatively high diameter of about 5 to about 50 μm. Due to the high diameter, the carbon fibers have a low flexural strength and are not thus easy to apply to compress processing.
In recent years, electrostatic spinning (also called “electrospinning”) has been used, which is a method capable of preparing ultrafine fibers from polymers via an electrostatic force, in contrast to the spinning methods depending upon a physical force. In accordance with the electrostatic spinning, a polymeric solution, to which a high-voltage electric field is applied, is sprayed to prepare fibers. More specifically, positive (+)-charged ions in the polymeric solution are discharged from an ejector and then adsorbed on a negative (−)-charged electrode collector to produce a nanofiber web.
The preparation of carbon nanofibers or activated carbon nanofibers using the electrostatic spinning is carried out by dissolving PAN, pitch or phenol in a solvent such as metacresol, subjecting the resulting solution to electrostatic spinning to prepare carbon nanofibers, and stabilizing, carbonizing or activating the carbon nanofibers.
For example, Korean Patent Laid-open Publication No. 10-2003-0089657 discloses preparation of carbon fibers and activated carbon fibers from polyamic acid (PAA) by electrostatic spinning and its applications to electric double layer supercapacitor electrodes.
More specifically, the afore-mentioned publication paper discloses preparation of polyimide fibers having nanometer-scale diameters with superior electrical conductivity by electrostatic spinning, preparation of carbon nanofibers and activated carbon nanofibers from the polyimide fibers, and the use thereof as electric double layer capacitor electrode materials.
Polyimide is a highly thermal and chemical resistant polymer having an imide group in the repeat units, imide monomers. In spite of these advantages, polyimide has limited applications. The reason is that polyimide has poor processability into a specific shape due to solvent-insolubility and heat resistance (flame resistance).
Accordingly, polyimide processing is carried out by processing polyimide into a specific shape in a PAA precursor solution using a polar solvent and converting the polyimide into imide using a thermal or chemical method.
Thus, the invention disclosed in the publication paper suggests a method for preparing nanometer-scale ultrafine carbon nanofibers and activated carbon nanofibers with a high specific surface area by electrostatic-spinning polyimide with superior electrical conductivity, and applications thereof to an electric double layer capacitor electrode without using any binder.
SUMMARY
However, these conventional methods for preparing polyimide by electrostatic spinning and manufacturing for a supercapacitor electrode material from activated carbon nanofibers have disadvantages in that electrostatic spinning cannot be smoothly performed due to a high viscosity of spinning solution, the diameters of carbon nanofibers cannot be controlled via optimization of complicated conditions, and the surface area of the prepared carbon nanofibers cannot be increased due to their relatively large diameters (i.e., about 400 nm).
In addition, when the conventional supercapacitor electrode material is utilized in a CID apparatus, the supercapacitor electrode cannot efficiently exert its functions on the CID apparatus due to the difference in use conditions between the capacitor and the CID apparatus.
In attempts to solve the problems of the prior art, one object of the present invention is to provide a method for manufacturing a polyimide carbon nanofiber electrode and/or a carbon nanotube composite electrode, wherein the diameters of carbon nanofibers can be lessened by optimizing the electrostatic spinning in order to improve spinnability.
Another aspect of the present invention is to provide a method for manufacturing a polyimide carbon nanofiber electrode and/or a carbon nanotube composite electrode, capable of improving electrical conductivity.
Another aspect of the present invention is to provide a CDI apparatus capable of improving ion collection capability by using the polyimide carbon nanofiber electrode and/or the carbon nanotube composite electrode.
Therefore, in accordance with one aspect of the invention, a method to manufacture a carbon fiber electrode comprises: synthesizing polyamic acid (PAA) as a polyimide (PI) precursor from pryomellitic dianhydride (PMDA) and oxydianiline (ODA) as monomers and triethylamine (TEA) as a catalyst; adding dimethylformamide (DMF) to the polyamic acid (PAA) solution to prepare a spinning solution and subjecting the spinning solution to electrostatic spinning at a high voltage to obtain a PAA nanofiber paper; converting the PAA nanofiber paper into a polyimide (PI) nanofiber paper by heating; and converting the polyimide (PI) nanofiber paper into a carbon nanofiber (CNF) paper by heating under an Ar atmosphere.
The method may further comprise: activating the CNF paper by acid- or base-treatment to increase the surface area of the CNF paper and control the distribution of pores in the CNF paper; and subjecting the CNF paper to acid-treatment and heat-treatment to distribute mesopores into the CNF paper.
An amount of the TEA catalyst contained in the spinning solution may be 1 to 5% by weight.
The content of the PAA polymers contained in the spinning solution may be 17 to 20% by weight.
The conversion of the polyimide (PI) nanofiber paper into a carbon nanofiber (CNF) paper may further include: pressurizing the polyimide (PI) nanofiber paper to increase electrical conductivity of the carbon nanofiber (CNF) paper.
The acid-treatment may be carried out by treating the CNF paper with nitric acid and the heat-treatment may be carried out by heating the CNF paper at 400° C.
The capacitive deionization (CDI) apparatus according to the present invention comprises the carbon fiber electrode manufactured according to the method.
In accordance with another aspect of the invention, a method to manufacture a carbon nanotube composite electrode comprises: sequentailly adding carbon nanotubes (CNTs) and triethylamine (TEA) as a catalyst to pryomellitic dianhydride (PMDA) and oxydianiline (ODA) as monomers to synthesize a polyamic acid/carbon nanotube (PAA/CNT) composite; subjecting the PAA/CNT composite spinning solution to electrostatic spinning to obtain a PAA/CNT nanofiber paper; converting the PAA/CNT nanofiber paper into a polyimide/carbon nanotube (PI/CNT) nanofiber paper by heating; and converting the PI/CNT nanofiber paper into a carbon nanofiber/carbon nanotube (CNF/CNT) composite by heating under an Ar atmosphere.
A content of the CNT in the CNF/CNT composite may be 0.001 to 50% by weight.
The method may further comprise: activating the CNF/CNT composite by acid- or base-treatment to increase the surface area of the CNF/CNT composite and control the distribution of pores in the the CNF/CNT composite; and subjecting the CNF/CNT composite to acid-treatment and heat-treatment to distribute mesopores into the CNF/CNT composite.
The method may further comprise: after the activation, subjecting the CNF/CNT composite to acid-treatment and heat treatment to distribute mesopores in the CNF/CNT composite.
The capacitive deionization (CDI) apparatus according to the present invention comprises the carbon nanotube composite electrode manufactured according to the method.
Additional aspects and/or advantages of the invention will be set forth in part in the description which follows and, in part, will be apparent from the description, or may be learned by practice of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
These and/or other aspects and advantages of the invention will become apparent and more readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings of which:
FIG. 1 is a flow chart illustrating a method to manufacture a carbon fiber electrode according to a preferred embodiment of the present invention;
FIG. 2 is a view illustrating an electrostatic spinning apparatus used to manufacture the carbon fiber electrode according to the preferred embodiment of the present invention.
FIG. 3 is a graph showing a mean diameter of PAA fibers prepared by electrostatic spinning under the conditions that a content of PAA polymers in the spinning solution is kept constant and a TEA catalyst amount is varied;
FIG. 4 is a graph showing mean diameters of PAA nanofibers, PI nanofibers and carbon nanofibers prepared by electrostatic spinning under the conditions that a TEA catalyst amount is kept constant and a content of PAA polymers is varied;
FIG. 5 is a graph showing correlation between the molecular weight, voltage and flow rate obtained under optimum electrostatic spinning conditions, while constantly maintaining the amount of PAA polymers in the spinning solution in the manufacturing process of FIG. 1 ;
FIG. 6 is a graph showing a correlation between a diameter of carbon nanofibers according to the preferred embodiment of the present invention, an electrical conductivity and a pressure;
FIG. 7( a ) is an electron microscope image of PAA nanofibers prepared in accordance with a preferred embodiment of the present invention;
FIG. 7( b ) is an electron microscope image of PI nanofibers prepared in accordance with a preferred embodiment of the present invention;
FIG. 7( c ) is an electron microscope image of CNT nanofibers prepared in accordance with a preferred embodiment of the present invention;
FIG. 8 is a flow chart illustrating a method to manufacture a carbon nanotube composite electrode according to a preferred embodiment of the present invention; and
FIG. 9 is a schematic diagram illustrating a CDI apparatus comprising the carbon nanofiber electrode or the carbon nanotube composite electrode manufactured according to the present invention.
DETAILED DESCRIPTION OF EMBODIMENTS
Reference will now be made in detail to the embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. The embodiments are described below to explain the present invention by referring to the figures.
FIG. 1 is a flow chart illustrating a method to manufacture a carbon fiber electrode according to a preferred embodiment of the present invention.
First, in order to synthesize polyamic acid (PAA) as a polyimide (PI) precursor, 4 g of oxydianiline (ODA) is dissolved in 20 g of dimethylformamide (DMF). After the resulting solution is allowed to stand at 5° C., 4.4 g of pyromellitic dianhydride (PMDA) is slowly added thereto over 30 minutes with stirring, to obtain the targeted polyamic acid (PAA).
In this embodiment, the weights of ODA, DMF and PMD are not intended to be restricted to the aforementioned specific values and are given for illustrating one example wherein a polyamic acid solution in which a weight ratio of ODA, DMF and PMD is approximately in the range of 4 20:4.4 is prepared.
After the solution is allowed to stand at −5° C., triethylamine (TEA) as a catalyst is added thereto (S 10 ) and mixed until polymerization is completed. An amount of the TEA catalyst used herein is in the range of 1 to 5% by weight to control a molecular weight.
The PAA solution thus prepared is given as a colorless liquid. To the solution, is further added DMF to adjust the content of the PAA to 20 wt %, and thereby to obtain a PAA/DMF solution (referred to as a “spinning solution”) (S 20 ). The PAA/DMF solution is subjected to electrostatic spinning to obtain a PAA nanofiber paper (S 30 ).
FIG. 2 is a view illustrating an electrostatic spinning apparatus used to manufacture the carbon fiber electrode according to the preferred embodiment of the present invention.
As shown in FIG. 2 , the electrostatic spinning apparatus used in the present invention comprises a syringe 10 to inject a spinning solution and a cylindrical collector 20 covered with aluminum foil.
The syringe 10 used to inject the spinning solution has an inner diameter of 2 cm and a length of 10 cm. The syringe 10 is provided at an end with a nozzle 30 having an inner diameter 0.5 mm and is filled with a spinning solution 40 (PAA/DMF solution). The collector 20 and the nozzle 30 are spaced apart from each other at a distance of about 15 cm.
In the fabrication of the carbon fiber electrode according to the preferred embodiment of the present invention, electrostatic spinning is optimized to design a stable Taylor cone-jet by controlling a spinning voltage and a flow rate depending upon the PAA molecular weight and solid content (wt %) using the electrostatic spinning apparatus having the aforementioned structure.
In this embodiment, triethylamine (TEA) is used as a catalyst. The embodiment is different from conventional cases using no catalyst, in terms of the tissue structure of the electrospun carbon fibers. That is, in conventional cases using no catalyst, carbon fibers with non-uniform diameters in which beads are dispersed are obtained, and on the other hand, in the preferred embodiments of the present invention using the catalyst, carbon fibers with a uniform diameter are obtained, independent of the amount of the catalyst (not less than about 1 wt %).
FIG. 3 is a graph showing a mean diameter of PAA fibers prepared by electrostatic spinning under the conditions that a content of PAA polymers in the spinning solution is kept constant and a TEA catalyst amount is varied. FIG. 4 is a graph showing mean diameters of PAA nanofibers, PI nanofibers and carbon nanofibers prepared by electrostatic spinning under the conditions that a TEA catalyst amount is kept constant and a content of PAA polymers is varied.
The diameter of the spun nanofibers is varied dependent upon an amount of the catalyst used for the polymerization and a content (wt %) of PAA polymers in the spinning solution. When the content of the PAA polymers is maintained at 20 wt % and the amount of the TEA catalyst is sequentially varied to 1, 3 and 5 wt %, as shown in FIG. 3 , a mean diameter of the PAA fibers is gradually increased to 160 nm, 200 nm and 225 nm, respectively. When the catalyst amount is kept at 1 wt % and the PAA polymer content is varied in the range of 17 to 20 wt %, the PAA nanofibers prepared from the spinning solution, wherein the PAA polymer content is 18 wt %, had the smallest mean diameter of about 125 nm.
These experiment results ascertained that the lower the amount of the TEA catalyst, the smaller the mean diameter of the PAA nanofibers, and when the PAA polymer content is 18 wt %, the PAA nanofiber diameter is minimized. Accordingly, it may be considered preferable to make the amount of the TEA catalyst as low as possible in order to lessen the diameter of the PAA nanofibers. However, when the TEA catalyst amount is lower than 1 wt %, as mentioned above, rather, PAA nanofibers whose mean diameter is increased and which are non-uniform are obtained. Preferably, the diameters of PAA nanofibers are minimized by utilizing the TEA catalyst amount and the PAA polymer content of about 1 wt % and about 18 wt %, respectively.
FIG. 5 is a graph showing correlation between the molecular weight, voltage and flow rate obtained under optimum electrostatic spinning conditions, while constantly maintaining the amount of PAA polymers in the spinning solution in the manufacturing process of FIG. 1 .
As can be seen from FIG. 5 , under the condition that the amount of PAA polymers contained in the spinning solution is maintained at 20 wt %, the PAA molecular weight (lower horizontal axis) is varied dependent upon the catalyst amount (upper horizontal axis), and the PAA molecular weight affects the spinning conditions.
That is, as the molecular weight of the PAA polymers becomes smaller, the critical voltage of the electrostatic spinning decreases, and as the molecular weight of the PAA polymers becomes larger, the critical voltage gradually increases, and then reaches a limit voltage.
As may be confirmed from FIG. 5 , the electrostatic spinning is optimized, under the condition that a flow rate of the spinning solution is also decreased, as the molecular weight becomes larger.
The graph of FIG. 5 indicates that according to the molecular weight, a critical voltage (left vertical axis) and a flow rate (right vertical axis) are varied. The optimum voltage and the flow rate of electrostatic spinning may be determined according to variation in the molecular weight of the PAA polymers.
As may be seen from FIG. 5 , under the condition that an amount of the PAA contained in the spinning solution is set at 20 wt %, when the catalyst is used in an amount of 1 wt %, the PAA molecular weight, the voltage and the flow rate are determined at about 1.25 g/mol, 20.5 kV and 0.2 mL/H, respectively, to thereby obtain optimum spinning conditions.
Consequently, with the method of manufacturing the carbon nanofiber electrode according to the preferred embodiment of the present invention, the diameter of the PAA fibers may be adjusted to about 100 nm by controlling the electrostatic spinning conditions (e.g., a molecular weight and content (%) of the PAA polymers, a voltage and a flow rate) that affect the diameter of the carbon fibers.
After the PAA nanofiber papers are obtained by electrostatic spinning as mentioned above, the PAA nanofiber papers are converted into polyimide through a series of heating steps in air, to obtain polyimide (PI) nanofiber papers (S 40 ).
The series of heating is carried out by heating the PAA nanofiber papers at 100° C. for 2 hours, at 250° C. for 2 hours, and at 350° C. for 2 hours. At this time, the heating rate is 5° C./min. After imidization through the heating process, the mean diameter of the nanofibers is decreased by about 5 to 15%, as is shown in FIG. 5 .
Then, the polyimide (PI) nanofiber papers are carbonized by heating (S 50 ).
More specifically, the PI nanofiber papers are carbonized at 1,000° C. under an Ar atmosphere to convert the PI nanofiber papers into carbon nanofiber (CNF) papers.
The carbonization of PI nanofiber papers is sequentially carried out by elevating the temperature from ambient temperature to 600° C. over about one hour, and from 600° C. to 1000° C. over about 1.3 hour and then by maintaining at 1,000° C. over one hour.
Before the carbonization, the thickness of PI nanofiber papers was 397 μm. After the carbonization, the thickness of PI nanofiber papers is slightly decreased to 379 μm. As shown in FIG. 4 , the diameter of carbon nanofibers is slightly decreased by about 10 to 18%, as compared to that of polyimide nanofibers.
Accordingly, when the content of the PAA polymers in the spinning solution is adjusted to 18 wt % and the electrostatic spinning conditions are satisfied, carbon nanofibers with a mean diameter of about 90 nm may be prepared and a specific surface area of carbon nanofiber electrodes may thus be increased.
FIG. 6 is a graph showing correlation between a diameter of carbon nanofibers according to the preferred embodiment of the present invention, an electrical conductivity and a pressure.
The electrical conductivity of the carbon nanofiber papers obtained in the present embodiment varies depending upon the diameter of the carbon nanofibers. As the diameter of the carbon nanofibers becomes smaller, the electrical conductivity increases. As shown in FIG. 5 , the electrical conductivity is increased by pressurizing the carbon nanofiber papers during the carbonization.
That is, in the case where the diameter of the carbon nanofibers is 100 nm, when a pressure of 4400 Pa is applied to the carbon nanofibers, the electrical conductivity thereof is about 9 S/cm, and when a pressure of 22,000 Pa is applied thereto, the electrical conductivity thereof is about 16 S/cm.
Accordingly, in the process of manufacturing the carbon nanofiber electrode according to the preferred embodiment of the present invention, the carbonization is performed together with pressurization, to improve the electrical conductivity of the carbon nanofiber electrode.
Then, the carbon fiber papers thus carbonized are activated by surface-treatment in order to increase the surface area of the carbonized carbon fiber papers for use in a CDI electrode, to produce a carbon fiber electrode (S 60 ).
The activation of the carbon fiber papers is carried out by primarily heating the carbon fibers and KOH in a ratio of 1:2 to 1:4 at 400° C. and then by activating the resulting materials at 700 to 1,000° C. under a nitrogen atmosphere. The primary heating time and the activation time are each in the range of 1 to 2 hours.
Then, in order to introduce mesopores having a size of about 2 to 50 nm into the carbon fiber papers, the carbon fiber electrode is repeatedly (i.e., about 5 to 10 times) subjected to treatment with 1 M nitric acid and heat-treatment at 400° C., to form a carbon fiber electrode for a CDI apparatus (S 70 ). At this time, the nitric acid treatment time and the heating time are about 20 minutes and about 30 minutes, respectively.
As mentioned above, when the carbon fiber electrode prepared in accordance with the method of the present invention is applied to a CDI apparatus, the ion collection capability of the CDI apparatus can be improved by introducing mesopores into the carbon fiber papers.
FIG. 7( a ) is an electron microscope image of PAA nanofibers prepared in accordance with the preferred embodiment of the present invention. FIG. 7( b ) is an electron microscope image of PI nanofibers prepared in accordance with the preferred embodiment of the present invention. FIG. 7( c ) is an electron microscope image of CNT (carbon nanotube) nanofibers prepared in accordance with the preferred embodiment of the present invention. As is apparent from FIGS. 7( a )- 7 ( c ), the PAA nanofibers, PI nanofibers and carbon nanotube nanofibers prepared in accordance with the preferred embodiment of the present invention are decreased in size.
Hereinafter, a method to manufacture a carbon nanotube composite electrode according to the preferred embodiment of the present invention will be illustrated.
FIG. 8 is a flow chart illustrating a method to manufacture the carbon nanotube composite electrode according to the preferred embodiment of the present invention.
The manufacturing of the CNT/PAA composite according to the preferred embodiment of the present invention is carried out in the same manner as in the manufacturing of the carbon nanofiber electrode, except that the synthesis of PAA and the introduction of carbon nanotubes (CNTs) are used.
The carbon nanotubes used herein may have a diameter of about 0.4 nm to about 200 nm. Depending upon the number of the walls of carbon nanotubes, single-walled carbon nanotubes (SWCNTs) or multi-walled carbon nanotubes (MWCNTs) may be used.
The CNTs are homogeneously dispersed in DMF using a method such as ultrasonic wave treatment or stirring, and an ODA /DMF solution is added thereto. Then, PMDA and a TEA catalyst are added to the resulting mixture and then the mixture is subjected to polymerization.
At this time, the weight of CNTs in the CNT/PAA composite is preferably in the range of 0.001% to 50%. The CNT/PAA composite in which a percolation threshold of the CNTs is observed near 0.001% and the CNT content is 50% may be used.
Then, the resulting polymers are subjected to electrostatic spinning to prepare PAA/CNT fibers. The PA/CNT fibers are imidized to prepare a PI/CNT composite. Then, the PAA/CNT composite is heated for carbonization and activated to manufacture a CNF/CNT composite electrode.
Then, the resulting CNF/CNT composite electrode is subjected to acid treatment and heat treatment to obtain the final CNF/CNT composite electrode for a CDI apparatus, capable of improving the efficiency of the CDI apparatus.
This manufacturing process is carried out under the same conditions as in the manufacturing process of the carbon fiber electrode according to the preferred embodiment of the present invention. Thus, a more detail thereof will be omitted.
Hereinafter, a CDI apparatus using the carbon fiber electrode and/or carbon nanotube composite electrode manufactured prepared in accordance with the afore-mentioned method will be illustrated.
The technology called capacitive deionization (CDI) is based on a simple principle that when a voltage is applied across two electrodes of a positive electrode and a negative electrode, negative ions are electrically adsorbed on the positive electrode and positive ions are electrically adsorbed on the negative electrode to remove the ions dissolved in a fluid such as water. In accordance with the CDI, when the ions are saturatedly adsorbed on the electrode, they can be readily desorbed by reversing the polarity of the electrode, thus making it simple to recycle the electrode.
Unlike other methods such as an ion exchange resin method and reverse osmosis, the CDI does not employ a cleaning solution, e.g., an acid or a base, for the purpose of recycling the electrode, thus advantageously being free of the secondary-production of chemical wastes. The CDI has great advantages of a semi-permanent lifespan due to almost freedom from corrosion or contamination and a 10- to 20-fold energy savings due to high energy efficiency, as compared to other methods.
FIG. 9 is a schematic diagram illustrating a CDI apparatus comprising a carbon nanofiber electrode or a carbon nanotube composite electrode prepared according to the present invention.
To apply the CNF porous carbon electrodes (or CNF/CNT porous carbon electrodes) 50 a and 50 b thus manufactured to a CDI apparatus, the electrodes 50 a and 50 b are made to a size of 10 cm×10 cm, and a CID system consisting of 20 cells is then obtained. The electrodes are designed to be spaced apart from each other at a distance of 1 mm using a spacer (not shown). Graphite is used as a collector.
When a voltage of 0 to 1.2 V is applied to the positive electrode, negative ions are adsorbed on the positive carbon electrode 50 a and positive ions are adsorbed on the negative carbon electrode 50 b . At this time, when hard water of 1,000 ppm is treated at a flow rate of 100 ml/min, an ion removal ratio and an ion recovery ratio are 90% and 70%, respectively.
The carbon nanofiber electrode and carbon nanotube composite electrode according to the method of the present invention may be used in the field of water treatment including sea water desalination facilities, water purifying plants, wastewater utilities, semiconductor wastewater treatment utilities, water purifiers, water conditioners, washing machines, dishwashers, air conditioners (water suppliers of water-quenching heat-exchangers), steam cleaners, boiler scale control facilities, etc. Furthermore, the carbon nanofiber electrode and the carbon nanotube composite electrode may be used not only in all treatment facilities and products that employ the principle of adsorbing/desorbing ions dissolved in water by electricity, but also in the field of supercapacitors.
As is apparent from the foregoing, the method according to the present invention, the carbon nanofiber electrode and/or a carbon nanotube composite electrode are manufactured using triethylamine (TEA) as a catalyst to synthesize polyamic acid (PAA) as a polyimide (PI) precursor. As a result, diameters of carbon fibers may be minimized, and a specific surface area of the carbon fiber electrode may be thus increased.
In the process of manufacturing the carbon nanofiber electrode and/or carbon nanotube composite electrode, the carbonization is performed together with pressurization. Accordingly, it is possible to improve electrical conductivity of the electrodes.
The CDI apparatus according to the present invention uses the carbon nanofiber electrode and/or the carbon nanotube composite electrode manufactured by the method, thus advantageously exhibiting an improved ion collection capability.
Although a few embodiments of the present invention have been shown and described, it would be appreciated by those skilled in the art that changes may be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the claims and their equivalents.
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A method to manufacture a carbon fiber electrode comprises synthesizing polyamic acid (PAA) as a polyimide (PI) precursor from pryomellitic dian hydride (PMDA) and oxydianiline (ODA) as monomers and triethylamine (TEA) as a catalyst, adding dimethylformamide (DMF) to the polyamic acid (PAA) solution to prepare a spinning solution and subjecting the spinning solution to electrostatic spinning at a high voltage to obtain a PAA nanofiber paper, converting the PAA nanofiber paper into a polyimide (PI) nanofiber paper by heating, and converting the polyimide (PI) nanofiber paper into a carbon nanofiber (CNF) paper by heating under an Ar atmosphere. Also, the method to manufacture a polyimide carbon nanofiber electrode and/or a carbon nanotube composite electrode may utilize carbon nanofibers having diameters that are lessened by optimizing electrostatic spinning in order to improve spinnability.
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BACKGROUND OF THE INVENTION
This invention relates generally to retractable awnings, and more particularly, to an intermediate support for a retractable awning for use with recreation vehicles having retractable slide-out portions.
Typical vehicles which must be transported over the roads, such as travel trailers and motor homes, are restricted in width to about eight feet. Any vehicle having a greater width usually requires a wide load permit. This width limitation severely limits the interior lay-out of the vehicle. Therefore, some recreational vehicles have been provided with retractable structures generally referred to as a “slide-outs” or slide-out rooms have been provided in many recreational vehicles. Such slide-outs are generally rectangular, and in some instances, extend lengthwise of the vehicle for substantial distance. Further, because of their size, such slide-outs are generally moved between the retracted and extended position by powered actuators. An example of a slide-out is illustrated in the U.S. Pat. No. 4,500,132.
It is customary to form the roof of the slide-out as a flat surface extending parallel to the roof of the vehicle. Such slide-out roofs, which are flat and extend horizontally, tend to collect leaves, snow, dirt and other debris. Although seals have been provided for slide-outs to resist the movement of such debris into the vehicle interior when the slide-out is retracted, difficulty is often encountered because such debris is carried past the seal and enters the interior of the vehicle when the slide-out is retracted for road travel.
In order to prevent the collection of debris on the roof of a slide-out, a retractable awning system has been provided in which a retractable awning was mounted so as to cover a substantial portion of the roof of the slide-out when the slide-out was extended. The intention of such awning was to cause any rain, snow, leaves or other debris to collect on the surface of the awning, and not on the roof, per se. The awning is structured so that as the slide-out is retracted, the awning rolls up on a roll journaled at the outer surface of the slide-out and drops the debris harmlessly on the ground. The roll is supported and journaled by a pair of brackets located at either end of the roll. Such a retractable awning is illustrated and described in the U.S. Pat. No. 5,280,687.
For especially long rolls, since they are only supported at their ends, the middle section of the roll may tend to sag or bow. The disadvantage of such sagging is an untidy appearance, as well as diminished shedding of water and debris.
SUMMARY OF THE INVENTION
The present invention provides a recreational vehicle comprising a side wall, a slide-out room extendable from the side wall of the vehicle, a roll awning journaled to the slide-out room by a pair of brackets at ends of the roll awning, the roll awning comprising a fabric having one edge secured to the side wall. The recreational vehicle further comprises an intermediate support attached to the slide-out room and comprising a supporting surface that supports the roll awning at a location between the pair of brackets as the slide-out room is being extended from the side wall.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWING
FIG. 1 is a perspective view showing an intermediate support for a slide-out room of a vehicle according to the present invention;
FIG. 2 is a side view of the support of FIG. 1;
FIG. 3 is a schematic sectional view of an intermediate support according to the present invention;
FIG. 4 is a front elevation showing supports according to an alternative embodiment of the invention;
FIG. 5 is a perspective view showing the intermediate support of FIG. 1;
FIG. 6 is a perspective view showing an intermediate support for a slide-out room of a vehicle according to a first alternate embodiment of the present invention; and
FIG. 7 is a side view showing an intermediate support for a slide-out room of a vehicle according to a second alternate embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1-3, the present invention provides an intermediate support 10 for a slide-out awning or cover assembly 12 used for a vehicle slide-out room 14 . The awning assembly 12 comprises an awning roll 16 journaled to a pair of brackets 18 acting as end supports that are attached a wall 20 of the slide-out room 14 . An awning 22 comprising a sheet of fabric is wound around the roll 16 and secured at one edge 24 to a stationary wall 26 of the vehicle 28 . As the slide-out 14 is extended from the wall 26 of a vehicle 28 , the rolled awning 22 unwinds while the edge 24 of the awning 22 remains secured to the stationary vehicle wall 26 .
The support 10 of the present invention attaches to the wall 20 of the slide-out room 14 and supports the awning assembly 12 at a location intermediate to the brackets 18 . The support 10 is secured to the wall 20 by one or more screws 30 .
As best shown in FIGS. 2 and 3, the support 10 is generally L-shaped having a relatively flat bottom surface 32 and a sloped back or rear surface 34 , both of which contact the awning assembly 12 proximate to its midpoint as it unrolls or rolls up on the support 10 . The support 10 prevents bowing or sagging of the roll 16 . One or more of the support surfaces 32 , 34 may have a friction-reducing coating, such as polytetrafluoroethylene (PTFE), to facilitate rolling up or unwinding of the awning 22 . Alternatively, the support 10 itself may be made from a low friction material.
As shown in FIG. 3, the support 10 both lifts the roll 16 and spaces it from the wall 20 . The position of the middle of the roll 16 is schematically shown in broken lines 16 a as sagging without the support 10 and in solid lines 16 b as supported. The distance, x, from the wall 20 is set to hold the roll 16 straight or slightly bowed away from the wall 20 at the midpoint of its length. The height of the support 10 is set so the roll 16 is straight or slightly bowed up at the midpoint of its length. Since the roll 16 decreases in diameter as the awning 22 is unwound, the bowed support prevents the roll 16 from sagging due to this decrease in diameter.
Alternatively, as shown in FIG. 4, multiple supports 10 can be used, spaced apart along the length of the roll 16 . The number of supports 10 required to adequately support a particular roll depends upon the roll's length and girth.
As best shown in FIG. 5, three holes 36 are provided on the support 10 to accommodate the screws 30 for securing the support 10 to the wall 20 . As a first alternative embodiment, shown in FIG. 6, elongated holes 38 can be provided to allow for vertical adjustment of the support 10 ′. Further, it should be appreciated that any number of holes can be provided. Further, other means of fastening the support 10 , 10 ′ to the wall 20 can be used, such as riveting, welding or gluing.
As a second alternative embodiment, shown in FIG. 7, a curved support 10 ″ has a single curved support surface 40 , as a substitute for the two support surfaces 32 , 34 of the support 10 , 10 ′ of FIGS. 1-6. The shape of the surface 40 provides the horizontal and vertical support of the previous embodiment and additionally provides support in the negative vertical direction to prevent the awning roll 16 from being lifted under the tension of being deployed. Further, roller or ball bearings 42 , as schematically shown, are provided to reduce the friction between the roll 16 and the surface 40 . Although five bearings 42 are shown, any number of rollers can be used according to the present invention. Further, the bearings 42 could be replaced by other means of reducing friction, such as balls bearings or a low friction surface such as PTFE, as in the previous embodiments. Moreover, it should be appreciated that the bearings 42 of the embodiment of FIG. 7 could be adapted for use in the embodiments of FIGS. 1-6.
It should be evident that this disclosure is by way of example and that various changes may be made by adding, modifying or eliminating details without departing from the fair scope of the teaching contained in this disclosure. The invention is therefore not limited to particular details of this disclosure except to the extent that the following claims are necessarily so limited.
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An intermediate support for a retractable roll awning. The support is positioned between two end brackets and provides additional support. The support includes a two support surfaces for supporting the roll awning in two directions. Alternatively, the support may comprise a single curved support surface. The support surface or surfaces include an arrangement for reducing friction.
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CROSS REFERENCE TO RELATED APPLICATION
This application claims the priority of German Application No. P 44 39 564.7 filed Nov. 5, 1994, which is incorporated herein by reference.
CROSS REFERENCE TO RELATED APPLICATION
This application claims the priority of German Application No. P 44 39 564.7 filed Nov. 5, 1994, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
This invention relates to an apparatus for cleaning and opening fiber material such as cotton, synthetic fiber or the like presented in tuft form. The apparatus includes a fiber tuft feeding device such as a feed roller cooperating with a feed tray and at least one downstream-arranged opening device such as an opening roller with a cleaning device. The fiber material passes through the feeding device and the opening device and is thereafter advanced to a fiber processing machine.
According to a prior art arrangement, the feed tray of the feeding device is movably supported for the purpose of effecting a clamping of the fiber material by the feed roller and the feed tray.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved apparatus of the above outlined type in which the fiber material throughput is improved while maintaining a highly satisfactory clamping effect and which is simple to manufacture.
This object and others to become apparent as the specification progresses, are accomplished by the invention, according to which, briefly stated, the fiber tuft feeding device for a fiber processing machine includes a fiber advancing member; and an extruded, light-metal feed tray defining, with the fiber advancing member, a nip between which the fiber tufts pass in a feed direction. The feed tray which has a length extending transversely to the feed direction, includes an elongated cavity extending along the tray length. An elongated element which is resistant to bending, is received in the cavity and is oriented parallel to the tray length. The feeding device further includes a support for positioning the feed tray adjacent the fiber advancing member.
The use of an extruded, light-metal feed tray permits to so design the feed tray surface oriented towards the fiber material that an optimal fiber flow rate is achieved. In particular, the desired feed tray shape is obtained in a simple manner by an extrusion process. By virtue of the fact that the extruded component is associated with an element having a substantial resistance to bending, such as a steel core, flexing of the light-metal (for example, aluminum) feed tray along the machine width is prevented or at least reduced. In this manner the shape of the feed tray and thus the feed gap for the fiber material defined between the feed tray and the feed roller is configured in an optimal manner and, at the same time, the feed tray may be manufactured in a simple manner.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic side elevational view of a three-roller fiber tuft cleaner having a resiliently supported feed tray according to the invention and a stationarily supported feed roller.
FIG. 2 is a schematic side elevational view of a preferred embodiment of the invention.
FIG. 3 is a sectional view taken along line III--III of FIG. 2.
FIG. 4 is a sectional elevational view of some of the components shown in FIG. 3.
FIG. 5 is a sectional elevational view of another preferred embodiment of a component of the invention.
FIG. 6 is a sectional side elevational view of yet another preferred embodiment of a component of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning to FIG. 1, there is illustrated therein a fiber tuft cleaner which may be a CVT model manufactured by Tr utzschler GmbH & Co. KG, M onchengladbach, Germany. The apparatus is disposed in a closed housing and the fiber material B, such as cotton, is introduced in fiber tuft form into the cleaner. Such a material supply is effected by means of a non-illustrated feed chute or a conveyor belt or the like. The fiber mass is advanced to a rapidly rotating pin roller 3 by a feed roller 1 in cooperation with a feed tray 2, whereby a clamping effect is exerted on the material. The pin roll 3 may have a diameter of, for example, 250 mm and is rotatably held in the cleaner housing for a counterclockwise rotation as indicated by the arrow 3b. The pin roll 3 is followed by sawtooth rolls 4 and 5. The sawtooth roll 4 may have a diameter of approximately 250 mm. The pin roll 3 and the sawtooth roll 4 may have a circumferential speed of, for example, 15 m/sec and 20 m/sec, respectively. The circumferential speed of the sawtooth roll 5 is greater than that of the sawtooth roll 4. The diameter of the sawtooth roll 5 is also approximately 250 mm. The pin roll 3 is surrounded by a housing 6 and is associated with a discharge opening 9 for ejecting fiber impurities whose size is adapted to the grade of soiling of the cotton. The waste outlet opening 9 is bordered by a mote knife.
The feeding device includes the slowly rotating feed roller 1 rotating in the direction of the arrow 1a and the feed tray 2 situated above the feed roller 1. The feed tray 2 is supported at one end of a lateral extension 2a in a rotary bearing 7. The outer upper feed tray surface 2' is contacted by a compression spring 8 which resiliently loads the feed tray 2. The rotary support for the feed roller 1 is stationary.
The above described device operates as follows: the fiber lap B formed of fiber tufts is clamped by the feed roller 1 and the feed tray 2 and is advanced to the pin roll 3 which combs the fiber material and entrains, on its pins, fiber bundles from the fiber lap. As the material, carried in a circular path by the pins of the roll 3 passes by the waste discharge opening and the mote knife 10, dependent upon the circumferential speed and the curvature of the pin roll 3 as well as the size of the waste discharge opening 9, short fibers and coarse impurities are thrown out of the material by centrifugal forces. The fiber material pre-cleaned in this manner is taken over by the points 4a of the sawtooth roll 4 from the pin roll 3 and performs additional opening operations thereon. Thereafter the fiber material is taken over by the points 5a of the sawtooth roll 5 which is located immediately downstream of the roll 4, as viewed in the working direction A. The roll 5 further opens the fiber material and advances it to a pneumatic removal device 11 which transports the fiber material to a non-illustrated further fiber processing machine.
The feed tray 2 is an elongated, extruded aluminum component having a cavity which extends along the length of the feed tray, that is, along the width dimension of the cleaning apparatus and accommodates an elongated element, such as a steel bar (steel core) 12 which is resistant to bending and thus prevents undesired flexing of the feed tray along its length.
Turning to FIGS. 2 and 3, the steel bar 12 has, at its opposite ends, stepped-down extensions 12a, 12b which have a length b and which serve for supporting the feed tray 3 in the machine frame. FIG. 3 shows such a supporting structure for the extension 12a which passes through an opening 13a in the machine stand 13. The extension 12a is, for example, by a screw 14, secured in a lever arm 15a of a holding element 15 which is pivotal in the direction 18 and 19 in a rotary bearing (such as a ball bearing) 16 about a pivot pin 17 affixed to the machine frame 13 and having a rotary axis which is perpendicular to the direction of fiber feed and parallel to the length dimension of the feed tray 2. Another lever arm 15b of the holding element 15 is engaged by a compression spring 20, against the force of which the feed tray 2 executes excursions in case of a thickness variation of the lap B. The machine frame 13 further carries a stop 21 which determines the minimum clearance between the feed roller 1 and the feed tray 2. As seen in FIGS. 2 and 3 when viewed together, the steel bar 12 is received in the C cavity of the feed tray 2 with a close fit. FIG. 2 further shows that the distance between the cooperating, fiber-engaging surfaces of the feed roller 1 and the feed tray 2 decreases in the direction of fiber feed.
Turning to FIG. 4, the feed tray 2 has, along its length, a rectangular, laterally open cavity 2b receiving the steel bar (steel core) 12 of complemental rectangular cross section. Screws 22, 23 secure the steel bar 12 to the feed table 2. A closure element 24 covers the lateral opening of the feed tray 2 and is coupled thereto by a securing attachment 25. The closure element 24 is also secured to the steel core 12 by a screw 26.
FIG. 5 illustrates an embodiment where the steel bar (steel core) 30 is a cross-sectionally circular component having a flattened, planar securing surface 31. The feed tray 32 has a cavity shaped complementally with the circumferential outline of the steel core 30. The steel core 30 is tightened to the feed tray 32 by a screw 33.
The feed tray 34 according to the embodiment shown in FIG. 6 has a curved surface 2" which is oriented towards the fiber lap B during operation and which is provided with a wear resistant, thin sheet metal member 27 made, for example of high grade steel and is made to conform in a simple manner to the particular configuration of the surface 2" to which it may be secured by gluing. The sheet metal member 27 has smooth surfaces so that a firm connection with the feed tray surface 2" and a low-friction contact with the fiber lap B may be ensured. Instead of providing a sheet metal member, the surface 2" of the feed tray 34 may be made wear-resistant by metal plating, by providing a wear-resistant coating or by surface-hardening.
The apparatus according to the invention may find application in a machine which serves only for opening the fiber material, for example chemical fibers or which serves for both the opening and the cleaning of the fiber material, such as cotton.
It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims.
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A fiber tuft feeding device for a fiber processing machine includes a fiber advancing member; and an extruded, light-metal feed tray defining, with the fiber advancing member, a nip between which the fiber tufts pass in a feed direction. The feed tray which has a length extending transversely to the feed direction, includes an elongated cavity extending along the tray length. An elongated element which is resistant to bending, is received in the cavity and is substantially coextensive therewith. The feeding device further includes a support for positioning the feed tray adjacent the fiber advancing member.
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CROSS REFERENCE TO RELATED APPLICATIONS
This patent application claims priority from Japanese Patent Applications Nos.: 2005-311950 and 2005-311951 both filed in JP on Oct. 26, 2005, the contents of which are incorporated herein by reference.
BACKGROUND
1. Field of the Invention
The present invention relates to a liquid ejecting apparatus, a recording apparatus, and a field generating unit. More particularly, the present invention relates to a liquid ejecting apparatus and a recording apparatus for attaching liquid discharged from an aperture of a nozzle plate mounted on a liquid ejecting head to a recording material, and a field generating unit capable of being used in these apparatuses.
2. Related Art
In a liquid ejecting apparatus, according to the demand for resolution improvement of a recording image, a droplet discharged from an aperture of a nozzle plate in a current liquid ejecting apparatus is miniaturized up to about several pl or pico-litter. Since such a minute droplet has extremely small mass, kinetic energy is rapidly lost by viscous resistances of an atmosphere once the droplet is discharged. Specifically, the speed of droplet becomes substantially zero, for example, when a droplet less than 3 pl flies a distance of about 3 mm in the atmosphere. Since a falling motion by acceleration of gravity and a viscous resistance force of an atmosphere are nearly balanced in a minute droplet of which kinetic energy is lost, it takes a long time to fall completely.
Moreover, in order to give larger kinetic energy to a droplet, it is also possible to raise jet velocity of liquid ejected from a liquid ejecting head. However, when actually increasing jet velocity from the nozzle plate, it is easy to produce an extremely minute droplet referred to as an ink mist when a droplet leaves the nozzle plate. Moreover, since viscous resistance of an atmosphere acting on each droplet becomes still larger, it is found that a travel distance of the droplet shortens rather than that of a droplet before increasing jet velocity.
A floating droplet produced as a result of various phenomena as described above is referred to as an aerosol, and floats in the vicinity of a traveling area of the liquid ejecting head. A part of aerosols floats up to an outside of the liquid ejecting apparatus, and thus adheres to the vicinity of the liquid ejecting apparatus to deface the apparatus. Moreover, most of aerosols adhere to each portion within the liquid ejecting apparatus before long. Particularly, when aerosols adhere on a carrying path of a recording material such as a platen, a recording material to be next carried is polluted. Moreover, when aerosols adhere to an electric circuit, a rotary scale, a linear scale, or various types of optical sensors of the liquid ejecting apparatus, this may cause malfunction of the apparatus. Furthermore, when a user touches a portion to which aerosols adhere, a hand of the user is polluted.
A liquid ejecting apparatus described in the following Japanese Patent Application Publication 2005-186290 forms an electric field between a nozzle plate and a matter to be processed to make Coulomb force facing the matter act on a droplet. In this way, it is described to make the droplet surely arrive at the matter to prevent the generation of aerosols. Moreover, Japanese Patent Application Publication 2005-186290 proposes that electrification of a matter to be processed caused by attaching the charged liquid to the matter is prevented by reversing the polarity of voltage to be applied to the matter.
However, the configuration disclosed in Japanese Patent Application Publication 2005-186290 includes, as essential components, a switching means for reversing the polarity of applied voltage, a control means for measuring a timing of switching, or the like, in addition to a voltage applying means for applying a voltage to a matter to be processed. Therefore, the magnitude and manufacturing cost of the liquid ejecting apparatus just have to be raised in order to realize a configuration as described in Japanese Patent Application Publication 2005-186290.
SUMMARY
Therefore, it is an object of some aspects of the present invention to provide a liquid ejecting apparatus, a recording apparatus, and a field generating unit that can solve the foregoing problems. The above and other objects can be achieved by combinations described in the independent claims. The dependent claims define further advantageous and exemplary combinations of the present invention.
To solve this problem, according to the first aspect of the present invention, there is provided a liquid ejecting apparatus including a liquid ejecting head that has a nozzle plate and ejects liquid from an aperture of the nozzle plate toward a recording material while reciprocating over the recording material and a platen that supports the recording material from a rear face thereof to position the recording material at a position facing the nozzle plate in a direction in which the liquid is ejected. The liquid ejecting apparatus includes: a first electrode being provided on the platen side between the liquid ejecting head and the platen; a second electrode being provided on the liquid ejecting head side between the liquid ejecting head and the platen; and a potential difference generating section of which one end is connected to the first electrode and the other end is connected to the second electrode and that generates a potential difference between the second electrode and the first electrode.
The potential difference generating section may constantly keep a potential difference between the second electrode and the first electrode.
The second electrode may be a conductive nozzle plate and the first electrode may be electrically coupled to the recording material supported on the platen. Moreover, the liquid ejecting apparatus may generate an electric field between the nozzle plate and the recording material on the platen to electrically attract liquid ejected from the aperture of the nozzle plate toward the recording material. In this way, an electric field is formed between the nozzle plate and the recording material. In this way, since the ejected droplet surely arrives at the recording material, the generation of aerosols is prevented. Moreover, a potential difference between the nozzle plate and the recording material generating this electric field is constantly kept by the potential difference generating section. Therefore, since the electric field is constantly kept even if the charged liquid adheres to the recording material, it is not necessary to provide a switching means of an applied voltage or a control means for controlling a switching timing.
Moreover, in the liquid ejecting apparatus, the first electrode may be mounted on the platen, and be electrically coupled to the recording material supported on the platen.
Moreover, in the liquid ejecting apparatus, the first electrode may include a conductive member mounted on a part in the platen abutting on the rear face of the recording material. In this way, since the first electrode touches the recording material right under the nozzle plate to control the potential, it is possible to efficiently control electric potential of the recording material.
Moreover, in the liquid ejecting apparatus, the first electrode may include a conductive member mounted through the platen in a direction in which the liquid is ejected, and one end of the first electrode may be in contact with the recording material and the other end may be electrically connected to the potential difference generating section. In this way, wiring for connecting the first electrode to the potential difference generating section can be performed in the rear face of the platen. Therefore, the layout in the liquid ejecting apparatus becomes easy.
Moreover, in the liquid ejecting apparatus, the first electrode may include a conductive member being in contact with the recording material on at least one side of just before and just after the platen on a carrying path of the recording material. In this way, it is possible to select an arbitrary place and an arbitrary material to form the first electrode.
Moreover, the liquid ejecting apparatus may further include: a carrying portion that includes a rotationally driven carrier driving roller and a carrier driven roller rotated with the rotation of the carrier driving roller while pressing the recording material on the carrier driving roller and sends the recording material onto the platen; and a discharging portion that includes a rotationally driven discharge driving roller and a discharge driven roller rotated with the rotation of the discharge driving roller while pressing the recording material on the discharge driving roller and sends away the recording material from the top of the platen, at least one of the carrier driving roller, the carrier driven roller, the discharge driving roller, and the discharge driven roller may be a conductive roller formed of a conductive material, and the conductive roller may be electrically coupled to the recording material as the first electrode. In this way, the electric field is formed between the nozzle plate and the recording material. In this way, since the ejected droplet surely arrives at the recording material, the generation of aerosols is prevented. Moreover, a potential difference between the nozzle plate and the recording material generating this electric field is constantly kept by the potential difference generating section. Therefore, since the electric field is constantly kept even if the charged liquid adheres to the recording material, it is not necessary to provide a switching means of an applied voltage or a control means controlling a switching timing.
Moreover, in the liquid ejecting apparatus, the carrier driving roller and the discharge driving roller may be the conductive roller. In this way, since the recording material is coupled to the potential difference generating section just before and just after the platen, the electric potential of the recording material on the platen is stabilized.
Moreover, in the liquid ejecting apparatus, the carrier driven roller and the discharge driven roller may be the conductive roller. In this way, the liquid ejecting apparatus can control the electric potential of recording material by means of an existing member. In this way, since the recording material is coupled to the potential difference generating section just before and just after the platen, the electric potential of recording material on the platen is stabilized. Moreover, since the carrier driven roller and the discharge driven roller have simple support structure, the electric coupling to the potential difference generating section is easy.
Moreover, in the liquid ejecting apparatus, all of the carrier driving roller, the carrier driven roller, the discharge driving roller, and the discharge driven roller may be the conductive roller. In this way, it is possible to surely control the electric potential of recording material passing over the platen.
Furthermore, according to the second aspect of the present invention, there is provided a field generating unit mounted on a liquid ejecting apparatus including a liquid ejecting head that has a nozzle plate and ejects liquid from an aperture of the nozzle plate toward a recording material while reciprocating over the recording material and a platen that supports the recording material from a rear face thereof to position the recording material at a position facing the nozzle plate in a direction in which the liquid is ejected. The field generating unit includes: a first electrode being provided on the platen side between the liquid ejecting head and the platen; a second electrode being provided on the liquid ejecting head side between the liquid ejecting head and the platen; and a potential difference generating section of which one end is connected to the first electrode and the other end is connected to the second electrode and that generates a potential difference between the second electrode and the first electrode. In this way, a generation prevention function of the described above aerosol can be added to the existing liquid ejecting apparatus that did not have such a function at first.
The second electrode may be a conductive nozzle plate, the first electrode may be electrically coupled to the recording material supported on the platen, and the field generating unit may generate an electric field between the nozzle plate and the recording material on the platen to electrically attract liquid ejected from the aperture of the nozzle plate toward the recording material. In this way, a generation prevention function of the described above aerosol can be added to the existing liquid ejecting apparatus that did not have such a function at first.
Moreover, in the liquid ejecting apparatus on which the field generating unit is mounted, the first electrode may be mounted on the platen, and be electrically coupled to the recording material supported on the platen.
Moreover, the liquid ejecting apparatus on which the field generating unit is mounted may further include: a carrying portion that includes a rotationally driven carrier driving roller and a carrier driven roller rotated with the rotation of the carrier driving roller while pressing the recording material on the carrier driving roller and sends the recording material onto the platen; and a discharging portion that includes a rotationally driven discharge driving roller and a discharge driven roller rotated with the rotation of the discharge driving roller while pressing the recording material on the discharge driving roller and sends away the recording material from the top of the platen, at least one of the carrier driving roller, the carrier driven roller, the discharge driving roller, and the discharge driven roller may be a conductive roller formed of a conductive material, and the conductive roller may be electrically coupled to the recording material as the first electrode. In this way, a contamination prevention function by the described above aerosol can be added to the existing liquid ejecting apparatus that did not have such a function at first.
Moreover, according to the third aspect of the present invention, there is provided a recording apparatus including a recording head that has a nozzle plate and discharges ink from an aperture of the nozzle plate toward a recording material while reciprocating over the recording material and a platen that supports the recording material from a rear face thereof to position the recording material at a position facing the nozzle plate in a direction in which the ink is discharged. The recording apparatus includes: a first electrode being provided on the platen side between the liquid ejecting head and the platen; a second electrode being provided on the liquid ejecting head side between the liquid ejecting head and the platen; and a potential difference generating section of which one end is connected to the first electrode and the other end is connected to the second electrode and that generates a potential difference between the second electrode and the first electrode. In this way, the recording apparatus can prevent the generation of an aerosol.
Moreover, the second electrode may be a conductive nozzle plate, the first electrode may be electrically coupled to the recording material supported on the platen, and the recording apparatus may generate an electric field between the nozzle plate and the recording material on the platen to electrically attract ink ejecting from the aperture of the nozzle plate toward the recording material.
Moreover, in the recording apparatus, the first electrode may be mounted on the platen, and be electrically coupled to the recording material supported on the platen.
Moreover, the recording apparatus may further include: a carrying portion that includes a rotationally driven carrier driving roller and a carrier driven roller rotated with the rotation of the carrier driving roller while pressing the recording material on the carrier driving roller and sends the recording material onto the platen; and a discharging portion that includes a rotationally driven discharge driving roller and a discharge driven roller rotated with the rotation of the discharge driving roller while pressing the recording material on the discharge driving roller and sends away the recording material from the top of the platen, at least one of the carrier driving roller, the carrier driven roller, the discharge driving roller, and the discharge driven roller may be a conductive roller formed of a conductive material, and the conductive roller may be electrically coupled to the recording material as the first electrode. In this way, the recording apparatus prevents the generation of an aerosol.
The summary of the invention does not necessarily describe all necessary features of the present invention. The present invention may also be a sub-combination of the features described above.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects and features and advantages of the present invention will become more apparent from the following description of the presently preferred exemplary embodiments of the invention taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a perspective view surveying the whole of an ink-jet type recording apparatus;
FIG. 2 is a perspective view showing an internal mechanism of an ink-jet type recording apparatus;
FIG. 3 is a sectional view showing a structure of an aerosol generation preventing mechanism according to an embodiment;
FIG. 4 is a schematic block diagram explaining an operation of an aerosol generation preventing mechanism;
FIG. 5 is a sectional view showing a structure of an aerosol generation preventing mechanism according to another embodiment;
FIG. 6 is a sectional view showing a structure of another aerosol generation preventing mechanism;
FIG. 7 is a sectional view showing a structure of further another aerosol generation preventing mechanism;
FIG. 8 is a sectional view showing a structure of further another aerosol generation preventing mechanism;
FIG. 9 is a schematic block diagram explaining an operation of an aerosol generation preventing mechanism;
FIG. 10 is a sectional view showing a structure of an aerosol generation preventing mechanism according to another embodiment; and
FIG. 11 is a sectional view showing a structure of another aerosol generation preventing mechanism.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
The embodiments of the invention will now be described based on the preferred embodiments, which do not intend to limit the scope of the present invention, but just exemplify the invention. All of the features and the combinations thereof described in the embodiment are not necessarily essential to the invention.
FIG. 1 is a perspective view surveying an ink-jet type recording apparatus 10 that is an example of an embodiment of the present invention, and shows a state that a top case 110 as a cover is opened. As shown in the present drawing, the ink-jet type recording apparatus 10 includes a bottom case 120 that is a base of the apparatus, a top case 110 that forms a casing with the bottom case 120 , a paper support 130 that is mounted to a rear portion of the bottom case 120 , and a discharge tray 140 that is formed on a front face of the bottom case 120 . Moreover, the ink-jet type recording apparatus 10 includes a platen 150 that is horizontally arranged in the bottom case 120 and a carriage 160 that is arranged on the upper side of the platen 150 , on the inner side of the casing.
In the ink-jet type recording apparatus 10 as described above, a data sheet 170 accommodated on the paper support 130 is sent onto an inside one piece by one piece by means of a feeding portion not shown, and is next sent to the platen 150 by means of a carrying portion not shown. Further, the data sheet is sent to the discharge tray 140 by means of a discharge portion not shown. Moreover, in each of the feeding portion, the carrying portion, and the discharge portion, the data sheet 170 is feed, carried, and discharged while holding the sheet between a rotationally driven driving roller and a driven roller rotated with the rotation of the driving roller.
Moreover, in the ink-jet type recording apparatus 10 , the carriage 160 reciprocates in the direction perpendicular to a transportation direction of the data sheet 170 on the upper side of the platen 150 . Therefore, since the transportation of the data sheet 170 and the reciprocation of the carriage 160 are performed alternately, the whole top face of the data sheet 170 can be scanned by the carriage 160 , and thus the carriage 160 can perform a record operation at an arbitrary area on the data sheet 170 .
FIG. 2 is a perspective view showing an internal mechanism 20 of the ink-jet type recording apparatus 10 shown in FIG. 1 in a state that a frame 210 including side face portions 212 and 214 is pulled out. As shown in the present drawing, the internal mechanism 20 is mainly formed inside an area bounded by the frame 210 that is arranged backward and generally vertically and the pair of side face portions 212 and 214 that are extended from both ends of the frame 210 to the front parallel to each other.
As shown in the present drawing, in the internal mechanism 20 , the carriage 160 is supported by a guide shaft 220 penetrating through the carriage. Both ends of the guide shaft 220 are supported by the side face portions 212 and 214 , and the guide shaft 220 is arranged parallel and horizontally to the frame 210 . Therefore, the carriage 160 can horizontally move along the guide shaft 220 .
At the back of the carriage 160 , a pair of pulleys 232 and 234 and a timing belt 230 that is hung on the pulleys 232 and 234 are arranged in the front of the frame 210 . One pulley 234 is rotationally driven by a carriage motor 236 . Moreover, the timing belt 230 is coupled to a rear portion of the carriage 160 . Therefore, the carriage 160 can be reciprocated according to an operation of the carriage motor 236 .
Moreover, the carriage 160 loads an ink cartridge 162 from the upper side, and also includes a recording head 164 in the lower part. The recording head 164 includes a nozzle plate 166 made of metal including an aperture to discharge ink on the upper face. Therefore, ink is discharged from the carriage 160 toward the lower side. Furthermore, the carriage 160 is coupled with an electronic circuit 250 in the rear of the frame 210 via a tape-shaped multicore cable 240 . Since the multicore cable 240 is flexibly bended according to a movement of the carriage 160 , the multicore cable 270 does not disturb a reciprocation of the carriage 160 .
The platen 150 is arranged on the lower side of an area along which the carriage 160 reciprocates. The platen 150 supports the data sheet 170 passing along a bottom of the carriage 160 from the lower side, in order to hold a distance between the nozzle plate 166 and the data sheet 170 constant. Moreover, a concavity 152 is formed on a top face of the platen 150 and an absorbing member 260 is accommodated in the concavity 152 . The absorbing member 260 receives ink discharged from the recording head 164 toward an area on which the data sheet 170 does not exist.
In addition, as the operating time of the ink-jet type recording apparatus 10 elapses, ink adheres to the absorbing member 260 . When the data sheet 170 comes in contact with the absorbing member 260 to which ink adheres, a rear face of the data sheet 170 is contaminated with ink. Thus, since a rib-shaped portion is formed on a top face of the platen 150 to lift and support the data sheet 170 from the lower side, an interval between them is maintained to prevent them from being in contact with each other. Specifically, a gap of around 2 to 4 mm is provided between the data sheet 170 and the absorbing member 260 . In addition, an interval of about 1 mm is preserved between a surface of the nozzle plate 166 and surfaces of the data sheet 170 .
Moreover, since a material of the absorbing member 260 is selected in consideration of absorption velocity on the surface, absorption capacity is limited. Thus, a larger waste liquid absorbing member 262 is arranged on the lower side of the platen 150 , and the absorbing member 262 partially comes in contact with the absorbing member 260 . In the waste liquid absorbing member 262 , the absorption capacity is important, and thus a material having large absorbing power by a capillary phenomenon is selected. Therefore, the waste liquid absorbing member 262 can absorb a large quantity of ink from the absorbing member 260 .
Moreover, the absorbing member 260 directly receives ink not attached to the data sheet 170 while being discharged from the nozzle plate 166 . At this time, when the absorption velocity of the absorbing member 260 is slow, so-called a milk crown phenomenon occurs due to an impact by which the ink collides with the surface of the absorbing member 260 . Minute ink occurs on the periphery of a milk crown, and the ink causes the generation of aerosols. Thus, as the absorbing member 260 , a material having high absorption velocity, in other words, high percentage of voids is selected.
Moreover, the absorbing member 260 partially communicates with the waste liquid absorbing member 262 arranged beneath the platen 150 in FIG. 2 , in which this configuration is not shown. For this reason, since ink absorbed by the absorbing member 260 is sequentially absorbed by the waste liquid absorbing member 262 having high absorbing power, the absorbing power of the absorbing member 260 lasts over a long term.
On the other hand, the carrier driving roller 282 and the carrier driven roller 284 are arranged at the back of the platen 150 to from the carrying portion 280 . The carrier driving roller 282 is rotationally driven by a carrying motor 286 arranged in the rear of the frame 210 . Moreover, the carrier driven roller 284 presses the data sheet 170 on the carrier driving roller 282 . Therefore, the carrier driven roller 284 is rotated according to the rotation of the carrier driving roller 282 , and the data sheet 170 is sent away on the platen 150 . Since ink is discharged from the carriage 160 on the platen 150 as described above, an image can be recorded by ink on the data sheet 170 .
Moreover, the discharge driving roller 292 and the discharge driven roller 294 are arranged at the front of the platen 150 to form the discharging portion 290 . The discharge driving roller 292 is rotationally driven by power distributed from the carrying motor 286 . Moreover, the discharge driven roller 294 presses the data sheet 170 passing over the platen 150 on the discharge driving roller 292 . Therefore, the discharge driven roller 294 is rotated according to the rotation of the discharge driving roller 292 , the data sheet 170 is sent away from the platen 150 to an outside.
Furthermore, in the internal mechanism 20 , a cap member 270 is arranged at a lateral side of the platen 400 near the side face portion 212 . The cap member 270 can move up and down, and thus ascends and seals a lower face of the nozzle plate 166 when the carriage 160 stops at the home position near the side face portion 212 . Moreover, an inside of the cap member 270 is coupled with a pump unit 272 . The pump unit 272 can absorb ink attached to the surface of the nozzle plate 166 . The ink absorbed by the pump unit 272 is absorbed into the waste liquid absorbing member 262 through a pipe not shown.
Furthermore, a wiping means 274 is arranged between the platen 150 and the cap member 270 . When the carriage 160 released from the sealing by the cap member 270 passes above the wiping means 274 , the wiping means 274 wipes out the lower part of the nozzle plate 166 to clean it.
FIG. 3 is a sectional view typically showing a structure of an aerosol generation preventing mechanism 31 formed in the ink-jet type recording apparatus 10 as described above. As shown in the present drawing, the platen 150 includes a rib portion 154 protruded upward, and positions the data sheet 170 up and down by supporting the rib portion from the lower part on the upper end. Furthermore, a rib electrode 156 made of metal is mounted on an upper end of the rib portion 154 . The rib electrode 156 is electrically connected to a positive pole of the potential difference generating means 330 via a short protecting resistor 320 and also contacts a lower face of the data sheet 170 . Therefore, when the potential difference generating means 330 operates, the data sheet 170 has the same electric potential as that of the positive pole of the potential difference generating means 330 .
On the other hand, the nozzle plate 166 is connected to a negative pole of the potential difference generating means 330 . Therefore, a potential difference according to the potential difference generated from the potential difference generating means 330 is generated between the data sheet 170 and the nozzle plate 166 , and electric field E according to the potential difference is formed between both. In addition, the potential difference generating means 330 is a constant voltage generating circuit, and adjusts an output so that the potential difference becomes an original value when the potential difference between the nozzle plate 166 and the rib electrode 156 is changed by some kind of cause. In this manner, the rib electrode 156 forms a potential controlling electrode for the data sheet 170 .
In the above aerosol generation preventing mechanism 31 , the rib electrode 156 can be formed of metal having high resistance to wear and high conductivity such as stainless steel, iron plated with nickel, duralumin, iron including chrome or molybdenum, tungsten, titanium, alloy including titanium. Moreover, the rib electrode 156 can be integrated with the platen 150 by embedding, attaching, and two-body shaping using a material such as carbon, metal, conductive polymer. Furthermore, the rib electrode 156 can be formed by partially depositing an amorphous semiconductor such as selenium and silicon or metal on the rib portion 154 .
FIG. 4 is a schematic block diagram explaining an operation of the above aerosol generation preventing mechanism 31 . As shown in the present drawing, a plurality of apertures 168 for discharging ink is formed in the nozzle plate 166 . Moreover, as shown with an arrow X in the present drawing, the nozzle plate 166 moves from right to left on the present drawing with the movement of the carriage 160 .
Meanwhile, ink pushed from the aperture 168 of the nozzle plate 166 forms an ink pillar 340 drooping from the nozzle plate 166 at the moment immediately before the ink becomes an ink drop 342 . At this time, electric charges are accumulated by so-called lightning conductor effect between a leading end A of the ink pillar 340 and an area B adjacent to the ink pillar 340 on a lower face of the nozzle plate 166 .
That is, the above lightning conductor effect means that the area B on the surface of the nozzle plate 166 surrounded with a conical shape including a range of a vertex angle from 50° to 60° with the leading end A (a bottom end in the present drawing) of the ink pillar 340 at the top contributes to the charge of the ink drop 342 . By this lightning conductor effect, the ink drop 342 has an electric charge q larger than that corresponding to a horizontal cross-section area of the ink pillar 340 and equal to that of the nozzle plate 166 .
On the other hand, in the aerosol generation preventing mechanism 31 , an electric field E is formed between the nozzle plate 166 and the rib electrode 156 and the data sheet 170 . As described above, since the ink drop 342 is charged with an electric charge q, the ink drop 342 obtains kinetic energy by a Coulomb force F (qE) from the electric field E, and thus moves on the lower side without deceleration to finally arrive at the data sheet 170 . In this manner, in the electric field E, the generation of aerosols is prevented because the ink drop 344 surely arrives at the data sheet 170 .
In addition, in the ink-jet type recording apparatus 10 as shown in FIGS. 1 to 4 , in order to make a Coulomb force act on the ink drop 342 to prevent the generation of aerosols, it is desirable to set field intensity of the electric field E to the order of 100 kV/m. Moreover, when a potential difference is formed using the nozzle plate 166 as one electrode in order to form such an electric field, an electric charge accumulated in a droplet discharged from the nozzle plate 166 is about 4*10-14Q.
On the other hand, when the data sheet 170 is general premium grade paper or paper made by coating porous silica on the premium grade paper, the volume resistivity is about 107 to 1013 Ωcm. When ink having electrical conductivity penetrates such a data sheet 170 , the volume resistivity deteriorates to 105 to 107 Ωcm. Moreover, surface resistivity of the data sheet 170 to which the ink adheres becomes about 103 to 107 Ω/square.
Therefore, when the rib electrode 156 formed of metal having sufficiently high electrical conductivity touches the data sheet 170 to be connected to the potential difference generating means 330 , electric potential of the data sheet 170 can be controlled so as to be identical with an output voltage from the potential difference generating means 330 by going through the data sheet 170 itself and the ink on the data sheet 170 . Moreover, since electric charges in the ink drop 342 is discharged through the data sheet 170 and the ink 344 already attached to the sheet when the charged ink drop 342 is deposited on the data sheet 170 , electric potential on the data sheet 170 does not vary.
Moreover, in the above embodiment, the rib electrode 156 is connected to a positive pole side of the potential difference generating means 330 and the nozzle plate 166 is connected to a negative pole side of the potential difference generating means 330 . However, although all polarities are reversely connected, a similar function is realized. Moreover, it is possible to simplify wiring within the aerosol generation preventing mechanism 31 by setting electric potential of one end of the potential difference generating means 330 to ground potential.
FIG. 5 is a sectional view typically showing a structure of an aerosol generation preventing mechanism 32 according to another embodiment. In addition, in FIG. 5 , the same reference numbers are put on components common to the other drawings and the description is omitted.
As shown in the present drawing, a structure of the aerosol generation preventing mechanism 32 according to this embodiment has a characteristic peculiar to the shape of the rib electrode 156 . That is to say, this rib electrode 156 penetrates through the rib portion 154 of the platen 150 up and down to expose the lower end on the lower face of the platen 150 . Therefore, wiring from the rib electrode 156 and the potential difference generating means 330 can be coupled in the lower part of the platen 150 . According to such a structure, since wiring is not shown to a user even if a function as the rib electrode 156 and the aerosol generation preventing mechanism 32 equals to that of the aerosol generation preventing mechanism 31 shown in FIG. 3 , safety and merchantability are high.
FIG. 6 is a sectional view typically showing a structure of an aerosol generation preventing mechanism 33 according to further another embodiment. In addition, in FIG. 6 , the same reference numbers are put on components common to the other drawings and the description is omitted.
As shown in the present drawing, a structure of the aerosol generation preventing mechanism 33 according to this embodiment has a characteristic peculiar to the shape of the rib electrode 156 . That is to say, this rib electrode 156 is formed of an electrically conducting layer 157 formed on the whole surface of the platen 150 . Such an electrically conducting layer 157 can be formed by two-body shaping with the platen 150 in addition to application or vapor deposition to the platen 150 . According to such a structure, although a function as the electrically conducting layer 157 as a potential controlling electrode and the aerosol generation preventing mechanism 33 equals to that of the aerosol generation preventing mechanism 31 shown in FIG. 3 , since a contact area between the data sheet 170 and the rib electrode 156 becomes wide to the maximum, both stably have the same electric potential. Therefore, an operation as the aerosol generation preventing mechanism 32 is also stable.
FIG. 7 is a sectional view typically showing a structure of an aerosol generation preventing mechanism 34 according to further another embodiment. In addition, in FIG. 7 , the same reference numbers are put on components common to the other drawings and the description is omitted.
In the embodiment shown in the present drawing, a plurality of conductive brushes 350 is arranged closest to the platen 150 as a means for obtaining electrical connection to the data sheet 170 . Each conductive brush 350 is formed of a member having electrical conductivity and elasticity, and one end thereof is electrically connected to the potential difference generating means 330 . Moreover, the other end of the conductive brush 350 contacts the data sheet 170 at a plurality of points. That is to say, the conductive brushes 350 are arranged on a surface and a rear face of the data sheet 170 immediately before the platen 150 in a transportation direction of the data sheet 170 , and respectively contact the surface and the rear face of the data sheet 170 . Moreover, the conductive brush 350 is arranged on the rear face side of the data sheet 170 immediately after the platen 150 , and contacts the rear face of the data sheet 170 .
Such a configuration should introduce a dedicated member referred to as the conductive brush 350 . However, since the conductive brush 350 is a dedicated part for obtaining electrical connection, arrangement can be freely selected. Therefore, the conductive brush can be arranged closest to the platen 150 , the nozzle plate 166 , and so on related to aerosol collection, and thus electric potential of the data sheet 170 can be efficiently controlled. In addition, the conductive brush 350 can be formed of resin fiber containing carbon or metal powder in addition to a metal wire rod such as stainless steel.
FIG. 8 is a sectional view typically showing a structure of an aerosol generation preventing mechanism 531 according to further another embodiment. As shown in the present drawing, the platen 150 includes a rib portion 154 protruding upward, and supports the data sheet 170 on the upper end from the lower part to position the data sheet 170 up and down. Here, in order to attach ink discharged from the recording head 164 to the data sheet 170 , it is necessary to carry the data sheet 170 from the outside to feed it onto the platen 150 . Moreover, the data sheet 170 to which ink adheres on the platen 150 is sent away from the top of the platen 150 to the outside to be discharged. Transportation and discharge of the data sheet 170 are performed by a carrying portion 280 and a discharging portion 290 each including a pair of rollers.
The carrying portion 280 includes a carrier driving roller 282 contacting the lower face of the data sheet 170 and a carrier driven roller 284 contacting the upper face of the data sheet 170 to press it on the carrier driving roller 282 . Here, the carrier driving roller 282 is rotationally driven by a carrying motor 286 . On the other hand, the carrier driven roller 284 does not have driving force, and is rotated with the rotation of the carrier driving roller 282 while pressing the data sheet 170 on the carrier driving roller 282 . These carrier driving roller 282 and carrier driven roller 284 continues to touch the data sheet 170 from the leading end to the rear end of the data sheet 170 during carrying the sheet. Therefore, the carrier driving roller 282 is formed of a conductive material and is also connected to the potential difference generating means 330 so that electric potential of the data sheet 170 can be controlled via the carrying portion 280 .
The discharging portion 290 includes a discharge driving roller 292 contacting the lower face of the data sheet 170 and a discharge driven roller 294 contacting the upper face of the data sheet 170 to press it on the discharge driving roller 292 . Here, the discharge driving roller 292 is rotationally driven by the carrying motor 286 via transfer mechanism not shown. On the other hand, the discharge driven roller 294 does not have driving force, and is rotated with the rotation of the discharge driving roller 292 while pressing the data sheet 170 on the discharge driving roller 292 . These discharge driving roller 292 and discharge driven roller 294 continues to touch the data sheet 170 from the leading end to the rear end of the data sheet 170 during carrying the sheet. Therefore, the discharge driving roller 292 is formed of a conductive material and is connected to the potential difference generating means 330 so that electric potential of the data sheet 170 can be controlled via the discharging portion 290 .
Furthermore, both of the discharge driving roller 292 and the discharge driven roller 294 are formed of a conductive material and is electrically connected to the potential difference generating means 330 , so that electric potential of the data sheet 170 can be continuously controlled from when the leading end of the data sheet 170 comes to the platen 150 to when the rear end passes over the platen 150 . In this embodiment, the carrier driven roller 284 and the discharge driven roller 294 are together connected to a positive pole of the potential difference generating means 330 via a short protecting resistor 320 . On the other hand, the nozzle plate 166 is connected to a negative pole of the potential difference generating means 330 . Therefore, in the ink-jet type recording apparatus 10 , electric field E is formed between the nozzle plate 166 and the data sheet 170 .
In addition, materials of these carrier driving roller 282 and discharge driving roller 292 can include metal material having rigidity and electrical conductivity such as iron, iron plated with nickel, stainless steel. Furthermore, in order to prevent the carrier driving roller 282 from sliding on the data sheet 170 , it is preferable to attach alumina grains to a surface of the carrier driving roller to improve frictional force of the surface. Moreover, the surface may be coated with conductive rubber instead of attaching alumina grains to the surface.
FIG. 9 is a schematic block diagram explaining an operation of the aerosol generation preventing mechanism 531 . As shown in the present drawing, a plurality of apertures 168 for discharging ink is formed in the nozzle plate 166 . Moreover, as shown with an arrow X in the drawing, the nozzle plate 166 moves from right toward left on the drawing with the movement of the carriage 160 .
When the data sheet 170 exists right under the nozzle plate 166 , the ink drop 342 is discharged from the aperture 168 of the nozzle plate 166 toward the data sheet 170 . Kinetic energy given to the ink drop 342 after being discharged from the aperture 168 is rapidly lost by viscous resistance of an atmosphere, and a part of the ink drops 342 is perfectly lost far before arriving at the data sheet 170 . Moreover, since the mass of the ink drop 342 is extremely small, a falling motion by acceleration of gravity and a viscous resistance force nearly balances, and thus fall velocity of the ink drop 342 becomes extremely late. In this way, the ink drop 342 floating beneath the nozzle plate 166 becomes an aerosol.
Meanwhile, ink pushed from the aperture 168 of the nozzle plate 166 becomes the ink pillar 340 drooping from the nozzle plate 166 at the moment immediately before being the ink drop 342 . At this time, electric charges are accumulated by so-called lightning conductor effect between a leading end A of the ink pillar 340 and an area B adjacent to the ink pillar 340 on the lower face of the nozzle plate 166 .
That is to say, the lightning conductor effect means that the area B on the surface of the nozzle plate 166 surrounded with a conical shape including a range of a vertex angle from 50° to 60° with the leading end A (a bottom end in the present drawing) of the ink pillar 340 at the top contributes to the charge of the ink drop 342 . By this lightning conductor effect, the ink drop 342 has an electric charge q larger than that corresponding to a horizontal cross-section area of the ink pillar 340 and equal to that of the nozzle plate 166 .
On the other hand, in the aerosol generation preventing mechanism 531 , an electric field E is formed between the nozzle plate 166 and the data sheet 170 . As described above, since the ink drop 342 is charged with the electric charge q equal to that of the nozzle plate 166 , the ink drop 342 obtains kinetic energy by a Coulomb force F (qE) from the electric field E, and thus moves on the lower side without deceleration to finally arrive at the data sheet 170 . In this manner, the generation of aerosols is prevented because the ink drop 342 in the electric field E surely arrives at the data sheet 170 .
In addition, in the ink-jet type recording apparatus 10 as shown in FIGS. 2 to 9 , in order to make a Coulomb force act on the ink drop to prevent the generation of aerosols, it is desirable to set field intensity of the electric field E to the order of 100 kV/m. Moreover, when a potential difference is formed using the nozzle plate as one electrode in order to form such an electric field, an electric charge accumulated in a droplet discharged from the nozzle plate 166 is about 4*10 −14 Q.
On the other hand, when the data sheet 170 is general premium grade paper or paper made by coating porous silica on the premium grade paper, the volume resistivity is about 10 7 to 10 13 Ωcm. When ink having electrical conductivity penetrates such a data sheet 170 , the volume resistivity deteriorates to 10 5 to 10 7 Ωcm. Moreover, surface resistivity of the data sheet 170 to which the ink adheres becomes about 10 3 to 10 7 Ω/square.
Therefore, when the carrier driving roller 282 and the discharge driving roller 292 formed of metal having sufficiently high electrical conductivity touches the data sheet 170 to be connected to the potential difference generating means 330 , electric potential of the data sheet 170 can be controlled so as to be identical with an output voltage from the potential difference generating means 330 by going through the data sheet 170 itself and the ink drop 344 on the data sheet 170 . Moreover, since electric charges in the ink drop 344 is discharged through the data sheet 170 and the ink attached to the sheet when the charged ink drop 344 is deposited on the data sheet 170 , electric potential on the data sheet 170 does not vary.
Moreover, in the above embodiment, the data sheet 170 side is connected to a positive pole side of the potential difference generating means 330 and the nozzle plate 166 is connected to a negative pole side of the potential difference generating means 330 . However, although all polarities are reversely connected, a similar function is realized. Moreover, it is possible to simplify wiring within the aerosol generation preventing mechanism 531 by setting electric potential of one end of the potential difference generating means 330 to ground potential.
FIG. 10 is a sectional view typically showing a structure of an aerosol generation preventing mechanism 532 according to further another embodiment. In FIG. 10 , the same reference numbers are put on components common to the other drawings and the description is omitted.
As shown in the present drawing, in this embodiment, the carrier driven roller 284 and the discharge driven roller 294 are electrically connected to the potential difference generating means 330 in each of the carrying portion 280 and the discharging portion 290 . A function obtained in this way is similar to that of the configuration shown in FIG. 8 . However, this embodiment has the following advantage. That is to say, the carrier driving roller 282 and the discharge driving roller 292 are mechanically coupled with rotation transfer mechanism such as a gear group for rotational driving. Therefore, using mechanical contact in the transfer mechanism, they can be electrically connected to the potential difference generating means 330 . However, in order to realize this, the whole of the rotation transfer mechanism should be formed of a conductive material. However, this kind of rotation transfer mechanism is formed of gears formed of a resin material in many cases. When this resin material is changed into a metal material, this change causes the increase of manufacturing cost and the increase of operating noises.
In this regard, since the carrier driven roller 284 and the discharge driven roller 294 are only supported to be able to be rotated, a potential difference controlling means can be simply formed when these rollers are formed of a conductive material and a shaft supporting means is electrically connected to the potential difference generating means 330 . In addition, materials of the carrier driven roller 284 and the discharge driven roller 294 can include iron, iron plated with nickel, metal having electrical conductivity such as stainless steel, or a resin material containing carbon or metal powder and having electrical conductivity.
FIG. 11 is a sectional view typically showing a structure of an aerosol generation preventing mechanism 533 according to further another embodiment. In FIG. 11 , the same reference numbers are put on components common to the other drawings and the description is omitted.
As shown in the present drawing, in this embodiment, all of the carrier driving roller 282 , the carrier driven roller 284 , the discharge driving roller 292 , and the discharge driven roller 294 are formed of a conductive material and electrically connected to the potential difference generating means 330 in each of the carrying portion 280 and the discharging portion 290 . A function obtained in this way is similar to that of the configuration shown in FIGS. 8 and 10 . However, this embodiment has the following advantage. That is to say, although each roller touches the data sheet 170 , each roller microscopically repeats contact and detachment when really carrying or discharging the data sheet 170 . For this reason, focusing attention on single roller, the roller is not stably connected to the data sheet 170 . However, since either of rollers touches the data sheet 170 as a whole by increasing the number of rollers having contact with the data sheet 170 , electric potential of the data sheet 170 can be stabilized.
As described above in detail, the ink-jet type recording apparatus 10 can actively collect droplets by forming an electric field between the nozzle plate 166 and the data sheet 170 to prevent the generation of aerosols. Moreover, since the data sheet can be coupled with the potential difference generating means 330 via a potential controlling electrode in order to constantly preserve electric potential of the data sheet 170 , it is not necessary to perform a complicated control such as an inversion of an applied voltage. Therefore, a liquid ejecting apparatus that does not generate aerosols can be realized with a plain structure. Furthermore, it is possible to realize a function similar to that of the existing liquid ejecting apparatus by providing the apparatus as a configuration of a field generating unit.
In addition, in the above embodiment, a concrete configuration has been described using the ink-jet type recording apparatus 10 as an example. However, the liquid ejecting apparatus can be implemented as a color material injection system in manufacture of a color filter for a liquid crystal display, an electrode formation apparatus in manufacture of an organic EL display, FED (a plane emission display), or the like, a sample injection head used in manufacture of a biochip, a sample injection head as a precise pipette, an apparatus that pictures a picture and a character on artificial nails, and so on, and further the liquid ejecting apparatus is not limited to them.
Although the present invention has been described by way of an exemplary embodiment, it should be understood that those skilled in the art might make many changes and substitutions without departing from the spirit and the scope of the present invention. It is obvious from the definition of the appended claims that embodiments with such modifications also belong to the scope of the present invention.
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There is provided a liquid ejecting apparatus including a liquid ejecting head that ejects liquid from an aperture of a nozzle plate toward a recording material while reciprocating over the recording material and a platen that supports the recording material from a rear face thereof to position the recording material at a position facing the nozzle plate in a direction in which the liquid is ejected. The liquid ejecting apparatus further includes: a first electrode being provided on the platen side between the liquid ejecting head and the platen; a second electrode being provided on the liquid ejecting head side between the liquid ejecting head and the platen; and a potential difference generating section of which one end is connected to the first electrode and the other end is connected to the second electrode and that generates a potential difference between the second electrode and the first electrode.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority of United States of America (U.S.) Provisional Application Ser. No. 62/007,029 filed Jun. 3, 2014.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable.
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISK APPENDIX
Not Applicable.
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates generally to floating platforms that support sustainable energy producing mechanisms like wind, wave, solar, and tidal.
There are many reasons to locate sustainable energy creation devices offshore. Offshore wind is where the strongest winds in the world are located. Also, wave and tidal energy is located there. In calm conditions, the sun generally shines and with no trees or other shade-causing structures, solar energy generation should be a consideration. Thermal differences in water can also provide energy creation options. Offshore locations are not in anyone's back yard so there will be less public outcry due to noise, visibility, strobing effect, transmission lines, or property value impacts. Eminent domain issues can be minimized with offshore locations. Therefore, offshore locations are preferred for sustainable energy production.
There are many challenges with locating sustainable energy capture devices offshore. For example, a wind turbine embedded in the ocean/lakebed permanently is very expensive to build. Because it is permanent, lengthy permits need to be obtained which require lengthy studies to be completed, including geotechnical/foundation studies to determine how deep into the ocean/lakebed a tower must be embedded. For turbines embedded in the ocean/lakebed, the pieces used for construction are quite heavy.
Multi-megawatt (MW) wind power generation units generally have hub heights of around 285 feet (′) (86.9 meters (m)) and lifting large weights, 100 (90.7 metric tonnes (Mt)) to 300 tons (272 Mt), to this height requires large ships with powerful cranes to meet these demands. These large crane ships are very expensive. Because the crane ships are so expensive, there are few of them available at any given time to ensure the ships are fully utilized. This means wind energy capture devices must wait in a queue for maintenance. This lowers availability of the wind energy capture devices and lowers the economic viability of offshore wind energy production. People working at these heights also are put at significant safety risks.
Permanent wind energy capture devices located offshore can only be used for one purpose. This lack of functional flexibility also lowers the economic viability of sustainable offshore wind energy production.
Permanent wind energy capture devices located offshore can be damaged by ice flows/icebergs and destroyed. This level of risk is borne by offshore wind farm financiers and also lowers the economic viability of sustainable offshore wind energy production.
Large floating wind turbines that are assembled at dry dock and towed into position require large, specially built docks with cranes that can reach heights of over 300′.
U.S. Pat. No. 4,159,427 “Apparatus for Using Natural Energies” (Weidemann) discloses a floating system using a hull design like a ship, either singular or dual, that supports a superstructure that holds various kinds of natural energy capture devices such as multiple wind turbines.
U.S. Pat. No. 6,100,600 “Maritime Power Plant System with Processes for Producing Storing and Consuming Regenerative Energy” (Pflanz) discloses a floating system that creates energy from regenerative means above and below ocean waves like wind, wave, solar, chemical, and temperature. It can support multiple wind turbines, but unlike this invention, it does not disclose the type or means of floatation.
U.S. Pat. No. 6,294,844 “Artificial Wind Turbine Island” (Lagerwey) discloses a floating system using a hull design like a ship, either singular or multiple, to support multiple wind turbines. It has the capability to rotate about a vertical axis to turn into the wind.
U.S. Pat. No. 7,075,189 “Offshore Wind Turbine with Multiple Wind Rotors and Floating System” (Heronemus) discloses a floating system of arrayed wind turbines for the purpose of producing hydrogen-based fuels far offshore. Various buoyant hulls are embodied, but none are similar to this invention.
US20120139255 “Technology for Combined Offshore Floating Wind Power Generation” (Zhu) discloses a floating system for supporting wind turbines and solar panels with wave/tidal capture devices attached to the octagonal frame. Each point of the octagonal frame has an independent corner floating unit. The connecting supports ( 8 ) float and have a plurality of independent chambers in it.
WO2014055027A1 “Floating Platform and Energy Production Plant” (Tunbjer) discloses floating or semi-submersible system for supporting wind turbines. It comprises at least three peripheral floating or semi-submersible units rigidly connected to a central floating or semi-submersible unit. The rigid connections can compress to capture wave/tidal energy.
BRIEF SUMMARY OF THE INVENTION
Object of the Invention
This invention differs from prior art in that a barge has been designed to support sustainable power generation (exempli gratia (e.g.), wind, wave, solar, et cetera (etc.)) in a four-season, shallow (50′ (15.2 m) to 60′ (18.3 m) offshore environment with a plurality of configurable bays that support sustainable energy capture devices. The barge is round or mostly round with a plurality of peripheral bays that curve inward, opposite the barge's curvature, and where sustainable energy capture devices can be placed. The bays allow the sustainable energy capture devices to be easily removed for maintenance on site by support ships. The bays are positioned such that no undesirable elements (e.g. turbulence, shade, etc.) can sap energy from the other sustainable energy capture devices. The barge is buoyant and floats independently of the sustainable energy capture devices in each bay. The barge is hollow and its entire circumference can be traversed by the crew; safe from harsh environments. Ice challenges will be mitigated by its shape and aeration of the water around the outside of the floating barge. A central platform is contained within the barge by cables that may have wave energy capture devices installed. The central platform can be accessed by the crew through one or multiple floating walkways. Sustainable energy capture devices at the bays will float independently of the barge and may have wave energy capture devices on them at the bay-device interface.
Advantages of the Invention
In order to meet the demands unique to offshore sustainable energy farms, a floating barge has been designed with an all-encompassing, systems approach. The barge is an integral part of a sustainable energy creation system. The advantage of this is lower total costs and operating costs because the total costs of the project were considered during the design.
The barge is designed to operate in shallow waters about 55′ (16.8 m) deep as well as deep waters, support a plurality of sustainable energy capture devices, survive winters with pack ice, and be capable of supporting some sort of industry (e.g. industrial, recreational, residential, etc.). The advantage of this is better survivability and more available sites from which to choose for installing sustainable energy farms.
By being close to shore in shallow waters, shorter cables lengths are required to bring electricity to onshore customers. The barge will allow for a draft of between 25′ (7.6 m) and 45′ (13.7 m). This will allow it to be placed close to shore (2-5 miles). The advantage of this is lower total costs and operating costs than the current state of the art.
If the barge is placed hundreds of miles from the coast, energy generated on it may be used for the industry employed on the floating, central platform (Platform) (e.g. industrial, recreational, residential, etc.) or it may be transmitted to land through an underwater cable. The advantage of this is enhanced marketability and functional flexibility.
The barge has a plurality of bays on it. The bays allow the sustainable energy capture devices to be removed quickly for onsite maintenance. There can be a different sustainable energy capture device associated with each bay. Each one could be studied and evaluated in a natural environment in order to enhance each sustainable energy capture device's capabilities using real-world data. The sustainable energy capture devices are meant to be quickly and easily removed for fast, onsite service. This will lower maintenance downtime and increase the availability of the sustainable energy capture devices.
The barge will survive winters in pack ice by being round or mostly round. This will prevent ice forces from concentrating anywhere on the barge. It also has a common aeration system. Air compressors will push air through air hoses around the ship to air stones lowered down into the water that churns up warm water from below to the surface and agitates the water that, in turn, melts ice within close proximity to the barge. The advantage of this is lower operating costs and improved safety because there will be less damage to the barge each winter.
Optionally, wave energy capture devices will be deployed. Tensioned cables holding the Platform in place relative to the barge may each have a wave energy capture device to harness the horizontal component of wave energy as the Platform moves independently of the barge. Each interface between the bay and the sustainable energy capture device may have a wave energy capture device to harness the vertical component of wave energy as the sustainable energy capture device bobs differently in relation to the bay. The advantage of this is greater energy creation from a single unit.
The Platform has been integrated into the design to provide functional flexibility. The Platform will hold the step-up transformer. In the currently considered embodiments, the Platform will be approximately 79′ (24 m) to 450′ (61 m) in diameter or 0.11 acres (ac) (0.05 hectares (ha)) to 3.65 ac (1.48 ha) in area, but can be bigger given a location in deeper water. It may also hold some sort of industry (e.g. industrial, recreational, residential, etc.) that will utilize the energy generated on the barge. Depending on the demand from this industry, electricity may not be transmitted onshore. In this embodiment, the barge and Platform will act as a self-powered island. The advantage of this is greater marketing potential as a self-powered island with plenty of electricity and potentially free from government constraints because it is located hundreds of miles from the coast in international waters.
The barge is hollow and allows the crew access around the entire watercraft. This keeps the crew out of the elements and much safer than walking on top of it where wind and waves can create risky situations regarding safety. The barge's hollow nature also provides its buoyancy. If any or all of the multiple sustainable energy capture devices becomes disabled and sink(s), the barge will remain afloat.
The barge has bow and stern thrusters to more quickly position it into the wind for improved efficiency when there are wind turbines in the configuration. In winds too slow to align the barge with a weather front approaching from a different direction, thrusters are incorporated at each bay to align the barge. The thrusters are powered by stored electricity generated on the barge. The advantage of this is increased efficiency as it may take up to 45 minutes for the wind to “weathervane” or align the barge into the most efficient position while the thrusters could do the job in about 10 minutes.
The barge is attached to a mooring system that allows the barge to “weathervane” around the anchor. If the barge is too slow to move into place using the natural wind-catching capabilities of the design, wind vanes or fins may be added where necessary. In some embodiments, station-keeping may be computerized with the thrusters for increased efficiency.
The barge's design produces lower initial capital costs than permanently embedded sustainable energy capture devices in the ocean/lakebed. It also lays the groundwork for lower operating costs than the current state of the art by merging industry with sustainable energy generation. Initially, it can be used as a real-world test bed for various sustainable energy capture devices. Lessons learned from these types of studies will enhance the sustainable energy capture devices, further improving their economics. This invention will lower the cost of sustainable energy to consumers.
The position of the wind turbines relative to each other is fixed when locked in place at each bay. This reduces the wake effect where wind turbulence coming off the tips of each blade increases wind shear and reduces turbine efficiency on the downwind turbines. Also, with three lower turbines in the bow and four higher turbines in the stern, this positioning also serves to capture more air in the middle of the barge that aids in its “weathervaning” and increases airflow through the four back turbines.
If the barge needs to be relocated, support equipment can tow it to another location. The advantage of this is as political winds change, offshore wind may be outlawed in one country and welcomed in another and costs would be lower for relocation of this invention than for the current state of the art.
If the barge needs to be decommissioned, it can easily be removed leaving no trace or lasting impact on the environment. If local authorities require it, it can be sunk to provide an artificial reef after the sustainable energy generation devices are removed.
If one sustainable energy capture method is deemed unlawful by local authorities and it is currently in use, support ships can quickly change out the unwanted sustainable energy capture devices with those that are needed.
In the embodiment shown in FIGS. 1 through 5 , the barge has 7 bays where horizontally aligned wind turbines (HAWT) are located. While the embodiment shown has 7 bays where different sustainable energy capture devices can be installed, it should be understood that alternative embodiments of the barge may be provided with a different number of bays, particularly where a smaller or larger barge is desired or required.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE INVENTION
FIG. 1 is an isometric view of the barge;
FIG. 2 is a plan view of the barge;
FIG. 3 is a section view of the barge;
FIG. 4 is an elevation view of the bow of the barge;
FIG. 5 is an elevation view of the port side of the barge;
FIG. 6 is a section view of another barge;
FIG. 7 is a section view of still another barge.
DETAILED DESCRIPTION OF THE INVENTION
Definitions
Barge: The floating, tubular, ship that is typically round or nearly round, but may be in any number of different configurations that support several sustainable energy capture devices at each bay and that has thrusters for station keeping.
Central Platform (Platform): A barge in the middle of the peripheral barge. It can be any shape that works effectively with the shape of the peripheral barge. In the embodiment shown in the figures, it is round where the peripheral barge is generally ring-shaped.
Bay: The location on the barge where the sustainable energy capture device is secured. The bay is a gap in the peripheral barge that is closed by an opposite-curving portion allowing the sustainable energy capture device to be removed.
Bow Bay: There are 3 front bays on the side of the barge considered the bow. The mooring cables may be attached on this side of the barge so the front bays are upwind of the back bays although any number of rigging configurations are possible.
Back Bay: There are 4 back bays on the side of the barge considered the stern. The back bays are downwind (wind direction 110 of FIG. 1 ) of the front bays.
Sustainable Energy Capture Device: In the embodiment shown in FIGS. 1-5 , the 7 HAWT serve this purpose. Other sustainable energy capture devices could include vertically aligned wind turbines (VAWT), solar panels, wave energy capture mechanisms, or tidal energy capture mechanisms.
DETAILED DESCRIPTION OF THE FIGURES
In FIG. 1 , the presented embodiment of the “Barge” ( 6 ) is viewed from an isometric perspective. Item 1 is the “Back HAWT.” It is a sustainable energy capture device translating wind energy to electrical energy and is attached to the “Barge” ( 6 ) at a “Back Bay” ( 7 b ). At the bay/device interface, a wave energy capture device 140 may be installed. “Back HAWT” are taller than “Bow HAWT” ( 2 ). Item 2 is the “Bow HAWT.” It is a sustainable energy capture device translating wind energy to electrical energy and is attached to the “Barge” ( 6 ) at a “Bow Bay” ( 7 a ). At the bay/device interface, a wave energy capture device may be installed. “Bow HAWT” are as close to the waterline ( FIG. 4 ) ( 13 ) as possible. Item 3 is a floating “Platform Access Walkway” and connects the bays ( 7 ) to the “Central Platform” ( 4 ). Item 4 is the floating, “Central Platform.” It is secured to the “Barge” by “Tensioned Cables” ( 9 ). Item 5 is a representation of the “Step-up Transformer.” Item 6 is the floating, peripheral “Barge.” The “Barge” is round, but may be nearly round. It is basically a hollow tube. The barge is buoyant. It is made of aluminum in this embodiment, but may be constructed of any economic material depending upon its project-specific industrial use. It is flat on the “Top Side” ( 8 ), “Inner Wall” ( 10 ), and “Bottom Side” ( FIG. 3 ) ( 12 ), but may be any shape based upon manufacturing efficiencies. Item 7 a is the “Bow Bay.” There are three “Bow Bays.” Item 7 b is the “Back Bay.” There are four “Back Bays.” Item 8 is the “Top Side” of the “Barge” ( 6 ). Item 9 is a tensioned cable securing the “Central Platform” ( 4 ) to the “Barge” ( 6 ). Wave energy capture devices 120 may be installed on these cables. Item 10 is the “Inner Wall” of the “Barge.” Item 11 is the “Outer Wall” of the “Barge.”
In FIG. 2 , the presented embodiment of the “Barge” ( 6 ) is viewed in plan. Item 1 is the “Back HAWT.” Item 2 is the “Bow HAWT.” Item 3 is a “Platform Access Walkway.” It is 6′ (1.8 m) wide and connects the bays ( 7 ) to the “Central Platform” ( 4 ). There may be any number of these walkways not to exceed the number of bays. Item 4 is the “Central Platform.” In the presented embodiment, the “Central Platform” is round and has a 150′ (45.7 m) diameter and an area of 0.41 ac (0.16 ha) that holds the “Step-up Transformer” ( 5 ) and may hold a laboratory, office, community, factory, greenhouse, desalination plant or the like. The crew can get to the “Central Platform” by 7 “Platform Access Walkways” ( 3 ), one from each bay, but may be accessed by any number of “Platform Access Walkways” ( 3 ) if a particular design requires it. Item 5 is a representation of the “Step-up Transformer.” Electricity generated from each bay ( 7 ) is collected at the “Step-up Transformer” on the “Central Platform” ( 4 ). Item 6 is the “Barge.” In the presented embodiment, the “Barge” has an outside diameter of 308′ (93.9 m) enabling it to hold 7 HAWTs ( 1 ) ( 2 ) with about a 95′ (29 m) rotor diameter ( FIG. 4 ) ( 1 ) ( 2 ), but may be of any diameter. The size of the “Barge” is determined by the wind-swept area of the blades ( FIG. 4 ) ( 1 ) ( 2 ). It is 6′ (1.8 m) wide at the waterline. Item 7 a is the “Bow Bay.” Item 7 b is the “Back Bay.” Item 8 is the “Top Side” of the “Barge” ( 6 ). Item 9 is a tensioned cable securing the “Central Platform” ( 4 ) to the “Barge” ( 6 ). There are 8 cables in this embodiment. Item 10 is the “Inner Wall” of the “Barge” ( 6 ). Item 11 is the “Outer Wall” of the “Barge” ( 6 ).
In FIG. 3 , the presented embodiment of the “Barge” ( 6 ) is viewed in section. Item 6 is the “Barge.” In this embodiment, the “Barge” has a maximum width of 6′ (1.8 m), but may be of any width. It has a height of 9′ (2.7 m), but may be of any height. Item 8 is the “Top Side” of the “Barge” ( 6 ). In this embodiment, it is flat and about 5′ 2 inches (″) wide, but may be curved, if necessary and any width depending on space requirements. Item 10 is the “Inner Wall” of the “Barge” ( 6 ). In this embodiment, it is straight and 9′ (2.7 m) high, but may be curved, if necessary and any width depending on space requirements. Item 11 is the “Outer Wall” of the “Barge.” In this embodiment, the “Outer Wall” has two straight, angled planes that meet at the “Waterline” ( 13 ), but the “Outer Wall” may be straight if ice mitigation is highly effective. The “Outer Wall” may be curved, if necessary and any height depending on space requirements. This design sheds and prevents the concentration of forces due to waves or ice. Item 12 is the “Bottom Side” of the “Barge” ( 6 ). In this embodiment, it is flat and about 5′-2″ wide, but may be curved, if necessary and any width depending on space requirements. Item 13 is the “Waterline” location.
In FIG. 4 , the presented embodiment of the “Barge” ( 6 ) is viewed from a bow, elevation perspective. Item 1 is the “Back HAWT.” The “Back HAWT” has a hub height of 206′ (62.8 m) above the “Waterline” ( 13 ) for a maximum height of about 253′ (77.1 m) due to the length of the blades; about 47′ (14.5 m). Overall heights can be reduced depending on local regulations and wind resource characteristics. Item 2 is the “Bow HAWT.” The bow HAWTs have hub heights of 119′ (36.3 m) for a maximum height of about 166′ (50.6 m) due to the length of the blades about 47′ (14.5 m). Bow heights can be reduced depending on local regulations and wind resource characteristics. Item 5 is a representation of the “Step-up Transformer.” Item 6 is the “Barge.” In the presented embodiment, the “Barge” is 9′ (2.7 m) high. Item 8 is the “Top Side” of the “Barge” (6). In this embodiment, it is flat, but may be curved, if necessary. Item 11 is the “Outer Wall” of the “Barge.” In this embodiment, the “Outer Wall” has two straight, angled planes that meet at the “Waterline” (13), but the “Outer Wall” may be straight ( FIG. 6 ) if ice mitigation is highly effective. The “Outer Wall” may be curved ( FIG. 7 ), if necessary and any height depending on space requirements. Item 12 is the “Bottom Side” of the “Barge” (6). In this embodiment, it is flat, but may be curved, if necessary. Item 13 is the “Waterline” location.
In FIG. 5 , the presented embodiment of the “Barge” ( 6 ) is viewed from a port elevation perspective. Item 1 is the “Back HAWT.” The “Back HAWT” has a hub height of 206′ (62.8 m) above the “Waterline” ( 13 ) for an overall height of about 253′ (77.1 m) due to the length of the blades; about 47′ (14.5 m). Overall heights can be reduced depending on local regulations and wind resource characteristics. Item 2 is the “Bow HAWT.” The bow HAWTs have hub heights of 119′ (36.3 m) for a maximum height of about 166′ (50.6 m) due to the length of the blades; about 47′ (14.5 m). Bow heights can be reduced depending on local regulations and wind resource characteristics. Item 5 is a representation of the “Step-up Transformer.” Item 6 is the “Barge.” In the presented embodiment, the “Barge” is 9′ (2.7 m) high. Item 8 is the “Top Side” of the “Barge” ( 6 ). In this embodiment, it is flat, but may be curved, if necessary. Item 11 is the “Outer Wall” of the “Barge.” In this embodiment, the “Outer Wall” has two straight, angled planes that meet at the “Waterline” ( 13 ), but the “Outer Wall” may be straight if ice mitigation is highly effective. The “Outer Wall” may be curved, if necessary and any height depending on space requirements. Item 12 is the “Bottom Side” of the “Barge” ( 6 ). In this embodiment, it is flat, but may be curved, if necessary. Item 13 is the “Waterline” location.
While values for dimensions, sizes and measurements have been provided in this specification for various components of the barge and the systems making up the barge, it should be understood that such values are for purposes of description and example only. Actual values may vary greatly depending on the particular designs chosen while still being within the scope and spirit of the invention.
Electric cables run from each bay ( 7 ) to the “Central Platform” ( 4 ) to the “Step-up Transformer” ( 5 ) and along the rigging to the anchor, eventually being laid on the ocean/lakebed leading to land and the substation and/or customers.
The invention is to be manufactured of aluminum onshore in about 10 pieces that are sealed and buoyant. The pieces will be transported to a dock and attached to support ships. The support ships will tow the pieces to the site. Once at the site, the first two pieces will be quickly bolted together. The third through ninth pieces will then be bolted to the predecessors one at a time and the partially assembled “Barge” ( 6 ) will be moved, or rotated, to allow space for the next piece to be moved into place. It is held in place by the support ships.
The “Central Platform” ( 4 ) parts will then be loaded onto supports ships, taken to the site and assembled through the remaining gap in the “Barge” ( 6 ). Next, “Tensioned Cables” ( 9 ) secure it to the “Barge” ( 6 ) and the appropriate number of “Platform Access Walkways” ( 3 ) are installed then the “Barge” ( 6 ) is closed by bolting on the tenth pieces, closing the ring. The invention is then connected to the rigging.
The seals are then broken so the “barge” ( 6 ) can be welded together at each connection. Air bladders will then be placed under the bolted areas of each piece and inflated to lift the “Barge” ( 6 ) above the water in order to weld it together.
It is anticipated that efficiencies will be discovered as the installation process is performed repeatedly. The pieces may be sealed or not, bolted together in the water, on the support ships, or in dry dock. It is desired to transport the unit to the site as quickly as possible and install it as quickly, simply, and safely as possible.
Each sustainable energy capture device will be assembled onshore, as completely as practicable, transported to the dock, loaded onto a support ship, and towed to the site for installation.
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A barge has been designed to function in a four-season environment with a plurality of configurable, peripheral bays (bays) that support sustainable energy capture devices (devices). The barge is round with bays that curve inward, opposite the barge's curvature, and where devices can be placed. The bays allow the devices to be removed for maintenance by support ships. The barge is buoyant and floats independently of the devices in each bay. The barge is hollow and its entire circumference can be traversed by the crew. A central platform is contained within the barge by cables that may have wave energy capture mechanisms installed. The central platform and can be accessed by the crew through one or multiple floating walkways. Devices installed at the bays will float independently of the barge and may have wave energy capture mechanisms on them at the bay-device interface.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. provisional patent application 61/442,374 filed Feb. 14, 2011 and hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a method of straightening a foundational wall and in particular for use in the repair and reinforcement of basement walls comprised of blocks or other materials.
BACKGROUND OF THE INVENTION
[0003] Below ground walls, such as those which provide for the walls of the basement, must be able to support the weight of a structure resting thereon and to resist lateral forces associated with the surrounding soil and hydrostatic pressure from water in the soil.
[0004] Particularly when a basement wall is constructed of masonry block, lateral pressure may cause the wall to deflect inwardly and cracks to appear on the inner surface of the wall as mortar joints yield to a tensile force component. If such deflection continues unabated, the entire wall may buckle and collapse with damage to the supporting structure.
[0005] A number of methods of straightening walls experiencing initial stages of deflection employ applying a counterbalancing force on the inner surface of the basement wall by means of cables or a threaded rod passing from a plate on the inner surface of the basement wall through the wall and anchored at a position outside the wall, for example, in a trench. Tightening the cable or threaded rod may then pull the wall back into alignment. A system of this type is taught by U.S. Pat. No. 4,189,891.
[0006] In a different approach, U.S. Pat. No. 4,353,194 teaches applying force by means of an ellis jack braced between the floor of the basement and the wall suffering from deflection.
SUMMARY OF THE INVENTION
[0007] The present invention provides an improved method of straightening walls that coordinates multiple jacks simultaneously with monitoring of the wall alignment during the jacking operation. In this way, a faster and more uniform straightening process may be obtained, the latter minimizing wall damage. Further, the wall may be straightened substantially immediately, and not over a lengthy period of time as required of other more gradual processes.
[0008] Other features and advantages of the invention will become apparent to those skilled in the art upon review of the following detailed description, claims and drawings in which like numerals are used to designate like features.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a side elevational view of a hydraulic jack mounted on a fixture for attachment to a concrete slab basement floor in one embodiment of the invention;
[0010] FIG. 2 is a side elevational view of the hydraulic jack of claim 1 positioned with a bracing system against a foundational wall shown in cross-section;
[0011] FIG. 3 is a top plan view of multiple braces of FIG. 2 , each with a hydraulic jack;
[0012] FIG. 4 is a fragmentary elevational view showing the interconnection of an electronic level-sensor to a control valve of the hydraulic cylinder of FIG. 1 ;
[0013] FIG. 5 is a figure similar to that of FIG. 4 showing an alternative mechanical implementation of the present invention;
[0014] FIG. 6 is a plot of data that may be sensed by the level-sensor of FIG. 4 to control hydraulic fluid gated to the cylinders to minimize wall damage;
[0015] FIG. 7 is a perspective view of a foot bracket used to prevent push-out of the basement wall near the floor.
[0016] Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] Referring now to FIG. 1 , a hydraulic cylinder 10 of the type known in the art may receive hydraulic fluid through electronically controllable valve 12 from hydraulic hose 14 . As is understood in the art, hydraulic cylinders provide for an enclosed chamber that may be pressurized with a hydraulic fluid to apply force to a shaft communicating with the enclosed chamber through a piston or the like.
[0018] The hydraulic cylinder 10 may provide for a piston driven shaft 15 having a portion extending from an end of the hydraulic cylinder 10 along an axis 16 tipped at approximately 45 degrees with respect to a plane of the floor 20 on which the hydraulic cylinder 10 rests. The end of the shaft 15 may connect with one end of a diagonal brace 22 also extending along the axis 16 .
[0019] A base of a hydraulic cylinder 10 may be attached to and supported by a bracket 24 orienting the shaft 15 along axis 16 , for example, the bracket 24 being fabricated of welded steel plate having a base plate 26 that may rest against the floor 20 with holes receiving anchor screws 28 or the like therethrough to anchor the bracket 24 to the floor 20 . The bracket 24 further provides an angled steel plate against which the base of the hydraulic cylinder 10 may rest so that the piston driven shaft 15 extends along the axis 16 . In an alternative embodiment, (not shown) the bracket 24 may provide a hinge plate allowing flexible adjustment of the angle of the base of the hydraulic cylinder 10 as required.
[0020] Referring now to FIG. 2 , the diagonal brace 22 may extend toward a basement wall 30 and be aligned to abut at a hinge 23 an upright brace 32 between the ends of the upright brace 32 . The upright brace 32 may fit against an inner surface of the wall 30 extending approximately vertically by about four feet so that pressure can be directed to a specific spot on the wall 30 . The position of the upright brace 32 is moved up or down the wall 30 depending on where the deflection is. For example, if the wall 30 is bowed at the center then that is where the center of the upright brace is located, if the wall 30 is tipped but essentially flat, then the upright brace is put as high as possible. In the case of severely bowed walls, this fitting against the inner surface may only contact portions of the inner surface. The lower end of the upright brace 32 will generally be above the floor 20 . The diagonal brace 22 and the upright brace 32 may be, for example, rectangular steel pipes or other steel shape including angles, tubes, or I-beams . . . .
[0021] Referring now to FIG. 7 , the foot bracket 39 may provide for an L-shaped bracket having a first face that may be attached to the floor 20 with anchor bolts and a second face extending vertically therefrom adjacent to the wall 30 to be anchored thereto. The foot bracket 39 prevents the base of the wall 30 from separating from the floor 20 and moving outward as the wall 30 is straightened. A similar top bracket may be used when it is desired to prevent movement of the top of the wall 30 with respect to the house joists.
[0022] Soil 34 outside of the wall 30 may be excavated to provide for a trench 36 on the outside of the wall 30 allowing the wall 30 to be pushed outward into alignment. This trenching operation may be used to replace a drain 33 placed at the bottom of the trench 36 .
[0023] A tilt sensor 37 may be attached to the top of the upright brace 32 (or other convenient location) to provide an indication of whether the brace 32 is level and/or to detect movement or acceleration of the top of the upright brace 32 . Typically before the straightening process, the brace 32 will not be vertical but will lean toward the cylinder 10 caused by inward deflection of the wall 30 .
[0024] Referring now to FIG. 3 , multiple brace systems comprised each of a cylinder 10 , a diagonal brace 22 , and an upright brace 32 (here shown as cylinders 10 a - d , diagonal braces 22 a - d , and upright braces 32 a - d ) may be simultaneously applied against the wall 30 with the cylinders 10 a - d connected to a common hydraulic pressure source 40 , for example an electric pump.
[0025] Referring now to FIG. 4 , in a first embodiment, an electronic control system 42 , for example a microcontroller or programmable logic controller, may receive a signal from tilt sensor 37 , for example a mercury switch, a pendulum and angle sensor (for example a potentiometer) combination, or a solid-state accelerometer, providing an indication of the vertical orientation of the upright brace 32 . In the case of the accelerometer, an angular deviation of a gravitational vector from the axis of the upright brace 32 may be determined as well as acceleration of the top of the upright brace 32 . It will further be appreciated that the indication of vertical orientation of the upright brace may be detected by measuring displacement of the shaft 15 (using a displacement sensor) and trigonometric formulae, for example using known positioning of the bracket 24 with respect to a base of the wall and the height of the hinge 23 .
[0026] The electronic control system 42 also provides electrical signals controlling valves 12 , one for each cylinder 10 a - d . Generally, during operation, the electronic control system 42 may, in a first embodiment, allow all valves 12 to be open and the cylinders 10 a - d to extend their shafts 15 outward to press upward on the brace 22 straightening the wall until a signal from the tilt sensor 37 of any upright brace 32 indicates that the upright brace 32 is vertical at which time the electronic control system 42 may shut the valve 12 associated with that upright brace 32 only. In this way each of the brace systems of FIG. 3 may operate simultaneously to bring the wall back into alignment.
[0027] Referring now to FIG. 6 , the ability to monitor the orientation of the braces 32 permits more sophisticated control strategies where a most out of alignment section of the wall 30 , indicated by signal 50 a from a tilt sensor 37 , is moved first during time terminating at t 1 and the other sections of the walls indicated by signals 50 b - c from corresponding tilt sensors 37 are moved only after time t 1 is passed. Upon completion of time t 1 , the other sections of the wall may be moved, for example the upright brace 32 associated with signal 50 b being moved after time t 1 , and the upright brace 32 associated with signal 50 c being moved after time t 2 is complete, and the upright brace 32 associated with signal 50 d being moved after time t 3 is complete. Using this technique, the amount of distortion of the wall 30 during this alignment may be significantly reduced thereby reducing additional damage from the alignment process.
[0028] Another possible control strategy moves the upright braces 32 at substantially constant angular rates that are different in proportion to the misalignment of the wall associated with that upward brace so that all upward braces move to reach alignment with vertical at substantially the same time.
[0029] It will be appreciated that even more sophisticated control algorithms may be developed that look at acceleration to control the valves 12 to reduce or warn of sudden acceleration, or that detect overcenter travel where the wall moves beyond vertical to provide warnings of this situation, or that monitor pressure differentials using pressure gauges (not shown) on each hydraulic hose 14 .
[0030] Referring now to FIG. 5 , the present invention contemplates that the sensing of the orientation of the upright braces 32 may be performed mechanically, for example, by attaching a pivot point 60 to the upper end of the upright brace 32 communicating via tie arm 62 to a lever-operated valve 12 ′ with a turnbuckle or other length adjusting mechanism used to cause movement of the upright brace 32 to shut off the valve 12 when the upright brace 32 is in the vertical position. In this case, the tie arm 62 provides a tilt sensor based on a known geometry of the system.
[0031] It will also be appreciated that the hydraulic cylinders may be replaced with, for example, electric screw jacks or the like. Further, it will be understood that the present invention is applicable to a wide variety of different types of walls beyond the block walls depicted but also including poured walls.
[0032] Certain terminology is used herein for purposes of reference only, and thus is not intended to be limiting. For example, terms such as “upper”, “lower”, “above”, and “below” refer to directions in the drawings to which reference is made. Terms such as “left”, “right”, “front”, “back”, “rear”, “bottom” and “side”, describe the orientation of portions of the component within a consistent but arbitrary frame of reference which is made clear by reference to the text and the associated drawings describing the component under discussion. Such terminology may include the words specifically mentioned above, derivatives thereof, and words of similar import. Similarly, the terms “first”, “second” and other such numerical terms referring to structures do not imply a sequence, or order unless clearly indicated by the context.
[0033] References to an electronic control system can be understood to include one or more processors that can communicate in a stand-alone and/or a distributed environment(s), and can thus be configured to communicate via wired or wireless communications with other processors, where such one or more processor can be configured to operate on one or more processor-controlled devices that can be similar or different devices.
[0034] When introducing elements or features of the present disclosure and the exemplary embodiments, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of such elements or features. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements or features other than those specifically noted. It is further to be understood that the method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.
[0035] Various features of the invention are set forth in the following claims. It should be understood that the invention is not limited in its application to the details of construction and arrangements of the components set forth herein. The invention is capable of other embodiments and of being practiced or carried out in various ways. Variations and modifications of the foregoing are within the scope of the present invention. It also being understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute various alternative aspects of the present invention. The embodiments described herein explain the best modes known for practicing the invention and will enable others skilled in the art to utilize the invention.
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A wall straightening apparatus provides multiple independently controllable jacking members pressing outward on diagonal braces to push those braces against the wall to move the wall into a vertical alignment. Feedback control of the jacking members provides coordinated straightening of large wall sections with lessened cracking and distortion.
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RELATED APPLICATION
This application claims priority of U.S. Provisional Application Nos. 60/325,670 filed Sep. 28, 2001, 60/349,968 filed Jan. 18, 2002, 60/388,358 filed Jun. 12, 2002, and 60/397,944 filed Jul. 23, 2002, the discosures of which are incorporated fully herein by reference.
FIELD OF THE INVENTION
This invention relates to the field of optical communications, and more particularly, to a reconfigurable optical add/drop system for use in optical multiplexing.
BACKGROUND OF THE INVENTION
For several decades, fiber optics have been used for communication. Specifically, fiber optics are used for data transmission and other telecommunication applications. Despite the enormous information carrying capacity of fiber, as compared to conventional copper cable, the high cost of installing fiber optics presents a barrier to full implementation of fiber optics, particular as the “last mile”, from the central office to residences and businesses.
One method of increasing carrying capacity without incurring additional installation costs has been to multiplex multiple signals onto a single fiber using various methods, such as time division multiplexing, where two or more different signals are carried over the same fiber, each sharing a portion of time. Another, more preferred multiplexing method is wavelength division multiplexing (WDM), where two or more different wavelengths of light are simultaneously carried over a common fiber.
Until recently, typical fibers used for communications applications had preferred wavelength bands centered at 850 nm, 1300 nm, and 1550 nm, wherein each band typically had a useful bandwidth of approximately 10 to 40 nm depending on the application. Transmission within these bands was preferred by systems designers because of low optical attenuation. Recent advances in fiber design now provides fiber that have low attenuation over a very broad transmission range, from 1300 –620 nm.
Wavelength division multiplexing can separate a fiber's bandwidth into multiple channels. Dividing bandwidth into multiple discreet channels, such as 4, 8, 16, 40, or even as many as 160 channels, through a technique referred to as dense channel wavelength division multiplexing (DWDM), is a relatively lower cost method of substantially increasing telecommunication capacity, using existing fiber optic transmission lines. Techniques and devices are required, however, for multiplexing the different discreet carrier wavelengths. That is, the individual optical signals must be combined onto a common fiber-optic line or other optical waveguide and then later separated again into the individual signals or channels at the opposite end or other point along the fiber-optic cable. Thus, the ability to effectively combine and then separate individual wavelengths (or wavelength sub-ranges) is of growing importance to the fiber-optic telecommunications field and other fields employing optical instruments.
Optical multiplexers are known for use in spectroscopic analysis equipment and for the combination or separation of optical signals in wavelength division multiplexed fiber-optic telecommunications systems. Known devices for this purpose have employed, for example, diffraction gratings, prisms and various types of fixed or tunable filters.
Approaches for selectively removing or tapping a channel, i.e., selective wavelengths, from a main trunk line carrying multiple channels, i.e., carrying optical signals on a plurality of wavelengths or wavelength sub-ranges, is suggested, for example, in U.S. Pat. No. 4,768,849 to Hicks, Jr. Hicks, shows filter taps, as well as the use of gangs of individual filter taps, each employing high performance, multi-cavity dielectric pass-band filters and lenses for sequentially removing a series of wavelength sub-ranges or channels from a main trunk line. The filter tap of Hicks, returns a multi-channel signal to the main trunk line as it passes the desired channel to a branch line. One known demux is disclosed in Pan et al., U.S. Pat. No. 5,652,814, FIG. 25. In Pan et al., the WDM input signal is cascaded through individual filter assemblies, consisting of a fiber collimator, thin film filter, and a fiber focusing lens. Each filter is set for a given wavelength. However, aligning the fibers for each wavelength is costly and errors in the alignment contribute significantly to the system losses. Further, FIG. 13 of Pan et al. teaches the use of a dual fiber collimator, thin film filter, and a dual fiber focusing lens to selectively DROP and ADD a single wavelength or range of wavelengths. As discussed above, aligning the collimators is expensive.
Polarization dependent loss (PDL) is also a problem in WDM system because the polarization of the light drifts as it propagates through the fiber and furthermore this drift changes over time. Thus, if there is PDL in any component, the drifting polarization will change the signal level, which may degraded the system operation.
Other multiplexer devices may be employed to add or drop channels in WDM systems. These systems are commonly known as optical add/drop multiplexers, or OADM. Another OADM, disclosed by Mizrahi U.S. Pat. No. 6,185,023, employs fiber Bragg gratings to demux and mux signals in a WDM system. This method requires optical circulators and multiple components.
However, the multi channel OADM designs discussed above are not programmable by the end user. That is, each multiplexers is designed and manufactured to mux (add) specific channels; or when used in reverse each multiplexers is also designed and manufactured to demux (drop) specific channels. This limitation mandates that the optical system's parameters be fixed before installation. Changes are not possible without replacing the fixed optical multiplexers with different designed multiplexers. This is expensive.
One known programmable OADM is discussed in Boisset et al, International Publication No. WO01/13151. In Boisset et al., the desired add/drop channel is programmed by translating a segmented filter. To achieve this translation however, a large mechanical mechanism is employed. A further limitation to Boisset et al. is that only a single channel may be added or dropped per device. Designers may employ multiple devices, deployed in series, and programmed as necessary to add/drop the correct channel; however, this approach requires multiple devices and has multiple points of failure. Furthermore, the size of such a device would be overly large and therefore not practical for many applications where space is limited.
Two other programmable OADMs are disclosed by Tomlinson, U.S. Pat. No. 5,960,133, and Aksyuk, et al, U.S. Pat. No. 6,204,946, both use bulk optics and gratings to demultiplex and multiplex WDM input and output signal. While OADM's disclosed by Tomlinson and Aksyuk are both programmable, neither provides for discrete adding or dropping of an individual optical signal in a multi signal system. To achieve discrete adding or dropping of an individual optical signal in a multi signal system using the systems disclosed in Tomlinson and Aksyuk, additional components are required. All the Add wavelengths must be multiplexed onto a single fiber before it is sent to the OADM. Likewise, a demultiplexer must be added to the Drop port to access the individual wavelength channels. The additional components require additional space, add attenuation, and add cost to the system.
It is an object of the present invention to provide improved optical multiplexing devices which reduce or wholly overcome some or all of the aforesaid difficulties inherent in prior known devices. Particular objects and advantages of the invention will be apparent to those skilled in the art, that is, those who are knowledgeable and experienced in this field of technology, in view of the following disclosure of the invention and detailed description of certain preferred embodiments.
SUMMARY OF THE INVENTION
In accordance with a first aspect of the invention, a programmable Littrow grating based optical add/drop multiplexing device, programmed to add and/or drop one or more optical channels from/to a multi-channel light signal, comprises a focal plane, in combination with a lens in combination with a prism, a Littrow grating, and a plurality of programmable mirrors.
The focal plane further comprises an IN port for receiving a multi-channel optical signal, a PASS port for transmitting a multi-channel optical signal, a plurality of ADD ports for receiving a plurality of optical channels, a plurality of DROP ports for transmitting a plurality of optical channels, and a plurality of programmable mirrors for directing light channels.
The multi-channel light enters the device by way of the IN port and is directed through the Lens to the Littrow grating, where selected channels are dispersed and directed through the lens and focused onto to the plurality of programmable mirrors. The Littrow grating separates the multi-channel optical signal into its individual optical channels and directs the individual optical channels through the Prism, the Lens, and onto the programmable mirror that corresponds with that individual channel.
Depending upon the programmed state of the mirrors, the channels are either directed through the lens, prism, and Littrow grating (or another wavelength separating medium) which combine the channels into a multi-channel light signal and directs it out of the system by way of the prism, lens and pass port, or the channels are directed through the lens, and mirror so as to exit the system by way of the Lens and one of the plurality of drop ports.
In the instance where the programmed state of the mirrors directs one or more channels through one of the plurality of drop ports, one or more channels may enter the device by way of one of the plurality of add ports, and are directed through the lens, mirror, and lens, to the one of the plurality of programmable mirrors so as to exit the system by way of the lens, prism, and Littrow grating, which combines the channels into a multi-channel light signal and directs it out of the system by way of the prism, lens and pass port.
To reduce polarization dependent loss (PDL) in the system a quarter-wave plate (QWP) may also be employed between the Lens and Littrow grating. The QWP rotates the polarization so that light that is s-polarized on the first pass is p-polarized on the second pass and there is no net polarization dependent loss (PDL) for light traveling between the IN and PASS ports.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a first embodiment of a Littrow grating based OADM detailing the various channel paths through the device.
FIG. 2 is a perspective view of the Focal Plane of the embodiment of FIG. 1 .
FIG. 3 is a schematic view of a Focal Plane for an eight-channel embodiment of a Littrow grating based OADM.
FIG. 4 is a schematic side view of a MEMS mirror in IN/PASS and DROP/ADD modes.
FIG. 5 is a perspective view of the embodiment of FIG. 1 detailing the channel paths through the device for an PASS channel.
FIG. 6 is a perspective view of the embodiment of FIG. 1 detailing the channel paths through the device for an DROP channel.
FIG. 7 is a perspective view of the embodiment of FIG. 1 detailing the channel paths through the device for an ADD channel.
DETAILED DESCRIPTION OF THE INVENTION
The Littrow grating based OADM of the invention has numerous applications, including use in fiber optic telecommunications systems. For purposes of illustration, the preferred embodiments described below in detail multiplexing and demultiplexing, and adding and dropping channels, in wavelength division multiplexing and demultiplexing for a multi-channel fiber optic telecommunication systems. Exemplary references to an optical channel, or simply to a channel, should be understood to mean an optical signal with a centered wavelength and an upper and lower wavelength. Channel spacing is measured from the center of the first channel to the center of an adjacent channel.
A three channel Littrow grating based OADM, employing one embodiment of the invention, is detailed in FIG. 1 . It is of note that while only three channels are used in this example, a substantially larger number of channels/ports may be employed. The Littrow grating based OADM allows for demultiplexing and multiplexing separate optical channels onto or off of a multi-channel light signal. The OADM of FIG. 1 may be dynamically programmed to demultiplex and multiplex any combination of channels onto or off the multi-channel light signal.
A first embodiment of the programmable OADM device of FIG. 1 comprises a focal plane 200 in combination with Lens 105 , a prism 107 , and a Littrow grating 109 . The device of FIG. 1 may be mounted within an enclosure optimized for optical transmission, including a gas-filled enclosure, or the like.
A Littrow grating is a grating that operates at or near Littrow. Littrow is a special, but common case, in which the light is diffracted off the grating back toward the direction from which it came (i.e., a=b); this is called the Littrow configuration, for which the grating equation becomes:
ml= 2 d sin( a )
where a is the incident angle, b is the diffracted angle, m is the grating order, l is the wavelength, and d is the grating groove spacing. In one embodiment, the grating is used near the Littrow condition, so the same lens can be used for collimating and focusing the light. Further, using the grating near the Littrow condition takes advantage of the high diffraction efficiency of the grating near the Littrow condition.
Lens 105 may be comprised of multiple lens elements 105 a , 105 b and 105 c . It is well known in the art that a lenses may be comprised of multiple lens elements to achieve a particular optical prescription.
Prism 107 may optionally be used in any embodiment of the system. Temperature changes cause grating to expand and contract. As gratings expand and contract the wavelength-sized gradations that cause diffraction increase and decrease causing a change in the diffraction angle from a grating. Prism 107 may be used to minimize the thermal affects on Grating 109 . When Prism 107 and Grating 109 are properly designed and configured the effects of temperature on the system are greatly reduced. However, some embodiments of the system do not contain Prism 107 .
Quarter-wave plate (QWP) 103 may also be employed between the Lens and Littrow grating to reduce polarization dependent loss (PDL) in the system a. The QWP 103 rotates the polarization so that light that is s-polarized on the first pass is p-polarized on the second pass and there is no net polarization dependent loss (PDL) for light traveling between the IN and PASS ports.
The focal plane 200 of FIG. 2 further comprises an IN port 201 for receiving a multi-channel optical signal 101 , a PASS port 203 for transmitting a multi-channel optical signal, a plurality of ADD ports 213 , 223 , and 233 , for receiving a plurality of optical channels, a plurality of DROP ports 215 , 225 , 235 , for transmitting a plurality of optical channels, and a plurality of Programmable Mirrors 211 , 221 , 231 , for directing light channels. Each DROP and ADD port is for a preassigned wavelength. All of these component are precisely aligned with each other, and mounted together so as to accommodate the entrance and exit of optical signals. Larger focal planes may be constructed and an eight channel system's focal plane is depicted in FIG. 3 comprising an IN port 301 for receiving a multi-channel optical signal 101 , a PASS port 303 for transmitting a multi-channel optical signal, a plurality of ADD ports 313 , 323 , 333 , 343 , 353 , 363 , 373 , 383 for receiving a plurality of optical channels, a plurality of DROP ports 315 , 325 , 335 , 345 , 355 , 365 , 375 , 385 for transmitting a plurality of optical channels, and a plurality of Programmable Mirrors 311 , 321 , 331 , 341 , 351 , 361 , 371 , 381 for directing light channels.
Turning again to FIG. 1 , as well as to FIG. 2 , a multi-channel light signal 101 enters the device through the IN port 201 on the focal plane 200 , and is directed through Lens 105 . The multi-channel light signal 101 is directed through the Lens 105 , QWP 103 , Prism 107 , and Littrow grating 109 . The Littrow grating 109 diffracts the individual channels of the multi-channel light signal 101 (hereafter channels) towards the Lens 105 , QWP 103 , to the channel's associated Programmable Mirror 211 , 221 , or 231 .
Depending upon the programmed state of the Programmable Mirrors channels received via the IN port 201 are either passed via the PASS port 203 or dropped via one of the plurality of DROP ports 215 , 225 , or 235 . In the event one or more channels received via the IN port 201 are passed via PASS port 203 , the channel(s) are directed through the Lens 105 , QWP 103 , Prism 107 , and Littrow grating 109 which multiplexes the channel with other passed and added channels into a multi-channel light signal 111 and directs it out of the system by way of the Prism 107 , QWP 103 , Lens 105 and PASS port 203 .
In the event one of more channels received via the IN port 201 are dropped via one of the plurality of DROP ports 215 , 225 , or 235 , the channel(s) are directed through the Lens 105 , and mirror 117 so as to exit the system by way of the Lens 105 and one of the plurality of DROP ports 215 , 225 , or 235 corresponding to the channel. Because the mirrors may be programmed individually, it will be clear to one skilled in the art that any channel may be dropped or passed.
In the instance where one or more of the received via the IN port 201 are dropped via one of the plurality of DROP ports 215 , 225 , or 235 , one or more channels corresponding channels may enter the device through one of the plurality of ADD ports 213 , 223 , or 233 . These added channels enter the system by way of one of the plurality of ADD ports 213 , 223 , or 233 , and are directed through the Lens 105 , Lens 105 , mirror 117 , Lens 105 , to the one of the plurality of Programmable Mirrors corresponding to the channel so as to exit the system by way of the Lens 105 , QWP 103 , Prism 107 , and Littrow grating 109 , which multiplexes the channel with other passed and added channels into a multi-channel light signal 111 and directs it out of the system by way of the Prism 107 , QWP 103 , Lens 105 and PASS port 203 .
Turning to FIG. 4 , in one embodiment the Programmable Mirrors 401 and 403 are constructed using Micro Electrical Mechanical Systems (MEMS). Programming of the Programmable Mirrors 401 and 403 is achieved by applying an electrical signal to the MEMS mirror. The Programmable Mirror 401 is programmed to reflect the IN port to the PASS port. The Programmable Mirror 403 is programmed to reflect the IN port to the DROP port, and to reflect the ADD port to the PASS port. A larger mirror may be employed by design to control more then one channel. Of course, other types of mirror actuators could be used.
By engaging the channel mirrors, one or more separate channels may be dynamically routed onto or off of a multi-channel light signal. Further, by engaging the channel mirrors as a function of time and in synchronous conjunction with other system components, time-division multiplexing of optical signals may be achieved.
One or more quarter-wave plates (QWP) may be employed in the system to reduce polarization dependent loss (PDL) in the system. The preferred location of the QWP is between Lens 105 and Grating 109 . QWP may be positioned such that they are substantially normal to the propagating light beam and the retardance axis is at 45 degrees to the light that is polarized parallel and perpendicular to the grating graduations. Passage through the QWP converts the parallel and perpendicular polarized components of the light into right and left circularly polarized states. Reflection off the grating converts changes the handedness of the polarization: right circularly polarized light into left circularly polarized light and visa versa. Passage through the QWP the second time converts the light back to a linearly polarized state, but it's departing polarization state is orthogonal to the input state. Thus, during one pass through the system the light is parallel and on the next is perpendicular leaving a substantially zero PDL for the system.
Consider again the three channel system depicted in FIG. 1 , where the multi-channel light signal 101 contains:
a channel one 501 (see FIG. 5 )—which is to be passed via PASS port 203 ; a channel two 601 (see FIG. 6 )—which is to be dropped via DROP port 225 ; no channel three comes into the system; and a channel three 701 (see FIG. 7 ) is added via ADD port 233 and passed via PASS port 203 .
Table 1 details the desired channel operation (i.e., PASS, DROP, ADD, etc.) for each channel, as well as the Programmable Mirror's state.
TABLE 1
CHANNEL
MODE
MIRROR STATE
One
PASS
IN to PASS
Two
DROP
In to DROP
Three
ADD
ADD to PASS
An optical prescription for a three channel Littrow grating based OADM is provided in Table 2 in CODE V format. The numerical aperture of the lens is 0.17 to accommodate standard fiber and the grating has 600 lp/mm. The root mean square wavefront error is less than 0.03 waves in double pass over the temperature range of −20 to +70 degrees centigrade, when the mount is made of 416 Stainless Steel.
TABLE 2
THICK-
RADIUS
NESS
RMD
GLASS
OBJ:
INFINITY
5.584779
1:
−62.78788
16.838678
SF11_SCHOTT
2:
−39.52723
96.862455
AIR
3:
−109.42245
1.700000
NSF15_SCHOTT
4:
76.61669
7.195070
NBAK1_SCHOTT
5:
−58.64552
0.100000
AIR
6:
520.40928
1.700000
NBK10_SCHOTT
7:
48.24900
6.885228
NBAK1_SCHOTT
8:
−199.75265
0.100000
AIR
9:
INFINITY
10.148101
NBK7_SCHOTT
10:
INFINITY
2.885689
AIR
ADE:
−22.806501
BDE:
0.000000
CDE:
0.000000 DAR
STO:
INFINITY
−50.000000
REFL
AIR
GRT:
GRO:
−1
GRS:
0.001667
GRX:
0.000000
GRY:
1.000000
GRZ:
0.000000
ADE:
−15.353235
BDE:
0.000000
CDE:
0.000000
Turning next to FIG. 5 and FIG. 2 , the path of channel one 501 of the three channel multi-channel collimated light signal 101 is more clearly illustrated. Recall that channel one 501 is to be received and PASSED by the system as follows. The multi-channel light signal 101 enters the device through the IN port 201 and is directed through the Lens 105 , Prism 107 , and Littrow grating 109 . Littrow grating 109 demultiplexes the channels of the Multi-channel light signal 101 and diffracts channel one 501 through the Prism 107 and Lens 105 to Programmable Mirror 211 . The state of Programmable Mirror 211 is set to “IN to PASS” and therefore reflects channel one 501 through Lens 105 , Prism 107 to Grating 109 . Grating 109 multiplexes channel one 501 with other passed and added channels into a multi-channel light signal 111 and directs multi-channel light signal 111 out of the system by way of the Prism 107 , Lens 105 and PASS port 203 . Turning next to FIG. 6 and FIG. 2 , the path of channel two 601 of the three channel multi-channel collimated light signal 101 is more clearly illustrated. Recall that channel two 601 is to be received and dropped by the system. The multi-channel light signal 101 enters the device through the IN port 201 and is directed through the Lens 105 , Prism 107 , and Littrow grating 109 . Littrow grating 109 demultiplexes the channels of the Multi-channel light signal 101 and diffracts channel two 601 through the Prism 107 and Lens 105 to Programmable Mirror 221 . The state set to “IN to DROP” and therefore reflects channel two 601 through Lens 105 , to Mirror 117 . Mirror 117 reflects channel two 601 out of the system by way of Lens 105 and DROP port 225 .
Turning next to FIG. 7 and FIG. 2 , the path of channel three 701 of the three channel multi-channel collimated light signal 101 is more clearly illustrated. Recall that the multi-channel light signal 101 does not contain channel three 701 , but instead, channel three 701 is added to multi-channel light signal 111 and directed out of the system. Channel three 701 enters the device through ADD 233 and is directed through the Lens 105 , and Mirror 117 . Mirror 117 reflects channel three 701 to Programmable Mirror 231 by way of Lens 105 . The state of Programmable Mirror 231 is set to “ADD to PASS” and therefore reflects channel three 701 through Lens 105 , Prism 107 to Grating 109 . Grating 109 multiplexes the channel with other passed and added channels into a multi-channel light signal 111 and directs multi-channel light signal 111 out of the system by way of the Prism 107 , Lens 105 and PASS port 203 .
Having thus described exemplary embodiments of the present invention, it should be understood by those skilled in the art that the above disclosures are exemplary only and that various other alternatives, adaptations and modifications may be made within the scope of the present invention. The presently disclosed embodiments are to be considered in all respects as illustrative and not restrictive. The scope of the invention being indicated by the claims, rather than the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
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A multi-channel optical switching system particularly usable as a programmable optical add/drop multiplexer in a multi-wavelength communication system. The switching system uses a grating operating at Littrow that separates a multi-channel optical signal into a plurality of optical channels, and combines a plurality of optical channels into a multi-channel optical signal. The system also uses a plurality of optical ports optically coupled to the grating and a selecting device to select which optical channel is directed to which of the optical ports.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the measurement of jitter in a digital signal. In theory, the spacing of the transitions between levels of a digital signal have a completely uniform spacing. In practice, particularly during transmission, there may be minute variations in the actual time of the transition, relative to the theoretical transition time defined by an absolute reference clock. These variations are referred to as jitter, and may be considered to be a spurious phase modulation of the signal.
2. Summary of the Prior Art
Known systems for measuring jitter involve a very stable phase-locked loop which compares the pulse train containing jitter with an internally generated, jitter-free reference clock. The phase-locked loop has a generator for generating the reference clock, the output of which is fed to the input of a phase demodulator which also receives a digital signal containing jitter. The phase demodulator converts the signal to pulse duration modulation, which is output to a low pass filter, the output of which gives the jitter measurement, and also is fed back to the input of the reference clock generator, to form the loop. The low pass filter has cut off frequency of 5-10% of the bit rate. But since the digital signal being investigated may contain long sequences of digital zeros, a pattern/clock converter may be used to convert the digital signal into a continuous pulse train with the same jitter as the original signal, which pulse train then forms the input to the phase demodulator. Analysis of the output may involve peak value rectification before the results are displayed, and/or analysis with a spectrum analyser.
As mentioned above, such a jitter measurement system involves a low pass filter, and this has a significant influence on the greatest measurable jitter frequency component. The known systems also involve many analog circuits, which are more expensive than digital components.
SUMMARY OF THE INVENTION
Therefore, the present invention seeks to provide a system for measuring jitter in a digital signal, in which a clock signal is extracted from the original digital signal, offset by a predetermined frequency, and smoothed to eliminate jitter therefrom. This gives an offset reference clock signal which is then used to sample the original input signal. Preferably, that offset clock signal is frequency multiplied by an integer factor before it is used for timing the sampling.
The effect of the offset of the reference clock signal is that the sampling point is not fixed relative to the transition point over the bits of the input signal, but instead moves relative thereto. The sampling points are then arranged such that, in the absence of the offset and in the absence of jitter, there is a predetermined number of sampling points (normally only one, but this is not essential) in each successive bit. The present invention then proposes that the occasions when a bit of said digital signal contains other than the predetermined number of sampling points are detected. The occasions when the number of sampling points differs from the predetermined number occur because of the offset of the clock, but also due to jitter when the sampling point approaches the theoretical (absolute) transition point of the bits, being the transition point that would occur in the absence of jitter. The count of the number of occasions a bit has more sampling points than the predetermined number for a suitable measuring duration then gives a measure of the jitter.
Note that a bit may have more samplings than the predetermined number and a later bit may have fewer samplings than the predetermined number and both are occasions to be counted. For simplicity, the number of samplings per bit in the absence of offset and jitter is preferably one. Then, a count is made of the occasions there are either two sampling times within a bit on no sampling times within a bit. It would also be possible to have more than one sampling time within a bit in the absence of offset and jitter, e.g. 2. Then the number of occasions of 3 or 1 sampling times in a bit would be counted.
The measurement period is preferably inversely proportional to the product of the bit rate and the difference between the original frequency and the offset frequency. Where the offset frequency is multiplied by an integer, the measurement period may be divided by that integer.
It is possible for the sampling to be at fixed intervals. However, where the offset clock signal is frequency multiplied by an integer factor, it is preferable that the sampling points are not regularly spaced by that integer factor, but are spaced by factors greater than or less than the integer factor. For example, if the integer is 4, then sampling may be at 3 and 5 intervals of the multiplied offset clock signal.
Thus a count is made of the occasions when there are more or less samplings, within the same bit than the predetermined number and the results of that count may be stored in a table whose size corresponds to the number of samples. The value stored in the table may increment and decrement depending whether the count is above or below the predetermined number. The value stored in the count thus increments and decrements depending on the jitter, with the increments and decrements occurring as the sampling point is close to the absolute transition point of the bits. It is then possible to use the difference between the maximum value counted and the minimum value counted, possibly with 1 subtracted, to be multiplied by the bit period to derived a coarse jitter value. Moreover, if the number of samples between the first occurrence of the maximum value and the last of the occurrence of the minimum value is determined, divided by the total number of samples, a fine jitter value may be determined. The jitter amplitude is then given by the sums of these two values.
It should be noted that where the offset clock is multiplied by an integer value, both of these values may need to be divided by that integer to obtain a jitter value which corresponds to the peak-to-peak value of the deviation of the phase function of the measured signal relative to time. It can also be noted that such a measurement is independent of bit rate, and independent of the shape of the binary signals being measured.
Thus, an aspect of the present invention may provide a system for measuring jitter in a digital signal having means for deriving a first clock signal from the digital signal, the first clock signal being offset by a predetermined frequency from the digital signal and being smoothed, means for sampling the digital signal using the first clock signal, such that, in the absence of jitter and said offset by a predetermined frequency, there are a predetermined number of sampling times in each bit of said digital signal, means for detecting occasions when the number of sampling times in any bit is different from the predetermined number, means for counting such occasions, and means for deriving a measurement of jitter from that count.
Another aspect of the invention relates to a method of measuring jitter using such a system.
The present invention, because it involves digital sampling and counting, can be embodied in a device which makes less use of analog circuits than known jitter measurement systems, which makes embodiments of the invention easier to produce.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention will now be described in detail, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 shows a schematic block diagram of a jitter measurement device being an embodiment of the present invention;
FIG. 2 is a flow-chart of the sampling sequence in the embodiment of FIG. 1 ;
FIG. 3 is a block diagram of components of the jitter measurement device of FIG. 1 ;
FIG. 4 shows in more detail a part (RXBERT) of the diagram of FIG. 4 ;
FIG. 5 shows in more detail another part (RXJITTER) of the block diagram of FIG. 3 ;
FIG. 6 shows in more detail yet another part (TXBERT) of the block diagram of FIG. 3 and
FIG. 7 shows in more detail yet another part (TXJITTER) of the block diagram of FIG. 3 .
DETAILED DESCRIPTION
FIG. 1 shows schematically a jitter measurement device according to an embodiment of the present invention. In FIG. 1 , a digital pulse train signal which may contain jitter is fed to an input 100 , and passed to a pattern clock converter 101 . The converter 101 performs a similar function to that in the known systems, in that it converts the digital pulse train received at input 100 , which may contain gaps in its pulse-train, into a continuous pulse-train with the same jitter as the original signal. That continuing pulse-train is then passed from the converter 101 to a clock frequency offset circuit 102 . The offset circuit 102 determines the frequency of the pulse-train received from the converter 101 using known clock recovery techniques, but then is offset by a frequency which is a small proportion of the frequency of the pulses received.
The offset clock pulses thus generated are passed to a phase locked loop (PLL) 103 with a long time constant. The loop has a phase comparator, a low pass filter and a voltage controlled oscillator, with the low pass filter having a very low cut off frequency it thus separates the relatively weak jitter component from the stronger modulation which is symmetric about the working frequency of the phase comparator. Therefore a slow-acting control voltage is produced which is used to regulate the oscillator to produce an average, constant phase. This generates a jitter-free pulse-train which can thus be used for a reference clock.
In this embodiment, the pulse-train thus generated is frequency multiplied by an integral factor. In the subsequent description, it will be assumed that integer factor is 4, but the embodiment is not limited to this. Thus, the output of the PLL 103 is a reference clock with a frequency multiplied by 4, and offset from the frequency of the digital signal received at the input 100 by a small frequency.
That reference clock is passed to a data sampler 104 , and is used to sample the pulse-train received at the input 100 . As can be seen from FIG. 1 , the pulse-train input at input 100 is passed to the data sampler 104 , as well as to the convertor 101 . The action of that data sampler 104 will now be described with reference to the flow chart of FIG. 2 .
As can be seen in FIG. 2 a sampling step 110 is carried out, in which the pulse-train received at input 100 is sampled at a time determined by the reference clock signal from PLL 103 . The logical level of the sample is then compared with that of the previous sample. There are four possibilities. In two of them, shown at steps 111 and 112 , the sample is different from the previous sample, being either a change from logical zero to logical one (step 111 ) or a change from logical one to logical zero (step 112 ). In the other two alternatives, the sample is the same as the previous sample. In step 113 , both are at logical one, and in step 114 both are at logical zero. From step 111 , a three clock delay is imposed at step 115 and, assuming that the sampling operation has not yet been completed (step 116 ), processing returns to sampling step 110 for another sample. A similar procedure occurs at step 112 , except that a five clock delay is imposed at step 117 .
If there was no offsetting of the reference clock from the PLL 103 , and the pulse-train received at input 100 had no jitter, then the effects of steps 111 , 112 , 115 and 117 would be for the sampling to switch across the logical transition of the pulse-train. If the sample was at logical level one, but had previously been a logical level zero, corresponding to step 111 , the three clock delay would move the sampling point back to logical level zero. Similarly, if the sampling was at logical level zero and the previous sampling at logical level one, the five clock delay 117 would move the sampling point back to logical level one. Thus, without offset and without jitter, the processing would pass alternately via steps 111 and 112 .
However, the offset circuit 102 output pulses to the PLL 103 which have an offset frequency relative to the pulse train received at input 100 . Thus, and still assuming that there is no jitter in the pulse-train received at input 100 , a sampling point which is initially spaced from the transition between logical levels would slowly move towards that transition, and would eventually reach it. As it crossed the transition, two sampling points would occur within the same pulse, and thus the step 113 would be triggered. From step 113 , a three clock delay again occurs at step 118 , but also a signal is passed to a counter step 119 which increments a counter (not shown in FIG. 2 ) by one. From counter step 119 , processing again passes to the sampling step 110 via step 116 . After the sampling point had crossed the transition, it would again return to the options envisaged by steps 111 and 112 , the counter step 119 would not again be triggered.
Thus, in the absence of jitter and over a sampling period equal to the inverse of four times the clock offset times the reference clock, counter step 119 would be triggered only once. It can be observed from FIG. 2 that if the movement of the sampling point was within a logical zero, indicated by step 114 , a five clock delaying step 120 would be triggered, and the counter step 119 activated to decrement the counter. Thus, in this case, the counter would count down once.
Now consider the effect of jitter in the pulse-train received by sample 100 . In the subsequent discussion, the position of the transitions in the pulse-train in the absence of jitter will be called the absolute transition point, to distinguish from the actual transition point. These two transition points differ due to jitter. Whilst the sampling point is remote from the absolute transition point, the processing envisaged by FIG. 2 will pass alternately via steps 111 and 112 , assuming that the magnitude of jitter is less than the pulse width of the output of the PLL 103 . However, as the sampling point approaches the absolute transition point, due to the offset of the reference clock, there is a possibility that a sampling point will occur within the same pulse as the previous sampling point, due to jitter. At that time, either step 113 or step 114 is triggered, and the counter step 119 either increments or decrements the counter.
Thus, over a part of the total sampling period, the counter step 119 may be triggered several times, depending on the magnitude of the jitter. It is this variation in the counter triggered by counting step 119 which enables jitter to be measured, as will now be described. Due to the jitter, the values stored by the counter triggered by counter step 119 will count up and down as steps 113 and 114 are triggered, if it is possible that the steps 113 and 114 may not be triggered alternately so that the counter step 119 may be triggered by the increment of step 118 more than once, before the counter step 119 is triggered by decrement step 120 . It is also possible, of course, for the decrements at step 120 to be triggered more than once. As a result, over a measurement cycle, the counter may count up to a maximum value, and down to a minimum value. This is then used to determine the jitter as will now be described.
Referring again to FIG. 1 , the counter step 119 triggers an accumulator 105 , which detects the counts and passes them to a store 106 to be stored in a table of a size corresponding to the measurement period. At the end of measurement period, triggered by end step 121 , the difference between the maximum counts stored and the minimum counts stored, is determined. If there were no jitter, the minimum count would be zero (or minus one) and the maximum count would be one (or zero). If there is jitter, however, either the maximum count or the minimum count may differ from that. Therefore, 1 is subtracted from the difference between the maximum count and the minimum count and multiplied by a quarter of the bit period of the input pulse-train received at input 100 . This one quarter multiple occurs because of the multiplication of the reference clock. This measurement gives a value known as “coarse jitter”. Secondly, the count table accumulator 105 is scanned to find the first occurrence at the maximum value count, and the last occurrence at the minimum value count. The difference in position is determined, divided by four and divided by the table size, which is equalled with a number of times the sampler 110 will be triggered during a measurement cycle. This gives a value known as the fine jitter. The sum of the course and fine jitter measurements are the peak-to-peak amplitude of the phase jitter of the input signals.
It can be noted that the term “jitter amplitude” designates the peak-to-peak value of the deviation of the phase function relative to time. The jitter amplitude is measured relative to the length of a clock period, so that it is independent of the shape of the binary signal of the pulse-train. Also, it is independent of bit rate, because it is relative to the clock period, making it a normalised parameter. It is thus possible to use this value to compare jitter amplitudes.
Moreover, and as shown in FIG. 1 , the output of the table of store 106 may be passed to additional filter 107 , or a discrete Fourier transform carried out on the count values stored. This enables the frequency content of the phase jitter of the input pulse-train received at input 100 to be determined.
In the embodiment described above, the PLL 103 multiplies the offset clock frequency generated by offset circuit 102 by 4. Other factors are useful, but it should be noted that this factor then determines the delays in steps 115 , 117 , 118 and 120 in FIG. 2 , and also the period of time of the measurement before end step 121 is reached. If, for example, a multiplier of 8 was used then steps 115 and 118 may have a seven clock delay, and steps 117 and 120 may have a nine clock delay. Moreover, the measurement period is then equal to the inverse of eight times the bit rate times the clock offset. Finally, when the fine jitter is measured, the subtraction of the table position of the first maximum value count from the table position of the last minimum count would then be divided by eight.
FIG. 3 is the top level functional block diagram for the entire jitter measurement device. It contains five main sections of circuitry, RX bit error rate testing (RX BERT) 10 , TX bit error rate testing (TX BERT) 11 , RX jitter 12 , TX jitter 13 and V40 interfacing circuitry 14 . The configuration can generate transmit jitter and also measure the incoming receive jitter while carrying out a bit error rate test at the same time. The V40 circuitry 14 controls operation of the configuration via V40 interface circuitry.
In the device of FIG. 3 , the signals considered are shown in Table 1.
TABLE 1
Signal Name
Description
AD(0:7)
This signal is the V40's databus and the lower 8 bits of its
address bus multiplexed together. Data travels backwards
and forwards along this bus between the configuration and
the V40.
AI(8:15)
This is the top 8 bits of the V40's address
bus. It is an input to the configuration and
indicates which address the V40 is accessing.
ASTB
This is the address/signal from the V40. It
is high when the V40 is presenting its
address on its external bus.
BEEPER
This signal oscillates at 2 megacycles per
second and is divided in the smaller xilinx
to form the beep signal.
CLKIN
This signal comes from the oscillator on the
PAX A board and oscillates at 12.298
megahertz.
CLKOUT
This signal is derived from signal CLKIN and
oscillates at twice the frequency of CLKIN ie
at 24.576 megahertz.
COMP
This is the comparison output to the phase
lock loop. It is used in the generation of
the received jitter clock SCLK.
COUNT
This signal indicates when a received jitter
phase change is to be counted. It is high for
phase changes of both plus a quarter of an
interval and minus a quarter of an interval.
The direction of the COUNT is controlled by
the signal UP.
CRCERR
This signal pulses whenever received CRC
error happens.
D(0:7)
This is the internal databus to the configuration.
It carries all the data from the V40 to and from
the configuration. It also carries the data which is
stored in the V40's memory during DMA accesses.
DLTCLK
This signal oscillates at the same period as
the transmit clock. It is fed to the Dallas
chip to provide the transmit clock. It is
also used to ensure the signals XTPOS and
XTNEG have the right mark space ratio.
DMAACK
This signal comes from the V40 and indicates that a DMA
cycle is occurring.
DMARQ
This signal is generated by the configuration
and is used to indicate to the V40 that a DMA
request is pending.
DOJIT
This signal goes high whenever a twelfth of
a unit interval jitter hit is to be inserted
into the transmit jitter. The transmit jitter
is comprised of a twelfth of a unit interval
hits.
E1CLK
This signal goes high once per received bit
in the RX jitter circuitry. Pulses on the
E1CLK are counted and after every 8 counts a
jitter result is DMA'd into the V40's memory.
FASERR
This signal pulses whenever the receiver detects a FAS
error.
HLDRQ
This signal is passed to the V40 and is held
permanently low in this configuration.
INJERR
The V40 controls the signal and can pulse it
in order to inject a bit error into the
transmit Bert pattern.
IOEN
This signal is used whenever the V40 carries out a IO
operation.
IORD
This signal goes low whenever the V40 is carrying out a IO
read instruction.
IOWR
This signal goes low whenever the V40 carries out an IO
rate instruction.
JCLKI
This signal is sourced from the jitter
attenuator chip. It oscillates at the same
frequency as the receive clock less
1/(3 × 2 18 ) (approximately 1.27 parts per
million). This signal is quadruple in
frequency to form signal SCLK which is used
to sample the received jitter.
JITAMP
This signal goes high whenever the V40 is
writing to the jitter amplitude register on
the transmit jitter circuitry.
JMODI
The transmit jitter waveform. It indicates
whether the jitter waveform is varying in
phase or otherwise.
JQ(0:2)
These signals are high whenever the V40 is
writing to the transmit jitter frequency
registers.
MNADDR
This signal is high wherever the received
jitter circuitry has taken a jitter sample
which is less than or equal to the previous
minimum jitter sample. It causes the
configuration to latch the DMA address of
the next DMA cycle. At the end of the
received jitter measurement the V40 reads
this address to determine the received
jitter.
MRD
This signal goes low whenever the V40 executes a memory
read instruction.
MWRD
This signal goes low whenever the V40 executes a memory
write instruction.
MWRI
This signal goes low whenever the V40 executes a memory
write instruction.
MXCADDR
This signal goes high whenever the received
jitter measurements is higher than any of
the previous received jitter measurements.
This signal is used to latch an address
which is later used by the V40 to determine
the received jitter.
OFFCLK
This signal is the received clock offset by
−1/(3 × 2 18 ) (approximately −1.27 parts per
million). This signal has quarter of a unit
interval hits on it and is dejittered using
the jitter attenuator chip.
RSERI
This is similar to RSER.
RSTS
This signal from the Dallas chip goes high
during time slot 16 of the E1 frame and is
decoded to indicate phase or CRC errors.
RXCKEN
This is the received clock enable signal
for the RX Bert circuitry. It goes high for
one CLKOUT period each received bit.
RXER
This signal is the data signal to the WG gate array.
RFER
This signal from the Dallas chip is de-coded to indicate
FAS or CRC errors.
RFSYNC
This signal is used to synchronise the
received time slot selection circuitry and
also de-coded to indicate phase or CRC
errors.
RSER
This is the E1 data from the Dallas chip.
It is passed to the WG gate ray to measure bit errors.
RSTS
This signal from the Dallas chip goes high
during time slot 16 of the E1 frame and is
RECONEN
This signal is used to reconfigure the
xilinx when the jitter test is complete.
RCHCLK
This signal from the Dallas chip is the
channel clock for the E1 receive frame. It
is de-coded to indicate FAS or CRC errors.
RDLCLK
This is the receive clock which is passed
to the Dallas chip. It is similar to
signal RXCKEN but is extended by one clock
period to meet the Dallas chip specifications.
SCLK
This is the master clock used by the RX
jitter circuitry. It oscillates at normally
8.192 megahertz, minus 1/(3 × 2 18 )
(approximately 1.27 parts per million). It
is used to sample in incoming received data
to detect jitter.
SIGIN
This is the signal input to the 4046 phase
up loop. It is used to quadruple the signal
JCLKI to form signal SCLK.
SMP(0:7)
This signal is the raw sample jitter from the received jitter
circuitry.
STOPPED
This signal is controlled by the V40 and is
driven high when the received jitter
measurement is stopped.
PDLCLK
This signal is the 2 megabit transmit clock
generated from the transmit BERT circuitry.
transmit jitter circuitry to insert a 12th
of a unit interval jitter hit into the
transmit clock. This signal prevents jitter
hits from being inserted while the transmit
bit is marking. This makes sure that the
transmitted bits meet the pulse mask.
TMO
This signal originates in the Dallas chip
and indicates the start of the transmit
multiframe. It is used to synchronise the
transmit time slot select circuitry.
TNEG
This signal originates in the Dallas chip
and together with signal TPOS forms the
transmit E1 stream.
TPOS
This signal originates in the Dallas chip
and is used to generate the E1 stream.
TWO
This signal goes high when ever the
received jitter is too much for the
received jitter circuitry to cope with. The
V40 can read whether this line as ever been
high. If this is the case then the jitter
measurement is discarded.
TXBERT
This signal goes high during time slots
where bit error rate test signals are being
transmitted.
TXBRTS
This signal goes high whenever a transmitted PRBS bit is to
be sent.
TXCKEN
This signal goes high for one CLKOUT period each
transmit bit.
TXCLK
This is the signal pass to the counter timer chip to indicate
the transmit bit rate.
TSPDAT
This is the transmitted PRBS signal which is injected into
the transmit data stream.
UP
This signal indicates the polarity of a
receive jitter phase change and is used in
conjunction with signal COUNT to accumulate
the received jitter.
V24RX
This signal is the received V24 data which is passed to the
V40.
V24RXD
This signal is the same as signal V24RX.
V24TX
This is the V24 data from the V40 transmitted out of the
V24 port.
V24TXD
This signal is the same as V24TX.
VCO
This signal comes from the 4046 phase lock
loop. It is used in the process whereby
signal JCLKI is quadruple in frequency to
form signal SCLK.
WGCLK
This signal is used to clock data into the
WG gate array during bit error tests. The
WG gate array then measures bit errors.
WGDATA
This is the data passed to the WG gate
array from the receive BERT circuitry. It
is used to perform bit error rate tests on.
WGERR
This signal originates in the WG gate array
and indicates when a received bit error has
occurred. It is passed to a counter timer
chip where bit errors are measured.
XRNEG
This is the re-timed received E1 data which is passed to the
Dallas chip.
XPNEGI
This is the raw E1 data from the B board.
XRBLS
This is the re-timed received E1 data which is passed to the
Dallas chip.
XRPOSI
This signal is the raw received E1 data from the B board.
XSM
This signal is XRNEGI re-timed to the clock
CLKOUT. The received clock is recovered
from this signal.
XSP
This is the signal XRPOSI re-timed to the
clock CLKOUT. Along with signal XSM this
signal is used to generate the received
clock.
XSPU
This is the unbuffered received E1 data
which is passed to the jitter detection
circuitry. Jitter is detected on this
signal.
XTNEG
This signal is passed to the B board and is used to generate
the transmit E1 string.
XTPOS
This signal is passed to the B board and is used to generate
the transmit E1 string.
The various components of the system of FIG. 3 will now be considered in more detail. Starting with the RX bit error rate testing circuitry (RX BERT) 10 , the detailed structure of this circuitry is shown in more detail in FIG. 4 . As can be seen, there are several circuit elements. The first is CLOCK GEN component 20 is used to double the frequency of the signal CLKIN. This forms a higher frequency clock CLKOUT which has a frequency of about 25½ meahertz. The logic for this clock doubling is placed in a CLB map at position AA. This ensures that the logic is very close on the LCA to the global clock buffer GCLK. The circuit works by forming a signal CLKBUF which is identical to the signal CLKIN except delayed by a small amount of time. The clock CLKOUT is passed to a GETCLOCK component 21 .
This GETCLOCK component 21 recovers the clock from the received E1 data to be used in the TX Bert circuitry. The raw incoming E1 data is sampled by the system clock CLKOUT and then the positive and negative streams are gated together to form signal RESET. This signal resets a four bit divided by twelve counter. This counter is then used to generate received blocks during times when there are no marks on the received data. CLB map in this drawing is used to try and squash as much logic as possible into the system. Thus, the GETCLOCK component 21 corresponds to the pattern clock converter 101 in FIG. 1 .
The signals shown in FIG. 4 are then listed in Table 2.
TABLE 2
Signal Name
Description
CLKOUT
This is the 24½ megahertz system clock.
CNT0 through to
These tour signals form a divide by twelve counter. It
CNT3
is divide by twelve as the received bit rate is a twelfth
of the system clock. This counter is reset by the signal
RESET. This occurs whenever a mark is received on
the incoming data.
During strings of 0's where there is no timing
information on the received E1 data then this counter
is used to 1 generate the signal RXCKEN which is the
received clock enable.
RDLCLK
This signal is generated for the Dallas chip. The signal
RXCKEN is only one CLKOUT clock period wide.
This is not a wide enough pulse to clock the Dallas
chip so the extra signal RDLCLK is generated which is
twice as long to clock the Dallas chip.
RESET
This signal pulse is high whenever a mark is received
on the incoming E1 data and is used to synchronise
the received counter.
RNEG
This signal is fed to the Dallas chip and is the received
negative E1 data.
RNEG0
This is the same signal as RNEG.
RPOS
This is the received E1 positive pulses which are fed to
the Dallas chip.
RPOS0
This is the same signal as RPOS.
RXCKEN
This signal is generated in his block and is the received
clock enable. This signal goes high for one CLKOUT
period every single received bit.
RXP
This signal is used in combination with signal
RXCKEN to generate the signal RDLCLK which is
used to clock the Dallas chip.
The component 22 is used to generate the enables for the RX BERT circuitry. A patched signal USERTA goes high whenever the received data is to be passed to the WG gate array for PRBS testing. Two other CLB maps are used simply to compress the logic into the smallest space as possible. The block consists of an 8 bit counter which is formed by signals CNT 0 through to CNT 7 . This counter is reset to 0 by the signal RFSYNC from a Dallas chip 23 . This counter is then de-coded to form the time slot select for the received PRBS data. Note that the high ordered 5 bits of the counter from signal CNT 3 through to CNT 7 are reset by the signal RFSYD. Again this technique is used to try and conserve space. The signal USERTS which is patched is then gated with the received clock enable to form the clock to the WG gate array which is signal WGCLK.
As mentioned above, the TSSEL component 22 receives the signal RFSYNC from the Dallas ship 23 . That signal is then passed to a G703ERRS component 24 . This component 24 is used to generate the CRC and FAS error signals. These signals are generated from gated signals from the Dallas chip 23 . The signal CRC error goes low whenever the signals RF since and RFER are high simultaneously, likewise the signal FASERR goes low whenever the signals RCHCLK and RFER are high while the signal RSTS is low.
Next the RX jitter circuit 12 will be considered in more detail. Its internal structure is shown in FIG. 5 . Again, it has several circuit elements. The first is a CLOCKOFF component 30 . The component 3 Q offsets the incoming received E1 clock by minus 1/(3×2 18 ). (approximately 1.27 parts per million) before passing this clock to a Dallas jitter attenuator 31 . It has a function which is used to divide the receive clock by 65,536. It also contains test functions and SLPYREG which are used to offset the clock by adding single periods of the clock CLKOUT every 65,536 received bits. Thus, the CLOCKOFF component 30 corresponds to the offset circuit 102 in FIG. 1 .
The CLIPYCNT function uses a four bit counter which performs a divide by twelve operation. Bits zero and one divide by three, and bits two and three divide by four, given a total of divide by twelve. The counter clock enabled by signal which goes high for one CLKOUT clock period every 65,536 received bits. The output of the counter is used to determine where in the twelve bit shift register in function SLIPYREG the received clock is inserted. In this way twelfth of a unit interval phase changes are introduced into the received clock in order to offset it by minus 1.27 parts per million. The SLIPYREG function uses a twelve bit shift register. It is used to inject slowly increasing twelfth of a unit interval jitter phase hits into received clock. Every 65,536 the point at which the received clock is injected into the shift register is moved closer to the beginning of the shift register. The output of the shift register ie the offset clock is at the last twelfth tap. When finally the RX clock has been injected into the first bit of the shift register and it is time to access another twelfth of a unit interval phase shift. This received clock is discarded and then the received clock is then injected into the end of the shift register. In this way the clock is offset. The MISSCNT function uses a linear feedback shift register counter. It consists of a sixteen bit shift register, of which four taps are fed back to the input. Other gates are used to detect when the shift register counter has reached its terminal count. This forms signal HIGHNR which is the output.
FIG. 5 shows that the output JCLKI of the Dallas jitter attenuator 31 passes to a PLLSTUFF component 32 . This PLLSTUFF component 32 is used to multiply the signal JCLKI by four to form the jitter sample block SCLK. It does this by doubling the frequency using the phase lock loop and then doubling the frequency from the phase up loop by two using an edge detection method. The Dallas jitter attenuator jitter 31 acts a phase lock loop which acts to remove the jitter component from the OFFCLK signal derived from the CLKOFF component 30 . This function of the Dallas jitter attenuator 31 , together with the PLLSTUFF component 32 thus form the PLL 103 of FIG. 1 which, as previously described, produces a jitter-free pulse-train, and then multiplies that pulse-train by the integer factor of 4.
A JITDET component 33 samples the incoming E1 data and from this measures the received jitter. It also recovers an E1 receive clock from the incoming E1 data stream. Thus, the JITDET component 33 forms the data sampler 104 in FIG. 1 . It receives the offset and multiplied clock signal from PLLSTUFF component 32 , and also the incoming signal which is being sampled for jitter.
A JITCOUNT component 34 generates the 8 bit jitter sample data. It consists of an 8 bit up/down counter which is enabled by the signal COUNT and the direct of the count is controlled by signal UP. The counter is set to value 80 HEX while the signal STOPPED is high. Notice that signal CNT 7 is inverted before emerging from this component 34 . Thus the JITCOUNT component 34 forms the accumulator 105 .
The output from this JICOUNT component 34 is signal SMP(0:7). That output SMP(0:7) passes to a JITOUT component 35 . This component 35 is used to transfer measured jitter into the V40's memory. This memory forms the sampler 106 of FIG. 1 . It is also used to detect the amplitude of the received jitter. It does this by storing the addresses of the first time that a maximum valued jitter sample was stored and also the address of where the last minimum value jitter sample was stored. The difference between these addresses ratio to the size of the whole DMA buffer gives an indication of the jitter amplitude. The current value of the sample jitter is stored in a shift register, along with the maximum value recorded up until now and the minimum value recorded up until now. These are compared in a block called compare which indicates when bigger or smaller samples are received. These signals are processed to generate latches for addresses.
Next the TXBERT circuit 11 will be considered in more detail with reference to FIG. 6 . The TXBERT circuit 11 has a TXTSSEL component 40 . The component 40 is used to generate the transmit enables for the transmit Bert data. It consists of an 8 bit counter formed by the signals CNT 0 through to CNT 7 . This counter is reset by the signal TMO which indicates the start of the transmit multiframe. The signal TMO comes from the Dallas chip 23 . It is latched and gated to form signal TS since which directly resets the counter. The output of this counter is then decoded to form a signal TXBERT. This signal goes high during which data is to be transmitted. In unframed mode this signal is patched permanently high. The signal is patched in the CLBTX time slot select. Note that signal TFSYNC directly resets the high five bits of the eight bit counter whereas the low three bits of the counter are set to the value 001 by this signal. This ensures everything lines up with the timing of the TMO signal.
The output TXBERTS of the TXTSSEL component 41 passes to a TXPRBS component 41 . This component 41 is used to generate the transmit PRBS Bert pattern. It consists of a 15 bit shift register formed by signals TAP 0 through to TAP 14 . Various outputs from this shift register are then gated together and fed back to the input of shift register to generate a PRBS pattern. The CLBTXPRBS select is patched to select which taps are enabled. The CLB map TX polarity select is patched to determine the polarity of the transmitted PRBS data. Signal INJER is controlled by the V40 14 . When this signal toggles high during the transmission of Bert data a bit error is injected into the transmitted data stream. This bit error signal is decoded to signal BERR which inverts the output of the PRBS shift register. Note the output of the shift register occurs from the eighth tap signal TAP 7 although it could have come from any of the other taps if desired.
The TXJITTER circuit 13 will now be described with reference to FIG. 7 . It has a TXCKEN component 50 . This component 50 is used to generate the transmit clock. The transmit clock can be jittered under the influence of signals DOJIT and JMOD 1 . When signal DOJIT is high a twelfth of a unit interval phase hit is introduced into the transmit click if a polarity depending the state of signal JMOD 1 . These phase hit insertion happen during the time when the line is not marking except in high jitter situations.
FIG. 7 also shows a TXHDB3 component 42 . This component 42 is used to encode the transmit data in a HDB3 format. Note it can be patched so that the transmit data is AMI. The configuration must do this encoding as the Dallas chip 23 can only encode for HDB3 during unframed transmission when the HDB3 coding is needed. For this reason the Dallas transmitter is always used to transmit AMI data. The CLB maps TX line code and TX framing are patched to enable AMI mode. In this mode, no extra violations are inserted into the transmit data.
FIG. 7 also shows a GRADREGO component 51 . This component 51 contains the circuitry which is used to set the frequency of the transmitted jitter. It consists of a nineteen bit counter which is formed by signals JCNT(0:19) together with registers which are used to compare against this count value. The output INCAMP indicates when it is time to inject a twelfth of a unit jitter hit into the transmitted jitter waveform. The block EXTRACLK also enables fine tuning of the jitter frequency. The output INCAMP of the component 51 passes to an AMPREG component 52 .
The component 51 is used to set the amplitude of the transmitted jitter. It consists of an eight bit latch which the V40 14 can write to and an eight bit counter which is compared to the contents of this latch to indicate when the required jitter amplitude has been reached.
The INCAMP signal also passes to a JITGEN component 57 . This component is used to control the generation of transmit jitter in the TX jitter generation circuitry.
It can be seen from the above discussion of FIGS. 3 to 7 that the embodiment of FIG. 1 makes use primarily of digital components. This makes embodiments of the present invention easier and cheaper to produce. In the embodiment of FIG. 1 , the PLL circuit 103 needs to be an analog circuit, but the fact that the PLL circuit 103 has a low time constant means that it is easy to produce and is thus inexpensive.
In the above discussion, it is assumed that the pulse-train received at input 100 is a co-directional digital data signal, in which the clock information and data are included together in one signal. The present invention may also be applied to clock signals which are not included with data, clocks still being recovered in the same way as discussed above. Moreover, the present invention may be used to investigate the jitter of an analog signal, by converting that to a digital signal before being input to input 100 .
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An apparatus for measuring jitter in a digital signal that includes an offset unit arranged to form an offset reference clock signal, being offset by a predetermined frequency amount from the digital signal. The apparatus also includes a sampler arranged to sample the digital signal at sampling times determined by the offset reference clock signal such that, in the absence of jitter and the offset by a predetermined frequency, there are a predetermined number of sampling times in each bit of the digital signal. The apparatus further includes at least one detector arranged to detect occasions when the number of sampling items in any bit of the digital signal is different from the predetermined number, and a counter arranged to count the occasions over a predetermined time. Also the apparatus includes an analyzer arranged to derive at least one measure of jitter from the counting of the occasions.
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BACKGROUND OF THE INVENTION
The measurement of fluid velocity is important in many industrial applications such as for instance, the measurement of the speed of coolant flow through pipes, as well as in scientific and medical applications, for instance in the measurement of fluid velocity in the wakes of moving vessels or models of vessels. Provided that the fluid carries scatterers capable of reflecting ultrasound such as tiny air bubbles in the case of water or liquid starch suspensions or red blood cells in the case of blood, pulsed doppler ultrasound systems have been found to be advantageous over other means of measuring fluid velocity. In the known doppler ultrasound systems a short burst or pulse of radio frequency sound is emitted from a transducer and sent towards the moving scatterers. The reflected echo is shifted in frequency because of the doppler effect, and by processing this echo in a receiver and measuring the shifted frequency with respect to the transmitted signal it is possible to estimate the velocity of the moving scatterers and thus of the fluid that contains them. Present techniques of measuring fluid velocity around ship models for instance, involve placing detectors at various points where the velocity of the liquid is to be measured. Using a pulsed ultrasonic doppler system, if it were not for the range limitations described below, it would be possible simply by pointing the ultrasound beam in different directions and adjusting the range, to obtain the velocity at any point in a fluid with only a single instrument, and to obtain the velocity over a whole region of fluid by rapidly scanning over the region at electronic speeds.
In medical applications, pulsed doppler ultrasound systems are used at this time to measure the blood velocity in peripheral blood vessels, i.e., vessels that lie close to the skin, with the transducer being positioned outside the body. This is a much more pleasant and convenient way of measuring blood velocity than other known techniques which involve cutting into the skin. It would be convenient and advantageous if it were possible to use this known technique to measure the blood velocity in vessels which are deeper in the body such as those near the heart, but this is at present impossible because of the range limitations of pulsed doppler systems.
SUMMARY OF THE INVENTION
In a typical pulsed doppler system the transmitter transducer emits pulses of radio frequency ultrasound having a known frequency which pulses are reflected from the moving scatterers and are picked up by the receiver tranducer in the form of a frequency shifted echo. The amplified echo is compared with a time gated sample of the transmitted signal in the phase comparator and the output of that circuit when passed through a low pass filter gives rise to the doppler shift frequency, whose frequency is proportional to the velocity of the scatterers. The width of the region from which such a system can receive echoes is determined by the time duration of the transmitted signal which is therefore kept as short as possible. The range of the point from which the system is receiving signals is determined by the time duration between the transmission of the signal and the receipt of the echo. If pulses are transmitted at too rapid a rate, the system suffers from range ambiguities. This is because it is unclear whether a particular echo corresponds to the most recently transmitted pulse reflected from a distant target or whether it corresponds to the echo of a pulse transmitted earlier, reflected from a closer target.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic representation of one embodiment of the invention that employs two transducers.
FIGS. 2A and 2B are is a graphic representations of the output signals of the system.
FIG. 3 is a graphic showing of an aimed system.
FIGS. 4A and 4B are block diagrams of a double transducer system, detailing the digital correlator.
FIG. 5 is a block diagram of a single transducer random signal system.
DETAILED DESCRIPTION OF THE INVENTION
For pulsed doppler systems which emit a single frequency burst of duration τ at a repetition rate f r , avoidance of range ambiguities makes it necessary to wait for the return of the echo from the most distant target before transmitting another burst.
Thus: ##EQU1## where c is the sound velocity and R max the maximum useful range. Furthermore the output doppler frequency is obtained from samples at the system repetition rate,
F.sub.r > 2f.sub.D, Equation (2)
where f D is the maximum frequency of the output doppler spectrum.
Combining the above two relations with the doppler equation ##EQU2## where v is the maximum velocity along the transducer axis and f o the frequency of the transmitted burst, gives ##EQU3## showing that the product of the maximum observable velocity and range are limited for conventional pulsed doppler systems.
Using the known velocity of sound in water or human tissue and assuming that the transmitted frequency f o is of the order of 5 MNz, Equation 3 shows that (vR) max is less than 0.1. Thus at 10 centimeters range for instance, it is not possible to measure velocities larger than one meter per second. This range velocity limit of pulsed doppler systems strongly limits its usefulness not only in applications such as measuring fluid flow in industrial and scientific applications but even in medical cases since important blood vessels near the heart are at ranges of between 6 and 20 centimeters from those points at the body surface from which ultrasound can penetrate into the body.
Another limitation of pulsed doppler systems is that the duration of the transmitted burst must be kept short to maintain fine range resolution. This requirement imposes very high ratios of peak to average transmitted powers. Since the echo from a target at range R gives a range delay or time of flight ##EQU4## it can be seen by differentiation that the range resolution ΔR for a transmitted burst of duration Δτ is at best ##EQU5## In terms of the bandwidth B of the transmitted signal the range resolution may be witten ##EQU6## as B is approximately (Δτ) - 1 .
The ratio of peak to average transmitted power can be written: ##EQU7## where τ r is the period of the transmitted signal, equal to the inverse of the repetition rate given in equation 1. Using the previous results, this gives: ##EQU8## which is equal to at least 10 2 in any high resolution system such as those used to observe deep lying structures in the body, or distant flow in general.
Use of random signals in radar has frequently been discussed but the only known implementation was described by McGillem, Cooper and Waltman in a paper entitled "Use of Wide Band Stochastic Signals for Measuring Range and Velocity," published in the EASCON '69 Record, pp 305 - 311. Practical implementation of noise as a transmitted radar signal was previously impossible because of the difficulties of handling random signals at the high frequencies required for broadcast radar. McGillem, Cooper and Waltman overcame this problem by using a scheme in which the transmitted and received signals were sampled. This led to a high performance but relatively complex system, which involved conversion from RF to video frequencies, with sampling and delay by means of digital shift registers.
The basic components of a random signal ultrasonic doppler system which uses separate transducers for transmitting and receiving are shown in FIG. 1.
In this basic random signal doppler flow measurement system the nose source 1 produces electrical signals fed to the transmitting transducer 2 and the delay line 3. Those fed to the transducer 2 are converted into sound waves 4 whose echoes 5 from any blood vessel 6 under investigation are received by the receiving transducer 7 and converted back into electrical signals. These signals, in addition to the noise signals that pass through the delay line, are fed into the multiplier 8 and from there to the low pass filter 9 which produces the output of the system.
A continuous or intermittent noise signal is reflected by scatterers in the fluid, detected, and correlated with a delayed version of itself. If the transmitted noise signal has amplitude x(t), the received echo from a single moving scatterer is of the form A × [(1 + α)t - τ s ], where A is the randomly varying scattering cross section, τ s is the signal time of flight and ##EQU9## θ and φ are the angles made by the transmitting and receiving transducers with the direction of flow. The time average of the correlator output Z(t) will be proportional to
Z(t) α E {A × [(1 + α)t - τ.sub.s ]× [t - τ.sub.s ]} = AR [αt - (τ.sub.s - τ.sub.d)], Equation (8)
where A is the time average of the scattering cross section and τ d is the reference delay imposed on a sample of the transmitted signal by the delay line (see FIG. 1). R[τ] is the autocorrelation function of the transmitted noise which is known to be equal to the inverse Fourier transform of the transmitted power spectral density. For example, for a transmitted spectral density ##EQU10## shown in FIG. 2 (a) the time average of the correlator output will be
Z(t) = Ae.sup.-.sup.B |.sup.αt .sup.- (.sup.τ.sub.s .sup.- .sup.τ.sub.d)| cos 2πf.sub.o (αt - τ.sub.s + τ.sub.d) Equation (10)
as shown in FIG. 2 (b). Thus a single scatterer passing through the "range cell," i.e., that region where τ s ˜τ d , will produce a correlator output of the form e - B |.sup.αt| cos 2πf o αt. This signal can be seen to be a burst at the doppler shift freqency, αf o , of approximate duration 2/αB. The spectrum S z (f) of this burst due to a single scatterer, is of width αB|π, and consists of a compressed version of the original transmitted spectrum, centered around the doppler shift frequency; that is: ##EQU11##
The fact a single particle leads to a finite width doppler spectrum is due to the limited time it spends in the range cell and can be shown to be identical to the transit time broadening found in conventional pulsed doppler systems. If a distribution of scatterers travelling at constant velocity pass through the range cell at random time intervals the correlator output spectrum is unchanged from that of a single scatterer. In fact, the correlator output spectrum produced by a noise system observing a distributed target such as moving blood can only depend on the spectral density of the transmitted signal. Thus, the relation between the doppler output spectrum and the transmitted spectrum is the same whether the transmitted ultrasonic signal is a burst of constant frequency or a stationary random signal.
There is a great advantage in using the random signal doppler because it does not suffer from the range ambiguity restriction on transmitted signal repetition rate as given in Equation 1. In a random signal doppler in which every signal is different from every other, an echo from any one burst cannot correlate with any other burst. Consequently, there is no upper limit on the repetition rate of the transmitted signal. (It is shown below in fact that this signal can be continuous). Hence the maximum range-velocity limit shown in Equation 3 for a conventional Pulsed Doppler Ultrasonic Flowmeter does not apply to a random signal doppler which can thus operate at any range.
The expression for Z(t) in Equation 10 shows that for a stationary target the correlator output approaches zero when Δτ = τ s - τ d > 1/B. The range resolution of the noise system can therefore be written: ##EQU12## which is exactly the same expression as the one shown in Equation 5 relating the range resolution and bandwidth of a conventional pulsed doppler system. The random signal system has an advantage over conventional systems however, in that its range resolution, dependent only on transmitted bandwidth, is independent of the transmitted pulse duration. For this reason, transmitted power in the random signal system can be spread over a much longer time interval than that for pulsed doppler systems. Since the sensitivity of optimized random signal and pulsed doppler systems can be shown to depend in the same way on the average transmitted power, the ratio of peak to average transmitted power can be made smaller in the random signal system then in the known pulsed doppler systems.
Unfortunately, if noise is transmitted continuously, reverberation type echoes from targets outside the range cell add in an uncorrelated manner to the desired signal, worsening the system signal-noise ration. In many applications these reverberation echoes can be tolerated, but if this cannot be tolerated, and if the various strongly reflecting targets are far apart, this problem can be overcome by transmitting bursts of noise which are short enough to only intercept one target at a time. Such procedures necessarily increase the ratio of peak to average transmitted power. A better means of avoiding clutter, one which does not impose restrictions on the transmitted signal, (so that the device may still utilize a continuous signal and still retain high sensitivity) is to arrange for the transmitting and receiving transducer patterns to only intercept in the region of the range cell, as shown in FIG. 3. Inspection of this arrangement shows that only echoes from the cross-hatched region are detected by the receiver. Echoes from other points of the transmitted beam approach the receiver at angles for which the receiving transducer is not sensitive. In this way reverberation noise can be reduced by an order of magnitude or greater.
One embodiment of a random signal ultrasound flow measurement system was made using separate transducers for transmitting and receiving, as shown in FIG. 4. FIG. 4 shows a double transducer system tested experimentally for flow measurement, a noise source 20 produces electrical output signals which are sent to the delay line 22 and to the transmitting transducer 23 as described in connection with FIG. 1. The echoes 25 from the target 24 resulting from this signal are reconverted into electrical signals by the receiving transducer 26 which transmits them to the R.F. amplifier 27 from where they go to the digital correlator 28. The correlator 28 is also fed with the signals that are passed through the variable delay line 22. The output of the digital correlator 28 is fed either through a frequency to voltage converter 29 and thence to a catheter type display 30, or to a spectrum analyzer 31 which incorporates its own display. The detail of the digital correlator 28 is seen to exist of an exclusive-or gate 35 followed by a nor gate 36 followed by an integrator 37. The nor gate 36 is driven by an inhibit line 40 whose function is described hereinafter in connection with FIG. 5.
Another embodiment of the present invention employs a single transducer system, such as that shown in FIG. 5. FIG. 5 represents a single transducer flow measurement system which has been tested experimentally. Either a pulsed rf generator 40 or a pulsed noise generator 41 feeds signals to the power amplifier 42 into the variable delay line 43, which delay line can include a multiple, or plurality, of ultrasonic transducers. The power amplifier 42 transmits signals through the transducer 45, these in the form of acoustic waves. The echoes from the flow to be measured are reconverted into electrical signals by the transducer 45 and fed through the input limiter 46, the high gain amplifier 47 and the squaring circuit 48 to the exclusive or circuit 49. This is also fed by signals passing through the delay line 43 and the other squaring circuit 50. The output of the exclusive-or circuit 49 passes to the gate 51 which corresponds to the nor gate described in connection with FIG. 4. The nor gate 51 is fed by an inhibit signal 53 (except during reflected signal reception) which insures that the integrator 54 fed by the gate 51 only receives signals during the time that an echo from the flow being measured arrives at the gate. The output of the integrator 54 is fed to either a spectrum analyzer 56 or a frequency to voltage converter 57. The major difference between this system and the two transducer system mentioned above is that power can be transmitted for a maximum of 50% of the time, and that rather elaborate electronics is required to block the transmitter during the time the transducer is receiving. This requirement (which also holds for conventional pulsed doppler systems) arises from the fact that scattering from targets such as blood cells can easily be 60 dB weaker than the transmitted signal.
The pulsed noise generator produces periodic bursts of noise which are transmitted and also sent through the variable delay line. The receiver amplifier input limiter circuit protects the high gain amplifier from overload during transmission. Both the echo and the delay reference signal are then clipped. This gives a slight reduction in signal-noise ratio, but allows the multiplication aspect of the correlator function to be performed by a very simple digital exclusive-or circuit. The correlator output signal is passed through a low pass filter for integration and displayed via either a spectrum analyzer or a frequency-voltage converter. A frequency shifting network (of the double mixer type) can be incorporated into the system to detect the direction as well as the magnitude of the flow.
Other well known techniques for distinguishing approaching from receding fluid involving phase quadrature techniques may also be used in these systems. By simply replacing the pulsed noise source with the pulsed RF source the system operates in a conventional pulsed doppler mode without the aforementioned ambiguity problems and peak power/average transmitted power problems of the conventional pulsed doppler systems.
The low peak to average transmitted power ratio of the random signal doppler system will be of advantage in giving such systems extra range when used in fluid media. This is so because the range of conventional pulsed echo systems is often limited by electrical breakdown which occurs in the transducers when a certain maximum peak transmitted power is exceeded. The range of conventional pulsed doppler flow meters is not limited by this effect since their range is usually much more strongly limited by the velocity range product maximum, as defined in Equation 3.
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A doppler effect flow measurement device using ultrasonic stationary random noise whereby errors and inaccuracies common in existing doppler flow measurement systems are overcome.
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BACKGROUND
[0001] The present invention relates to methodologies and an apparatus for the abatement of ozone produced during the processing of semiconductor wafers.
[0002] Semiconductor device fabrication involves various processing steps which may fall into four general categories: deposition, removal, patterning, and modification of electrical properties. Deposition is any process that grows, coats, or otherwise transfers a material onto the wafer. Available technologies include physical vapor deposition (PVD), chemical vapor deposition (CVD), electrochemical deposition (ECD), molecular beam epitaxy (MBE) and more recently, atomic layer deposition (ALD) among others. Removal is any process that removes material from the wafer; examples include etch processes (either wet or dry) and chemical-mechanical planarization (CMP). Patterning is the shaping or altering of deposited materials, and is generally referred to as lithography. For example, in conventional lithography, the wafer is coated with a chemical called a photoresist; then, a machine called a stepper focuses, aligns, and moves a mask, exposing select portions of the wafer below to short wavelength light; the exposed regions are washed away by a developer solution. After etching or other processing, the remaining photoresist is removed by plasma ashing. Modification of electrical properties has historically entailed doping transistor sources and drains (originally by diffusion furnaces and later by ion implantation). These doping processes are followed by furnace annealing or, in advanced devices, by rapid thermal annealing (RTA); annealing serves to activate the implanted dopants. Modification of electrical properties now also extends to the reduction of a material's dielectric constant in low-k insulators via exposure to ultraviolet light in UV processing (UVP). Modern chips have up to eleven metal levels produced in over 300 sequenced processing steps.
[0003] Many toxic materials are used in the fabrication process. These include: poisonous elemental dopants, such as arsenic, antimony, and phosphorus, poisonous compounds, such as arsine, phosphine, and silane, and highly reactive liquids, such as hydrogen peroxide, fuming nitric acid, sulfuric acid, and hydrofluoric acid.
[0004] One chemical that has recently been introduced into the process is ozone (O 3 ). DNS (Dainippon Screen Manufacturing Company) Single wafer processing wet tools DC-08, DC-09, DC-10 & DC-11 use a new cleaning chemistry of sulfuric acid and Ozone.
[0005] Ozone (O3) is a form of oxygen that consists of three oxygen atoms joined together into a molecule. This form of oxygen has significantly different characteristics than the common oxygen molecule (O2), which consists of two oxygen atoms. The ordinary O2 form of oxygen is, of course, present in the air we breathe and is indeed necessary for life.
[0006] The role of ozone in the environment is more complicated. First, ozone in the upper atmosphere plays an important role in protecting life on earth by absorbing dangerous short wavelength UV from the sun. However, it is harmful in the lower atmosphere since it is an irritant when breathed and is therefore an undesirable air pollution component.
[0007] The ozone used in fabrication must be abated before being exhausted into the environment. Conventional methods of ozone abatement utilize carbon filters to reduce the ozone and sulfuric acid to acceptable levels. The final stage of abatement systems is an acid scrubber to remove the remaining sulfuric acid. The acid scrubber is a water wash that the exhaust is passed through. One issue with the carbon filters is a result of the need to constantly change out the filters over time. This requires significant maintenance and cost.
SUMMARY
[0008] The inventors have proposed a new and novel approach to abate the level of Ozone in waste gasses for a semiconductor processing system. The inventor has determined that Ozone in semiconductor manufacturing waste gasses may be abated with the use of UV light to break down the Ozone from O 3 to O 2 .
[0009] In one embodiment the system may comprise a first reflective chamber, the reflective chamber having inner surfaces with a diffuse reflective material. An inlet is adapted to accept exhaust air from an exhaust duct and direct the exhaust air to the reflective chamber in a generally laminar flow. At least a first plate is located between the inlet and the reflective chamber to further induce laminar flow in the reflective chamber.
[0010] At least one plate may be located in the reflective chamber to further aid in the laminar flow through the reflective chamber. As the plate is located in the reflective chamber the plate may be coated with a diffuse reflective material.
[0011] As the exhaust air may include caustic materials such as sulfuric acid, and to reduce the ppmv of the ozone, the system may be adding bleed air to the exhaust duct. By introducing bleed air the system reduces the density of the ozone in the air making the reflective chamber more effective. In addition, the bleed air lessens the density of the caustic materials in the exhaust air improving the life of the system.
[0012] To improve the performance of the system, a second reflective chamber may be added in series with the first reflective chamber. To ensure laminar flow a plurality of plates may be added to the first and second reflective chambers. The plates may be perforated with a plurality of holes. The plates may be at least the cross sectional area of the chamber cavity to ensure laminar flow. In addition, the reflective plates may be coated with a diffuse reflective material such as polytetrafluoroethylene.
[0013] To further ensure laminar flow is achieved, a plurality of plates may be inserted between the inlet and the reflective chamber. In addition, a plurality of plates may also be inserted between the first and second reflective chambers to further induce laminar flow in the reflective chambers.
[0014] The method of abating the ozone from the semiconductor manufacturing exhaust waste may include introducing the exhaust containing ozone and sulfuric acid to a chamber. To reduce the density of the ozone and other caustic materials the system may introduce bleed air into the exhaust. To ensure performance of the system, laminar flow is promoted through the use of perforated plates and an inlet designed to promote a laminar transition from the exhaust duct to the reflective chambers. The ozone is then exposed to high doses of UV light to break down the ozone into oxygen. Finally the exhaust is provided to a regenerative thermal oxidizer (RTO).
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0015] FIG. 1 illustrates a schematic diagram of a prior art ozone abatement system.
[0016] FIG. 2 illustrates a schematic diagram of an embodiment of the invention.
[0017] FIG. 3 illustrates an embodiment of an ozone abatement chamber.
[0018] FIG. 4 illustrates an embodiment of a reflective chamber in the ozone abatement chamber.
[0019] FIG. 5 illustrates a plate for the promotion of laminar flow in the ozone abatement chamber.
[0020] FIG. 6 illustrates a method to abate ozone, according to an embodiment of the present invention.
DETAILED DESCRIPTION
[0021] Referring to the drawings, FIG. 1 illustrates a schematic diagram of a conventional solution to the ozone abatement for the DNS single wafer processing tool. The ozone is generated with an ozone generator 110 which is provided to a process chamber 120 . The ozone is mixed with sulfuric acid and off gases as the wafer 125 is processed. The off gas is exhausted through exhaust ducts 125 to a carbon filter 130 . The exhaust ducts 135 may be stainless steel and coated with Halar to prevent damage from the sulfuric acid. The gas passing through the carbon filter 130 is then provided to an acid scrubber 140 to remove any remaining sulfuric acid. The gas is then exhausted through stack 150 into the atmosphere. The carbon filters 130 require maintenance as the ozone and sulfuric acid is absorbed by the filters. This requires periodic replacement of the filter and disposal of the used filters. This may be costly and involve significant manpower. The inventor proposes a solution to this embodiment that avoids the constraints of the carbon filter system.
[0022] FIG. 2 illustrates a schematic diagram of an embodiment of the invention. The ozone is generated with an ozone generator 110 and provided to a process chamber 120 to process the wafers 125 . The process chamber 120 utilizes the ozone in combination with sulfuric acid to more precisely process the wafers 125 . The process chamber 120 may be a DNS (Dainippon Screen Manufacturing Company) single wafer processing wet tool, DC-08, DC-09, DC-10 or DC-11. DNS's process produces exhaust gas that comprises ozone at 250 CFM at 0.4 pounds of ozone per hour (lbs/hour) or 215 parts per million by volume (ppmv). In addition the exhaust gas comprises sulfuric acid which evaporates from the etching and cleaning solution.
[0023] The first step in the processing of the waste gas may be to dilute the waste gas by adding bleed air 230 at 50 to 250 CFM to the waste gas. The result of this additional bleed air may increase the flow of exhaust air to about 300 to 500 CFM and may be to reduce the sulfuric acid to non-detectable levels and the ozone from 179 to 107 ppmv. The reduced volume of sulfuric acid reduces the acid to a level that is less harmful to the abatement tooling. In addition, by reducing the ppmv of the ozone the inventor has determined that the effectiveness of the abatement at later stages improves.
[0024] The exhaust air may then be fed to an ozone abatement chamber 250 which will utilize UV energy to abate the ozone to about 21 ppm. The inventor has determined it may be useful to reduce the ozone further to a level below 10 ppmv to nitrous oxide prior to providing it to a regenerative thermal oxidizer or RTO 270 . Therefore, one embodiment of the invention may provide the exhaust air to a second chamber 260 . The exhaust air may be abated such that the level of ozone is reduced to about 9 to 5 ppm at from 300 to 500 CFM.
[0025] The final step in the process to remove any remaining sulfuric acid and/or ozone is to provide the exhaust air to an RTO 270 . An RTO is essentially a large oven that heats exhaust passing through it to 1500° C. As stated before, the inventor has determined that the level of ozone entering the RTO should be less than 10 ppmv. The inventor has found that when the ozone level is above this level, the RTO may produce unacceptable levels of nitrous oxide N 2 O. The exhaust gas is then exhausted through a stack 280 to the environment. The final exhaust gas must contain gas wherein the exhaust comprises gas with less than 3.0 lbs/hr of N 2 O.
[0026] The inventor has determined that ultraviolet energy at the proper wavelength interacts with ozone to disassociate it into ordinary oxygen (O 2 ) and atomic oxygen. The inventors have determined that one such system which may be utilized was created by Novatron. The wavelength used in Novatron's AUVS systems, may be effective for disassociation of ozone. The Novatron system is described in U.S. Pat. No. 8,404,186 issued on Mar. 26, 2013 and is hereby incorporated by reference. The key to the Novatron system is the introduction of surfaces with high reflectivity to UV light. In one embodiment, the emitter may be any source of UV, such as a flashlamp or a pulsed lamp, which provides broad spectrum pulsed light and can be purchased through vendors such as Fenix, of Yuma, Ariz., medium pressure mercury arcs, available from Hanovia Corp, and germicidal lamps.
[0027] The Novatron system further utilizes a coating on the surface of the chamber of a diffuse reflective material. The highly diffuse reflective material may comprise one or more of: Spectralon™ which has a reflectivity of about 94%, ODM, manufactured by Gigahertz-optik, which has a reflectivity of 95%, and DRP which has a reflectivity of 99.4 to 99.9%. Spectralon™, which is a highly Lambertian, thermoplastic material that can be machined into a wide variety of shapes to suit various reflectance component requirements, may be purchased from Labsphere, Inc. DRP can be purchased in sheet form, with a peel and stick backing from W. L. Gore and Associates. In another embodiment, the highly reflective material comprises an Alzak oxidized aluminum, which has a reflectivity of about 86%. One such diffuse reflective material is ePTFE (expanded PTFE, Polytetrafluoroethylene) and has a reflectivity of 99% or better in the UV. When PTFE (also known as Teflon®) is expanded, millions of microscopic pores are created in a three-dimensional membrane structure. DRP is an example of a surface with high reflectivity based on favorable multiple scattering of light from the structure of the solid. Spectralon (See U.S. Pat. No. 5,462,705) is another example of a highly reflective surface resulting from compaction of small fluorinated polymer components, for a patent describing this type of reflector is Seiner's U.S. Pat. No. 4,035,085, which is hereby incorporated by reference for all purposes. This Seiner patent describes methods of producing highly reflective coatings with fluorinated polymers and references the Kubelka-Munk scattering analysis.
[0028] Very high, uniform UV doses in large volumes of air may accomplish significant ozone reduction in industrial air streams. The inventor has determined that the Novatron's AUVS reflective cavity technology may meet the requirements to abate the ozone to an acceptable level prior to entry into the RTO. By utilizing a highly reflective cavity the system the level of ozone abatement is significant enough to reduce the levels to an acceptable level. However, the inventor has determined that to achieve the level of abatement desired, laminar flow through the system is required.
[0029] FIG. 3 illustrates an embodiment of an ozone abatement chamber 310 . The chamber 310 comprises a plurality of plates 320 , 321 , 322 , 323 and 324 to create laminar flow through the chamber. Two reflective chambers 330 and 335 are located in the system. Reflective chambers 330 and 335 further contain additional plates 331 , 332 , 333 and 334 to ensure laminar flow is maintained through chambers. Reflective chamber 330 follows plates 320 , 321 and 322 . Reflective chamber 335 follows plates 223 and 224 .
[0030] The exhaust is directed into the chamber 310 through ducts 350 . The ducting is arranged such that it promotes laminar flow into the chamber. The inlet 355 , take an exhaust input from a smaller diameter duct 350 . The inlet 355 is configured as a trapezoid. In one embodiment the opening of the duct 350 is 8 inches. The inlet takes the duct 350 up to the opening of the first plate of 24 inches by 48 inches. The inlet 355 is 36 inches long to allow for smooth transition to promote laminar flow through the chambers.
[0031] The first set of plate 320 , 321 , and 322 may be perforated plates of 316 stainless steel, 0.625 inches thick with an equidistant array of 288 holes, each having a 7/16 inch diameter to promote laminar flow. All of the plates 320 , 321 , 322 , 336 , 331 , 332 , 337 , 323 , 324 , 338 , 333 , 334 and 339 may be of the same size with the same characteristics. An embodiment of plates 320 , 321 , and 322 are better shown in FIG. 5 . The plates 320 , 321 and 322 are placed between the inlet 355 and the first reflective chamber 330 . An embodiment of reflective chamber 330 is better described in FIG. 4 .
[0032] Chamber 310 further comprises a plurality of dampers 360 and 365 . Dampers 360 and 365 comprise a plurality of opposed blades. The dampers 360 and 365 may comprise blades that rotate to close and prevent air flow or rotate open further assist the laminar flow through the chamber 310 . Dampers 360 and 365 are in place to allow for the chamber 310 to operate while shutting down one of the two reflective chambers 330 or 335 .
[0033] To shut off reflective chamber 330 , damper 372 and 360 are closed allowing for maintenance of reflective chamber 330 . In addition dampers 371 , 373 , 374 , and 376 are open, while damper 377 is closed. This allows exhaust air to flow through ducts 370 and 375 into reflective chamber 335 . While the laminar flow will not be optimal, some abatement of the ozone will occur.
[0034] To shut off reflective chamber 335 for maintenance, dampers 365 , 371 , 374 and 376 are closed. In addition, dampers 360 , 372 , 373 and 377 are open. This allows the exhaust to flow through reflective chamber 330 , while maintenance will be performed on reflective chamber 335 . During normal operation dampers 360 , 365 , 372 and 376 are open while dampers 371 , 374 and 377 are closed.
[0035] FIG. 4 illustrates an embodiment of a reflective chamber in the ozone abatement chamber. The reflective chamber 400 comprises a central chamber 430 through which the exhaust gases pass, on either side of the central chamber doors 410 and 420 are located. Banks of lamps 415 and 425 are located in the doors 410 and 420 respectively. The lamps in one embodiment comprise 20 lamps. These lamps produce 400 watts of UV light. The inner surfaces of the doors 410 and 420 are coated with a diffuse reflective material such as DPR. The internal surfaces of the central chamber are also coated with a diffuse reflective material. To promote laminar flow, the lamps 415 and 425 are located with in doors 410 and 420 outside the central chamber 430 to promote laminar flow. The inventor further identified that heating of the exhaust as it passes through the reflective chamber may cause the warm exhaust to rise, introducing turbulence into the system. To promote laminar flow as shown in FIG. 3 , plates 331 , 332 , 333 , and 334 are placed in reflective chambers 330 and 335 . The plates promote laminar flow in reflective chamber 400 and are coated with a diffuse reflective material such as DPR.
[0036] FIG. 5 illustrates a plate for the promotion of laminar flow in the ozone abatement chamber. The plate 500 is designed to fit the openings in the chamber 310 and promote laminar flow. The plates are generally 0 . 0635 inches thick and have a plurality of holes approximately 0.625 inches in diameter. Plates 331 , 332 , 333 , and 334 are also coated with a diffuse reflective material such as DPR. In addition, plates 336 , 337 , 338 , and 339 may also be coated with the diffuse reflective material to promote reflective.
[0037] FIG. 6 illustrates a method to abate ozone utilizing the embodiments illustrated in FIG. 2 - FIG. 5 . The first step 610 may be to introduce an exhaust containing ozone and sulfuric acid into an abatement system. While one embodiment may be to include sulfuric acid which may be produced in a system for cleaning wafers, the first step may be limited to providing only ozone to the abatement system. Step 620 may be add bleed air to the exhaust. This may raise the flow of exhaust from 250 CFM to anywhere from 300 CFM to 500 CFM. Step 630 may be to promote laminar flow in the exhaust to improve the efficiency of the abatement of ozone. Step 640 may be to expose the exhaust to high doses of UV light to break down the ozone to oxygen. The final step in the process may be to pass the exhaust through the RTO to eliminate any remaining pollutants in the exhaust.
[0038] The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.
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An apparatus and method for abating ozone and reducing sulfuric acid from an exhaust stream. In a semiconductor manufacturing plant the processing of wafers involves the cleaning and etching of wafers, the resultant processing may produce gasses which must be abated. The apparatus and method utilizes UV light in high doses to convert ozone (O 3 ) to oxygen (O 2 ). By ensuring laminar flow through the UV light chambers, the efficiency of the system is sufficient to allow for the remaining impurities in the exhaust air to be removed through the use of an RTO.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] None.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO A MICROFICHE APPENDIX
[0003] Not applicable.
BACKGROUND
[0004] Local area networks (“LANs”), Wireless local area networks (“WLANs”), and wired connections allow a group of devices (e.g., computers, workstations, printers, file storage devices, and other devices) to communicate and exchange information and share resources over a limited area using a pre-determined software protocol. Each device connected to the LAN, WLAN, and wired connections may be referred to as a “node.” The nodes communicate using a software protocol, which is an electronic method of communicating using a formal set of conventions governing the format and relative timing of electronic messages exchanged between nodes in the LAN. Nodes may be personal computers, equipment used to analyze or take measurements, or any other electronic device capable of signal communication with another node.
[0005] In the past, nodes have been forced to utilize matching hardware connections in order to work with hardware equipment. With the evolution of computing standards, hardware connections may exist on equipment, which are not compatible with new computer interfaces. Systems and methods are needed to allow communication between dissimilar interfaces.
SUMMARY
[0006] These and other features and advantages will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings and claims.
[0007] Disclosed herein is a wellbore servicing computing network, comprising a first component with a first interface coupled to a connection device, and a second component with a second interface coupled to the connection device; wherein the first component is capable of communication with the second component through the connection device; and wherein the first interface and the second interface are dissimilar; and wherein the first component is oilfield equipment and the second component is a computer.
[0008] Also disclosed herein is a network for conducting well treatment or well servicing operations, comprising a first node with a first communications interface coupled to a connection device, and a second node with a second communications interface coupled to the connection device; wherein the first node and second node are in communication with each other through the connection device; wherein the first communications interface and second communications interface are dissimilar; and wherein at least one node is coupled to well treating or well servicing equipment capable of assembling at a wellsite to perform a well treatment or well servicing operation.
[0009] Further disclosed herein is a method of wellbore servicing through network communications, comprising establishing a first electrical connection between a first node and a connection device, establishing a second electrical connection between a piece of well bore servicing equipment and the connection device, selecting a operational mode by the connection device, translating signals transmitted by the first node and the second node, relaying signals between the first node and the well bore servicing equipment, and conducting well site operations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] For a more complete understanding of the present disclosure and the advantages thereof, reference is now made to the following brief description, taken in connection with the accompanying drawings and detailed description, wherein like reference numerals represent like parts.
[0011] FIG. 1 is an overview of a network containing a signal conversion device.
[0012] FIG. 2 is a flowchart of one method of using an embodiment of a signal conversion device.
[0013] FIG. 3 is an embodiment of a network containing a signal conversion device.
[0014] FIG. 4 is a flowchart of a system which employs the signal conversion device to manually select a mode of operation.
[0015] FIG. 5 an embodiment of a signal conversion device.
[0016] FIG. 6 is a flowchart of a use of the signal conversion device.
[0017] FIG. 7 illustrates several serial interfaces.
[0018] FIG. 8 illustrates an exemplary general purpose computer system suitable for implementing the several embodiments of the disclosure.
DETAILED DESCRIPTION
[0019] It should be understood at the outset that although an illustrative implementation of one embodiment of the present disclosure is illustrated below, the present system may be implemented using any number of techniques, whether currently known or in existence. The present disclosure should in no way be limited to the illustrative implementations, drawings, and techniques illustrated below, including the exemplary design and implementation illustrated and described herein, but may be modified within the scope of the appended claims along with their full scope of equivalents.
[0020] The following definitions are intended to be helpful in clarification, and are not intended to be limiting. Each definition should be interpreted as including, but not limited to, the meaning defined. The phrase “in signal communication” is meant to refer to components which may be electrically connected, coupled, or otherwise configured to directly or indirectly send and receive signals including, but not limited to, electrical signals, radio signals, microwave signals, optical signals, ultrasonic signals, etc. By “in wireless communication”, it is meant to refer to the process whereby electronic devices are in signal communication via any type of wireless technology known in the art suitable for sending and/or receiving communication signals. “Acquired data” includes any information gathered from one or more sources (e.g., sensing devices, keypads, audio microphone, etc.) including, but not limited to, well treatment condition information, vehicle operating condition information, operator input information, etc. “Network information” means any information or data concerning the status of individual nodes or the network as a whole including, but not limited to, information on node identity, node input/output devices, node functionality, network functionality, etc. “Network instructions” means any instructions or commands directed to individual nodes, groups of nodes, or a network as a whole, including, but not limited to, commands related to changes in node functionality, changes in node identity, redeployment of one or more nodes or the entire network, etc. The phrase “hot swap” means the process by which hardware can be electrically connected or coupled without the need to remove power from the device. The phrase “serial format” is intended to refer to the specific implementation of the serial connection, including the connections used to make the serial connection as well as the power requirements required to drive the connection, and the phrase “serial communications” is intended to refer to the mode whereby data is sent one bit at one time, sequentially, over a communications channel or computer bus. The phrase “node functionality” means functions, characteristics and/or parameters associated with an individual piece of equipment associated with a given node (e.g. computer type, connection type), equipment type (e.g., pump truck, blender, delivery truck, master control van), equipment characteristic (e.g., engine model, pump capacity, horsepower, carrying capacity), etc. “Network functionality” means one or more selected or inherent characteristics possessed or performed by a given network, including network algorithms, checklists or other routines.
[0021] As shown in FIG. 1 , the present disclosure contemplates a system 10 wherein a connection device 16 is used to promote communication between equipment 12 through a first connection 14 , a first computer 22 through a second connection 18 , and second computer 24 through a third connection 20 . Connection device 16 may contain any number of connections including, but not limited to, universal serial bus (“USB”) devices, wireless network, wired network, IEEE 1394 (e.g. FireWire, i.Link, Lynx), or other connections. It is further understood that connection device 16 may be used to connect any number and type of electronic devices and any number and type of personal computers. One of the innovative features of connection device 16 is the ability to connect multiple devices to the same equipment with dissimilar connections. Connection device 16 may, in some embodiments, allow for the control of equipment even when one computer has failed. In some embodiments, connection device 16 allows for the ‘hot swapping’ of computers to connection device 16 , and for the ‘hot swapping’ of equipment 12 to connection device 16 . Hot swapping is intended to refer to the ability to connect and disconnect a computer or equipment to a device, without the need to power off the computer or equipment. In this way, connection device 16 allows for the connection of both first computer 22 and second computer 24 to equipment 12 regardless of the type of connection used by equipment 12 or first computer 22 and second computer 24 .
[0022] In one embodiment, connection device 16 is capable of translating a signal from equipment 12 . One of the innovative features is that connection device 16 may take any serial signal or parallel signal which is transmitted through a signal line and allow it to be used by one of the other devices. Examples of serial connections include, but are not limited to RS-232 serial connections, DB-25 serial connections, Ethernet connections, IEEE1394 connections, and USB connections. It is further contemplated that, in some embodiments, connection device 16 may be capable of signal conversion which allows different types of communication signals to be translated from one type of signal to another through signal translation. Therefore, connection device 16 is capable of promoting connections between dissimilar devices along dissimilar interface connections. One of the innovative features of connection device 16 is the ability to take a first device with a first connection and translate it into another format for a second connection to a second device. It is further contemplated that in addition to acting as a wired node, system 10 is capable of acting as a wireless node. In this way, connection device 16 is capable of communication in both a wired and wireless sense.
[0023] The equipment illustrated by FIG. 1 is intended to refer to any electronic equipment capable of performing a function involving both an input and an output. It is expressly understood that one of the problems with existing art is the incompatibility between devices. For instance, serial devices which required a specific kind of serial connection, such as a RS-232c to communicate are incompatible with newer devices which have another type of connection, such as a USB connection or a IEEE 1394 connection.
[0024] While all serial connections share the common process of sending data sequentially over a communications channel, not all serial connections are the same. For instance, a DE-9 serial connection contains nine separate connections: carrier detect, a receive data (usually +/−12V), transmit data (usually +/−12V), data terminal ready, system ground, data set ready, request to send, clear to send, and ring indicator, each of which are part of the signal. As data speeds have increased, the standard for port configuration has changed. For instance, a USB connection contains only four separate connections: a voltage bus (“VBUS”) which operates between approximately 4.75 and 5.25 volts, a D−, a D+, and ground. One of the innovative features of connection device 16 is the ability to take a signal from one serial format and convert it to another serial format. Systems and methods of amplifying or reducing a signal are known to one skilled in the art.
[0025] In addition to enabling the translation of signals, additional data may be added or removed to translate signals from one signal interface to another. For instance, in some serial connections, a specific signal is needed such as a clear to send (“CTS”) signal. In these embodiments, connection device 16 will emulate the required signals in order to conform to the serial connection requirements. It is expressly understood that the disclosed embodiments are capable of adding and stripping data from one source to another.
[0026] Another method of transferring data is through the parallel port. In parallel communication, sent through a parallel port, multiple data streams are sent simultaneously. If the serial port were a highway, it might be analogized to a highway with one lane in each direction. If the parallel port was a highway, it might be analogized to a highway with several lanes in each direction. Parallel communications also require adjusting the same two elements: the signal and the signal voltage. One of the innovative features of connection device 16 is the ability to translate the parallel port data stream into a serial data stream or vice-versa. This is accomplished by interleaving the parallel data into packets of known length by connection device 16 , then ordering the packets into a serial stream and transmitting them through connection device 16 .
[0027] It is contemplated that several modes of operation are possible for the connection device 16 including, but not limited to transmission, conversion, and splitting. In the first mode, transmission, a signal received from equipment 12 is passed directly to connection device 16 , and then passed to first computer 22 or second computer 24 . In the second mode, conversion, a signal is transmitted from equipment 12 to connection device 16 , converted from a first signal type to a second signal type by connection device 16 , and transmitted to first computer 22 or second computer 24 In the third mode, splitting, a signal a signal received from equipment 12 is passed directly to connection device 16 , and then passed to first computer 22 or second computer 24 While each of these modes are show separately, it is explicitly understood that any number of the modes could be used together (e.g., a signal could undergo both conversion and splitting). It is further understood that while the examples illustrated show a signal being propagated from equipment 12 , it is explicitly understood that any of the aforementioned methods could be used by first computer 22 , second computer 24 , or both first computer 22 and second computer 24 to transmit a signal to equipment 12 .
[0028] It should also be understood that an additional advantage of this disclosure is that in one embodiment of the disclosed systems, two or more computers may be in signal communication (e.g., by wireless and/or hardwire communication) to cooperatively accomplish one or more operational tasks, such as a well treatment operation, and/or to perform two or more separate operational tasks simultaneously (related or unrelated) with legacy devices or other devices through connection device 16 . It is further understood that in the case of a fault of a first computer, a second computer, third computer, or other device could connect, or be used to monitor one or more operational tasks, such as a recovery operation. Examples of information that may be exchanged between equipment 12 and first computer 22 include, but are not limited to, network information, network instructions, acquired data, etc.
[0029] It is contemplated that connection device 16 may further allow for redundancy, as multiple computers may be attached to a single equipment 12 , and, in addition, connection device 16 may be further capable of wirelessly transmitting a reformatted data stream. In some embodiments, where connection device 16 is equipped with WiMAX, Global System for Mobile Communications (“GSM”), Enhanced Data GSM Environment (“EDGE”), General Packet Radio Service (“GPRS”), or other long range wireless standards, connection device 16 may relay status information regarding first computer 22 , second computer 24 , or equipment 12 back to a remote location. Unlike short range WLAN configurations where there is a need for a local WLAN node location (e.g. within 100 ft), the decentralized long range network removes the equipment from the wellsite, and allows for enhanced network stability through the use of existing networks as well as increased safety as demolitions or other charges used at a drill site will not be exposed to high power low range WLAN signals. In this manner, the remote location may monitor sites based upon connection device 16 without the need for a local WLAN infrastructure. The remote data transmission capabilities of the disclosed long range wireless networks eliminate the need for engineers or other specialists to travel to these remote sites.
[0030] It should be understood that one benefit of this disclosure that other well treatments and well services employing equipment 12 known in the well servicing art may also be performed using embodiments of the disclosed connection device 16 . Such well treatments and services include, but are not limited to, treatment or services related to acidizing, condensate treatments, injectivity testing, gravel packing, frac packing, introduction of drilling fluids into a wellbore, etc. Other examples of well service operations (and/or related equipment) which may be advantageously performed and/or equipped using embodiments of the disclosed connection device 16 include, but are not limited to, perforating operations, coiled tubing operations, drilling and workover rig operations, as well as any other type of well service operation employing one or more pieces of mobile equipment (including, but not limited to, equipment that is truck-mounted, trailer-mounted, skid-mounted, barge-mounted, etc.). Since the equipment that is truck-mounted may vary in the connectivity available, connection device 16 can allow the equipment to be operated by any machine which is available. Connection device 16 will further allow for damaged or malfunctioning equipment to be operated by a secondary machine without the need to remove existing hardware.
[0031] In one exemplary embodiment of the disclosed system, oil well stimulation equipment may be transported by vehicle to job sites controlled or monitored by computer 22 or other device connected through connection device 16 . In the case of a fault in computer 22 , connection device 16 may, in some embodiments, announce this fault condition to another node. In this situation, second computer 24 may be hot swapped into connection device 16 to control the oil well stimulation equipment, even if second computer 24 , first computer 22 , and the oil well stimulation equipment do not have a common type of port.
[0032] FIG. 2 is a flowchart 30 of one embodiment of a method used by connection device 16 to translate a signal from a first connection to a second connection. In this embodiment, connection device 16 determines the type of the first connection (Block 32 ). The type of connection includes whether the connection is serial or parallel, the voltage requirements of the port, and the data format used to transmit information through the port. The signal conversion device also determines the type of the second connection (Block 34 ). One of the innovative features of connection device 16 is to match the voltage required to drive the first connection and the second connection (Block 36 ). Based on the determination of the type of the first connection and the type of the second connection, connection device 16 translates the signal from the first connection to the second connection (Block 38 ). In addition, connection device 16 translates the signal from the second connection to the first connection (Block 40 ). In this way, connection device 16 allows for nodes to communicate with one another without the need to have the same interface connection.
[0033] FIG. 3 is a block diagram 50 of connection device 16 and devices which may be attached through it. Connection device 16 may be connected to any kind of equipment, including a serial equipment 62 , a parallel equipment 64 , a network equipment 66 , and other equipment 68 . Connection device 16 may, in some embodiments, have different hardware ports which designate the type of connection, and, in other embodiments, have software detection. For instance, a parallel port and a serial port may have the same physical connection, but very different operation. Therefore, it is expressly understood that connection device 16 may have additional ports in which to connect other device. In addition, first computer 22 and second computer 24 may be connected to connection device 16 though any number of methods, including, but not limited to IEEE 1394 52, USB 54 , Wireless Network (e.g. 808.11, WiMax, GPRS, Satellite communications) 56 , wired network (e.g. ethernet) 58 , and other connections 60 . It is further contemplated that a local hub, or device which allows for multiple devices to be daisy chained to it, may be directly connected to connection device 16 .
[0034] FIG. 4 is a flowchart 90 of an embodiment of the present disclosure wherein an operational mode may be manually be selected by a user during a fault by a computer connected to connection device 16 . In this example, a fault develops with first computer 22 in the configuration shown in FIG. 1 , a second computer 24 could be added to connection device 16 , and second computer 24 could subsequently take control of equipment 12 . One example of the usefulness of this embodiment is a situation where a computer located at a well site experiences a failure, a computer that is located in another location, or a portable computer carried to the well site, may be used to connect to connection device 16 without the need to remove the equipment or restart the equipment connected to connection device 16 . In this embodiment, equipment 12 is connected to a hot swappable signal converter (Block 92 ). Hot-swappable signal converter takes signal from a first format and converts it into a second format (Block 94 ). A computer is connected to signal converter (Block 96 ). At this stage communication may commence between the first computer and the equipment. However, if a fault occurs with the first computer, a second computer may be connected to the signal converter to allow for the control of the equipment without the need to remove the first computer. (Block 98 ). Second computer and equipment communicate without the need to remove the first computer from the signal converter (Block 100 ). In this way, drill site operations may continue without the need to remove faulty equipment.
[0035] FIG. 5 is a block diagram of connection device 16 . A first port 102 , a second port 103 , and third port 104 are located on connection device 16 . First port 102 , second port 103 , and third port 104 may be a serial connection (e.g. RS232, USB, etc.), parallel connection, wireless antenna, or any other port or mechanism capable of transmitting or receiving signals. Indicator 105 is also illustrated on connection device 16 may be implemented as a light emitting diode (“LED”) and can be used to determine the operating status of connection device 16 . Connection device 16 also includes liquid crystal display (“LCD”) 106 which may be used to display information regarding the signals being converted in connection device 16 . Mode selection switch 107 may allow for a user to select a mode between transmission, conversion, and splitting operating modes.
[0036] FIG. 6 is a flowchart 110 of one method of implementing connection device 16 . In this flowchart equipment 12 to be operated and first computer 22 to be connected are selected (Block 112 ). The operator will identify whether equipment 12 is currently being controlled by a second computer 24 (Block 114 ). If equipment 12 is being controlled by second computer 24 , then connection device 16 must determine if equipment 12 can be operated when connected to multiple computers (Block 116 ). If equipment 12 is not being controlled by second computer 24 , then connection device 16 will determine if first computer 22 can correctly interpret signals from the equipment 12 (Block 120 ). If connection device 16 determines that equipment 12 can be operated when connected to multiple computers, connection device 16 will determine if computer 22 can correctly interpret signals from the equipment 12 (Block 120 ). If connection device 16 determines that equipment 12 cannot be operated when connected to multiple computers, connection device 16 must disconnect equipment from second computer 24 (Block 118 ) and then will determine if first computer 22 can correctly interpret signals from the equipment 12 (Block 120 ).
[0037] FIG. 6 continues when connection device 16 determines if first computer 22 can correctly interpret signals from the equipment 12 (Block 120 ). If connection device 16 determines that first computer 22 can correctly interpret signals from the equipment 12 it will connect first computer 22 to equipment 12 (Block 124 ). If connection device 16 determines that first computer 22 cannot correctly interpret signals from the equipment 12 , connection device 16 will convert the signals between equipment 12 and second computer 22 (Block 122 ), then it will connect first computer 22 to equipment 12 (Block 124 ). After first computer 22 and equipment 12 are connected, communication can proceed (Block 126 ). It is explicitly understood that for some connections, such as null connections, drivers may not be necessary, but that for other connections, such as USB connections, drivers will be required. This type of connection will require that equipment 12 be recognized by first computer 22 . If equipment transmits identification information that matches known equipment (Block 128 ), then first computer 22 will automatically install an appropriate driver for equipment 12 (Block 130 ), and then the user may operate the equipment 12 (Block 134 ). If equipment transmits identification information that does not match known equipment (Block 128 ), then first computer 22 will require the user to manually install an appropriate driver for equipment 12 (Block 132 ), and then the user may operate the equipment 12 (Block 134 ).
[0038] FIG. 7 illustrates the physical incompatibility of several types of serial devices 140 which can be connected to connection device 16 . One of the innovative features of connection device 16 is the ability to connect to several devices with physically incompatible standards. In this example, a DB-25 25 pin serial connection 142 , a DE-9 (RS-232C) connection 144 , and USB connection 146 are shown. Each of these serial devices shown is both electrically and physically incompatible, and therefore requires an intermediate device to allow for interoperability between devices.
[0039] The connection device 16 described above may be implemented on any general-purpose computer with sufficient processing power, memory resources, and network throughput capability to handle the necessary workload placed upon it. FIG. 8 illustrates a typical, general-purpose computer system suitable for implementing one or more embodiments disclosed herein. The computer system 150 includes a processor 162 (which may be referred to as a central processor unit or CPU) that is in communication with memory devices including secondary storage 154 , read only memory (“ROM”) 156 , random access memory (“RAM”) 158 , input/output (“I/O”) devices 160 , and network connectivity devices 152 . The processor may be implemented as one or more CPU chips.
[0040] The secondary storage 154 is typically comprised of one or more disk drives or tape drives and is used for non-volatile storage of data and as an over-flow data storage device if RAM 158 is not large enough to hold all working data. Secondary storage 154 may be used to store programs which are loaded into RAM 158 when such programs are selected for execution. The ROM 156 is used to store instructions and perhaps data which are read during program execution. ROM 156 is a non-volatile memory device which typically has a small memory capacity relative to the larger memory capacity of secondary storage. The RAM 158 is used to store volatile data and perhaps to store instructions. Access to both ROM 156 and RAM 158 is typically faster than to secondary storage 154 .
[0041] I/O devices 160 may include printers, video monitors, LCDs, touch screen displays, keyboards, keypads, switches, dials, mice, track balls, voice recognizers, card readers, paper tape readers, or other well-known input devices. The network connectivity devices 152 may take the form of modems, modem banks, ethernet cards, USB interface cards, parallel interfaces, serial interfaces, token ring cards, fiber distributed data interface (“FDDI”) cards, WLAN cards, radio transceiver cards such as code division multiple access (“CDMA”) and/or GSM radio transceiver cards, and other well-known network devices. These network connectivity devices 152 may enable the processor 162 to communicate with an Internet or one or more intranets. With such a network connection, it is contemplated that the processor 162 might receive information from the network, or might output information to the network in the course of performing the above-described method steps. Such information, which is often represented as a sequence of instructions to be executed using processor 162 , may be received from and outputted to the network, for example, in the form of a computer data signal embodied in a carrier wave.
[0042] Such information, which may include data or instructions to be executed using processor 162 for example, may be received from and outputted to the network, for example, in the form of a computer data baseband signal or signal embodied in a carrier wave. The baseband signal or signal embodied in the carrier wave generated by the network connectivity devices 152 may propagate in or on the surface of electrical conductors, in coaxial cables, in waveguides, in optical media, for example optical fiber, or in the air or free space. The information contained in the baseband signal or signal embedded in the carrier wave may be ordered according to different sequences, as may be desirable for either processing or generating the information or transmitting or receiving the information. The baseband signal or signal embedded in the carrier wave, or other types of signals currently used or hereafter developed, referred to herein as the transmission medium, may be generated according to several methods well known to one skilled in the art.
[0043] The processor 162 executes instructions, codes, computer programs, and scripts which it accesses from hard disk, floppy disk, optical disk (these various disk based systems may all be considered secondary storage 154 ), ROM 156 , RAM 158 , or the network connectivity devices 152 .
[0044] While several embodiments have been provided in the present disclosure, it should be understood that the disclosed systems and methods may be embodied in many other specific forms without departing from the spirit or scope of the present disclosure. The present examples are to be considered as illustrative and not restrictive, and the intention is not to be limited to the details given herein. For example, the various elements or components may be combined or integrated in another system or certain features may be omitted, or not implemented.
[0045] Also, techniques, systems, subsystems and methods described and illustrated in the various embodiments as discrete or separate may be combined or integrated with other systems, modules, techniques, or methods without departing from the scope of the present disclosure. Other items shown or discussed as directly coupled or communicating with each other may be coupled through some interface or device, such that the items may no longer be considered directly coupled to each other but may still be indirectly coupled and in communication, whether electrically, mechanically, or otherwise with one another. Other examples of changes, substitutions, and alterations are ascertainable by one skilled in the art and could be made without departing from the spirit and scope disclosed herein.
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A wellbore servicing computing network, comprising a first component with a first interface coupled to a connection device, and a second component with a second interface coupled to the connection device; wherein the first component is capable of communication with the second component through the connection device, and wherein the first interface and the second interface are dissimilar; and wherein the first component is oilfield equipment and the second component is a computer. A network for conducting well treatment or well servicing operations, comprising a first node with a first communications interface coupled to a connection device, and a second node with a second communications interface coupled to the connection device, wherein the first node and second node are in communication with each other through the connection device, wherein the first communications interface and second communications interface are dissimilar, and wherein at least one node is coupled to well treating or well servicing equipment capable of assembling at a wellsite to perform a well treatment or well servicing operation.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This is the first application for this invention.
FIELD OF THE INVENTION
[0002] The present invention relates generally to wireless networks. More particularly, the present invention relates to a method and system of managing wireless resources between different services.
BACKGROUND OF THE INVENTION
[0003] In the CDMA 1xRTT system, the forward radio resources, which include Walsh Code (WC) and Power, are shared by Voice channels and Data channels. Further more, there are two sub-types of data channels, namely Fundamental Channels (FCH) and Supplemental Channels (SCH).
[0004] Data calls or sessions can be divided into those which have a real-time packet transmission requirement, and those which do not. For example, a voice call requires real-time transmission in order to maintain the interactive nature of a conversation, whereas a file download or email message does not. Call types with a real-time requirement include Push-to-Talk (PTT) sessions and Voice over IP (VoIP) telephone calls. Note that real-time actually implies near real-time; and should be understood to require transmission without noticeable delay. Due to the nature of conversations, and the way speech is packetized, the packets do not actually need to be transmitted instantaneously as long as the speech is received at the far end without any noticeable delay.
[0005] Many data sessions without a real-time requirement desire higher bandwidth than is required for a typical VoIP call, but can withstand noticeable delays between the transmission of packets, and still be successfully received. Typically such transmissions are called bursty in nature, as they typically receive a series of packets in bursts, with gaps or delays between each burst. A file transfer is one example. There is no real-time requirement, as the receiving application can simply wait out any delays in transmission, but the bandwidth requirement is higher than a typical voice call, as there is more data that needs transmission than is required by a VoIP call. Every data call or session requires a data FCH, and those data calls or sessions which do not have a real time requirement, but which require higher bandwidth than can be provided by an FCH call, require one or more SCH bursts as required. The former defines the number of data users in a sector while the later provides additional data throughput per user.
[0006] One problem with this division of channels is that the demand for resources for data calls is inherently variable. Some services will require large data transfers. This can take a substantial amount of resources over a short period of time, or it can take a smaller amount of resources spread over a longer duration. It is desirable to allow variable transfer rates, in order to maximize resource utilization. If there is heavy demand for resources during some periods of time, and less in others, it is desirable to provide significant bandwidth to a file transfer during non-busy periods, in order to free up resources during busier periods. This will obviously reduce waiting time for users who perform data transfers during less busy periods. In order to ensure sufficient bandwidth for data transfers, conventional network design reserves a minimum amount of resources for the SCH.
[0007] However, a problem with permitting variable transfer rates is that data transfers, once commenced, can utilize a significant share of resources. This can lead to insufficient resources available to new requests for services once such a transfer commences, leading to blocked calls.
[0008] In order to provide minimum service levels, resources are typically partitioned by a base station resource manager in order to ensure a minimum level of service is available to all 3 types of channels (namely the voice FCH channels (VCs), the data FCHs and data SCHs).
[0009] This typically implies that there is an upper limit to the amount of resources (i.e., WC and power) used by each of the VC's, FCHs and SCHs. In other words the resources are partitioned between the VC's, FCHs and SCHs. While this tends to satisfy the requirement of ensuring minimum service levels for each set of channels, and also tends to allow data transfers while still allowing a specified minimum number of data calls, this often does not lead to the maximal use of resources. Furthermore, if the resources for each Channel type are fully utilized, any new request for service that requires such a channel will be blocked. This can happen even if there are substantial unused resources being reserved by the other channel types.
[0010] It is difficult to solve this problem without favoring one service (i.e., channel type) over another. For example, one approach, as will be discussed below with reference to FIG. 1 , favors SCH throughput at the expense of number of data users (FCH).
[0011] Thus, there is a need for a better system of managing resources to avoid unnecessary call blocking, while providing for minimum levels of service.
SUMMARY OF THE INVENTION
[0012] The invention provides for the management of wireless resources, which can reduce call blocking by allowing high priority services, under suitable conditions, to use resources allocated to low priority services. Thus high priority services can pre-empt the usage of wireless resources by low priority services. This has the advantage of reducing call blocking for high priority calls, while permitting low priority calls to have more access to radio resources than conventional systems with the same call blocking rate.
[0013] Thus, a broad aspect of the invention provides a method of allocating wireless resources at a base station comprising: Comparing resource usage with available resources to determine whether sufficient resources are available for an incoming high priority service; and If insufficient resources are available for said incoming service, pre-empting a low priority service in order to make sufficient resources available.
[0014] An example of a typical high priority service is a data call with a real-time requirement, or is delay sensitive. An example of a typical low priority service is a data call without a real-time requirement or a non delay sensitive service. However the operator of the base station may wish to configure their network in order to be able to specify what is a high priority versus low priority call or service. For example a file transfer is typically non delay sensitive. However an operator may wish to classify a particular file transfer as a high priority service, for example if it is for a client who has negotiated a high quality of service, or in the case of an emergency transmission.
[0015] One embodiment of the invention implements a preemption mechanism that would allow a base station (BTS) to reclaim Walsh Code and Forward Power resources from an active SCH burst in order to accommodate incoming FCH requests. Unlike a hard partition, such a system is adaptive, allowing for the re-allocation of resources within a “soft” partition space, based on demand at that period of time. It is preferable to reserve a minimum level of resources as a “head room”, for high priority data calls (e.g., VOIP, PTT, etc.).
[0016] Advantageously, such a system provides the operator with the ability to allow tradeoff between maximization of the number of data users per sector and per sector throughput. This capability is particularly important for support of Push to Talk (PTT) or VoIP which typically require data FCH.
[0017] According to an aspect of the invention, the BTS can manage the availability of WC and Forward Power resources for FCH requests by configurable resource partitioning and reservation. Such a system implements a preemption mechanism at the BTS that preempts SCH bursts to ensure that incoming FCH requests have necessary WC and Forward Power resources available as long as the FCH usage has not exceeded an upper limit. Said upper limit may be predefined—but it can be configurable.
[0018] According to one embodiment of the invention, once the system receives an FCH request (which can be a request for a new call, or for a hand-off), the system will grant the request provide sufficient FCH resources are available. Advantageously, if sufficient FCH resources are not currently available, the system will determine if one or more SCH bursts can be pre-empted in order to provide the needed resources to satisfy the FCH request. If so, one or more SCH calls are pre-empted. According to one embodiment of the invention, a pre-emption request results in an SCH burst being dropped. An alternative embodiment does not drop an SCH call if the needed resources can be provided by decreasing the bandwidth available to one or more SCH sessions.
[0019] According to an embodiment, once a pre-emption request is made, the system evaluates a service metric for each SCH session to determine which SCH session(s) is pre-empted. This Service metric typically includes the Quality of Service provided to the user, but can also factor any latency requirements, the relative size of the SCH transmissions, and the relative completeness of such transmissions.
[0020] According to an aspect of the invention there is provided a base station comprising: a. means for receiving a request for a data session; b. means for comparing resource usage with available resources to determine whether sufficient resources are available; c. means for allocating the resources if available to satisfy said request; and d. If insufficient resources are available for said call, means for determining whether sufficient resources can be made available by pre-empting a session without a real-time requirement, and means for pre-empting such a session in order to make the resources available to satisfy said request.
[0021] According to a further aspect of the invention there is provided a method of allocating resources between delay sensitive services and non delay sensitive services, comprising: a. Establishing a first threshold for said delay sensitive services and a second threshold for said non delay sensitive services; b. Allocating resources to each service on an as requested basis provided neither threshold is reached; c. If said second threshold is reached and there is additional demand for said non delay sensitive services and said first threshold is not reached, then allocating resources to said non delay sensitive services beyond said second threshold; and d. If resources are allocated to said non delay sensitive services beyond said second threshold, and said first threshold is not reached and there is demand for said first service for which there are insufficient resources available, then allocating resources to said delay sensitive services by pre-empting resources from said non delay sensitive services.
[0022] A further aspect of the invention provides a computer-readable storage medium comprising a program element for execution by a processor within a base station, the program element comprising computer-readable program code for comparing resource usage with available resources to determine whether sufficient resources are available for an incoming high priority service, and if insufficient resources are available for said incoming service, pre-empting a low priority service in order to make sufficient resources available.
[0023] Other aspects and features of the present invention will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] Embodiments of the present invention will now be described, by way of example only, with reference to the attached Figures, wherein:
[0025] FIG. 1 is a schematic drawing illustrating a problem with prior art systems.
[0026] FIG. 2 is a schematic drawing illustrating better performance according to an embodiment of the invention.
[0027] FIG. 3 is a flowchart illustrating a portion of the process carried out by an embodiment of the invention.
[0028] FIG. 4 is a flowchart illustrating a further portion of the process carried out by an embodiment of the invention.
[0029] FIG. 5 is a flowchart illustrating a further portion of the process carried out by an embodiment of the invention.
[0030] FIG. 6 is a flowchart illustrating a further portion of the process carried out by an embodiment of the invention.
[0031] FIG. 7 is a flowchart illustrating a further portion of the process carried out by an embodiment of the invention.
[0032] FIG. 8 is a flowchart illustrating a further portion of the process carried out by an embodiment of the invention.
DETAILED DESCRIPTION
[0033] We will discuss preferred embodiments of the invention with reference to CDMA 1xRTT systems whose primary radio resources include Walsh Code (WC) and Power, and which utilize VC's, FCHs and SCHs. However, it should be appreciated that the invention is applicable to other types of systems which allocate resources to different services.
[0034] The forward radio resources, i.e. Walsh Code (WC) and Power, used by Voice and Data calls are partitioned by a Radio Resource Manager (RRM) at the BTS. A conventional RRM algorithm utilizes the following 3 user-configurable parameters to partition WC and Forward Power between voice and data calls.
1. MaxVoiceResources—defines the upper limit for the resources available for Voice calls as a % of the total resources. 2. MaxDataResources—defines the upper limit for the resources available for Data calls as a % of the total resources. 3. MaxDataFCHResources—defines the upper limit for the resources available for Data Fundamental Channels (FCH) as a % of total Data resources (MaxDataResources).
These parameters allow the operator to limit the FCH usage (by setting MaxDataFCHResources appropriately) and thereby reserving the remaining data resources, (MaxDataResources−MaxDataFCHResources), for SCH usage. While the FCH usage is limited, the SCH usage is not. As third generation cellular systems were being designed to include VC's, FCHs and SCHs, voice calls were predominantly circuit switched (and therefore used VC's) and data calls were typically bursty in nature. Therefore, it was envisioned that most calls would either require VC's or SCH's. This led to network design which was biased to reserve minimal resources for SCH's, but not FCH's Thus this implementation favors throughput (SCH )at the expense of the number of data users (FCH).
[0038] As a result, traffic with heavy SCH load could consume most of the data resources and allow very little resource for FCH usage. This would lead to FCH requests being blocked due to lack of data resources as a result of SCH monopoly, even though FCH usage has not reached its upper limit. FIG. 1 illustrates this scenario.
[0039] FIG. 1 shows the partition of data resources between FCH and SCH (but not the VC's which will also have a reserved allocation of resources). In this figure, the box 10 represents the total data resources available, as defined by MaxDataResources 20 . MaxDataFCHResources 50 defines the upper limit of resources available to FCH. Utilization of resources by SCHs is illustrated from the top down by the thin line 30 . In other words points on line 30 illustrate the resources used by the SCHs, with points at the top of the figure representing zero utilization, and resource utilization by the SCH's increases as the line 30 moves away from the top of the figure. Thus the arrow at the far right of the FIG. 35 illustrates the resources guaranteed for SCH extends from the top of the figure to point 40 , which corresponds to MaxDataFCHResources 50 . The arrow extends downwards below point 40 , but resources below this point are not reserved for SCH, and are thus available on a first-come, first served basis.
[0040] Utilization of resources by FCHs is illustrated from the bottom up by the thick line 55 . In other words points on line 55 illustrate the resources used by the FCHs, with points at the bottom of the figure representing zero utilization, and resource utilization by the FCH's increases as line 55 moves away from the bottom of the figure.
[0041] Thus, the system is at full utilization of the data resources at points where the SCH resource line 30 meets the FCH line 55 .
[0042] As shown in the figure by the arrow 60 at the left, the data resources for FCH are not guaranteed to the FCH, but are available on a first-come-first-served basis between FCH users and SCH users.
[0043] Between points A and B, all new data calls are blocked due to full utilization. This is referred to as SCH monopoly, as the SCH is utilizing the majority of the data resources. This can be seen as line 30 descends far below the demarcation line 40 . This is considered to block FCH calls, as data resources available to FCHs are used by the SCH.
[0044] At point B, as SCH usage goes down, data resources become available and FCH requests are granted. At point C, FCH gets blocked due to FCH usage reaching its upper limit. The current implementation does not provide any guarantee on the availability of WC and forward power for FCH and hence new FCH requests could be denied even when the FCH usage is very low. With the increasing use of critical applications, like PTT and VoIP, that require FCH only, operators have a need to be able to maximize the number of FCH data calls by guaranteeing the partitioned FCH WC and forward power resources for FCH usage.
[0045] However, as discussed above, making MaxDataFCHResources a hard partition is not a satisfactory solution, as this will be often result in under-utilizing resources. This can be seen in FIG. 1 , where all points left of A, or to the right of B (except at point C) would have unused resources (which could have been used by the SCH) if MaxDataFCHResources was a hard partition.
[0046] Hence it is an objective of our solution to make MaxDataFCHResources available to FCH when needed by FCH users, but make unused resources available to SCH until they are needed by FCH.
[0047] According to a preferred embodiment of the invention, this is accomplished by allowing SCH to use resources below the MaxDataFCHResources point when needed by the SCH, but will pre-empt the use of SCH resources below MaxDataFCHResources when they are needed by FCH. This is illustrated in FIG. 2 . In FIG. 2 , SCH is allowed to use all of the resources it needs, until point A as FCH does not require the resources used by SCH. Between points A and C, full resource utilization is achieved. Between points A and B, FCH has not used all of its guaranteed resources, but some of those resources are used by SCH. Therefore, some portion of resources used by SCH are pre-empted in order to make the guaranteed resources available to FCH. As FCH's demand for resources increases, more SCH resources are pre-empted until point B is reached. After point B, pre-emption of SCH resources stops. Between points B and C, all new data calls are blocked, as both FCH and SCH have used all of their guaranteed resources
[0048] Preferably the system reserves some amount of resources to handle FCH requests, in order to ensure new FCH call requests are not blocked when SCH uses resources that are supposed to be reserved for FCH. We refer to these resources as “head room” resources. Thus, in the example shown in FIG. 2 , the system reserves “head room” at least between points A and B, in order to allow pre-emption. According to one embodiment, this can be implemented as follows. FCHHeadRoomResources is introduced as a BTS sector attribute to provide headroom resources (Walsh code and Power) to prevent blocking of FCH when its usage is less than MaxDataFCHResources. FCHHeadRoomResources Contains Two Parameters:
1. FCHHeadRoomPower: Power reserved for not blocking FCH (in unit of percentage of MaxPower). 2. FCHHeadRoomWalshCodes: Number of Walsh Codes with length of 128 reserved for not blocking FCH
[0051] Both the Walsh code and power head rooms should be adaptively changed based on the usage of FCH. For example, the required head room reserved for FCH will be decreased as the FCH resources usage approaches MaxFCHResources. If FCH resources usage reaches MaxFCHResources, for example, between points B and C in FIG. 2 , the BTS does not need to reserve head room for FCH. The required FCHHeadroomResources can be calculated based on the following formulas:
RequiredFCHHeadroomResources=min(CurrentAvailableFCHResources, FCHHeadRoomResources) 1.
CurrentAvailableFCHResources=MaxFCHResources−CurrentFCHResourcesUsage 2.
[0052] FIG. 3 is a flow chart illustrating a F-SCH Data call process executed by a base station controller, according to an embodiment of the invention. For an Incoming or Queued SCH request 100 , the system first compares FCH and SCH usage with the Maximum data resources which can be allocated (i.e., MaxDataResources less headroom) 110 . This step determines whether there are sufficient data resources for the incoming request.
[0053] Next step is to check total resources, including the voice channel. (Voice+FCH+SCH Usage)<MaxResources−RequiredFCHHeadRoomResources) 120 . This is used in systems that allow the voice channels to encroach on the Data channel resources in order to ensure a voice call is not dropped. In other words two conditions must be met before an incoming SCH request. Namely the system checks that the allocated data resources do not exceed the maximum data resources, and the total resources (including voice) do not exceed the maximum system resources.
[0054] Assuming both conditions are met, this implies there are sufficient resources available to satisfy the incoming request, so the appropriate resources are allocated to the incoming SCH request in the conventional manner 130 .
[0055] If either condition is not met, than traditionally the incoming request would be blocked. However, we have recognized that blocking requests is not satisfactory, especially if there is a way to provide service to all users in the area (or to provide an appropriate minimum level of service to users in the area, depending on their requirements and level of service agreements). Thus, according to this embodiment of the invention, the system determines if there is room in the Queue buffer 140 . If the Queue Buffer is full, then the incoming request is blocked 170 . However, if there is room in the-Queue, the new SCH request is placed in the Queue 150 , and a preemption request is executed 160 , which will be discussed below with reference to FIG. 6 .
[0056] We now discuss the FCH data call process illustrated in FIG. 4 , according to an embodiment of the invention. For an incoming or queued FCH request 200 , the BTS first compares the FCH usage with a MaxFCHResources threshold 210 to determine whether any new FCH can be allocated. MaxFCHResources is a configurable threshold managed by the BTS to ensure that a minimum desired level of resources is left available to the Supplemental Channel. If no such minimum is required, than this step can be omitted (or the threshold is set to the MaxdataResources threshold, or preferably, in order to reserve a minimum head room, it is set to MaxdataResources−RequiredFCHHeadRoomResources).
[0057] If there is insufficient resources, then the FCH request is blocked 205 , and the process will then proceed to pre-empt an SCH if necessasary to ensure that sufficient headroom is maintained, as shown in FIG. 8 .
[0058] Assuming the MaxFCHResources has not been exceeded, then the system checks whether there are sufficient resources to allocate the FCH. First, the system checks whether the Data usage exceeds the Maximum available Data resources 220 . Then it checks to see if the total usage (Data+Voice) exceeds the Maximum available Total resources (Data+Voice) 230 . If there are sufficient resources, then the FCH is allocated in the conventional manner 240 .
[0059] Once again, if either check fails, then FCH would typically be blocked in conventional systems.
[0060] Our system does not automatically block the FCH. Rather, it determines whether it is possible to allocate some resources from the SCH in order to allow the FCH request. To do this the system determines whether real time traffic (i.e. voice+FCH Resource Usage) already exceeds the MaxResources 250 . If yes, then there is insufficient resources that can be allocated to the FCH request, so the FCH is blocked 205 . As an alternative to 250 (not shown), it could check whether SCH usage has exceeded a threshold (MaxSCHResources).
[0061] Otherwise, the new FCH request is Queued 260 and an SCH Pre-emption request 270 occurs
[0062] FIG. 5 is a flowchart illustrating a SCH Preemption process based on a Power Usage check based on current power usage, according to an embodiment of the invention. This is optional, but preferred, as all new calls would be blocked if power resources are fully utilized. According to a preferred embodiment, rather than blocking all new calls in response to a maximum power check, an active SCH is pre-empted (if possible) in order to free up power resources. In the implementation shown, the total power used on each sector is estimated every two seconds. However, for some applications, e.g., Push to Talk (PTT), a large number of FCH data calls may be required to be established within the 2 seconds. Consequently, to avoid the total sector power exceeding its maximum power when allocating F-FCH and F-SCH this power check can additionally occur in response to each new request. The power usage during call set up is difficult to measure, but it can be estimated. The initial power during an FCH call set up can be estimated based on the average value of the power used by the current active FCH calls.
[0063] The initial power during an SCH call set up can be estimated based on a table look up based on its FCH power and data rate.
[0064] FIG. 6 illustrates process for responding to a pre-emption request, according to an embodiment of the invention. The pre-emption request 400 can originate from a new call -or hand off request (e.g., from FIGS. 3 or 4 ) or from a power check (e.g., FIG. 5 ). As shown, the system first determines if it can actually pre-empt to satisfy pre-emption request, and if so how to select which data SCH or data SCHes are pre-empted. The candidate for preemption shall be selected as a data SCH that passes a minimum active time (MinActive_Time) check 410 and belongs to the user with the least QOSPI (Quality of Service Priority Indicator) 440 .
[0065] If multiple users have the least QOSPI value with their data bursts having passed the minimum active time, the longest active burst among those users will be selected as the candidate for preemption 430 . Other tie-breaking criteria can be used, including the size, duration and completeness of an SCH transmission, or its subscriber priority if applicable.
[0066] Alternatively the system can select the longest active SCH as the candidate for preemption, irrespective of the QOSPI
[0067] The first step in this process is to determine whether there are any data SCHes past MinActive_Time 410 . This check is preferably made to ensure when a data SCH is assigned to a user, it should be used at least for a configurable duration of time before it is released. This is done to prevent wasting the signaling efforts of setting up the data SCH and also to avoid the “ping-pong” effect of repeatedly setting up/tearing down the data SCH.
[0068] FIG. 7 illustrates a conventional process for handling voice channels, with the exception that the system then proceeds to check whether sufficient headroom exists, as shown in FIG. 8 .
[0069] FIG. 8 illustrates a process, according to an embodiment of the invention, to ensure sufficient head room is reserved. If sufficient head room resources are maintained, than nothing happens. However, if there are insufficient head room resources, than a pre-emption request is made.
[0070] As should be apparent to a person skilled in the art, the above described processes are typically implemented by a Radio Resource Manager (RRM) of the Base Station. This is typically implemented in software executed on a processor in the base station.
[0071] Those skilled in the art will appreciate that in some embodiments, certain functionality may be implemented as pre-programmed hardware or firmware elements (e.g., application specific integrated circuits (ASICs), electrically erasable programmable read-only memories (EEPROMs), etc.), or other related components. In other embodiments, the system or sub-systems may comprise an arithmetic and logic unit (ALU) having access to a code memory (not shown) which stores program instructions for the operation of the ALU in order to implement the functional entities and execute the various processes and functions described above. The program instructions could be stored on a medium which is fixed, tangible and readable directly (e.g., flash memory, CD-ROM, ROM, or fixed disk), or the program instructions could be stored remotely but transmittable to the base station, for example via its backhaul network.
[0072] Note that the embodiments described herein assume that the voice resources are guaranteed, and they are therefore not allowed to be used, even if they are underutilized and the data resources are fully utilized. However, unused voice resources can also be “borrowed” in a similar manner. For example, rather than blocking a data call, unused voice resources can be allocated to a data call request. However, assuming voice calls have a higher priority, data calls can be pre-empted to satisfy subsequent voice calls, if necessary, in a similar manner.
[0073] The above-described embodiments of the present invention are intended to be examples only. Alterations, modifications and variations may be effected to the particular embodiments by those of skill in the art without departing from the scope of the invention, which is defined solely by the claims appended hereto.
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The invention provides for the management of wireless resources, which can reduce call blocking by allowing high priority services, under suitable conditions, to use resources allocated to low priority services. Thus high priority services can pre-empt the usage of wireless resources by low priority services. This has the advantage of reducing call blocking for high priority calls, while permitting low priority calls to have more access to radio resources than conventional systems with the same call blocking rate. Thus a base station can implement a preemption mechanism that would reclaim Walsh Code and Forward Power resources from an active Supplemental Channel (SCH) burst in order to accommodate incoming Fundamental Channel (FCH) requests.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention concerns a torque coupling unit in general. More specifically it relates to an improved heavy duty torque coupling that includes a dynamic torque measuring instrument.
2. Description of the Prior Art
Heretofore, the applicant has invented a torque meter which invention has been covered by his U.S. Pat. No. 3,295,367 issued January 3rd, 1967. Thereafter, the applicant has developed a structure for making use of the principles of a sensitive torque meter in accordance with his earlier patent, in a torque coupling structure according to his U.S. Pat. No. 3,599,482 which issued Aug. 17, 1971. Thereafter, the applicant also developed a heavy duty torque coupling which has been described and claimed in U.S. Pat. No. 3,823,607 issued July 16, 1974. The applicant's invention according to this application makes use of a torque meter structure which is in accordance with the torque meter described and claimed in the earlier indicated patents, and in addition this invention provides for an improvement that permits a direct longitudinal torque coupling that has the capability of including an alternative lateral torque coupling structure. The latter may be employed in emergency situations in order to include a torque meter coupling when a chain drive is put into use, on a rotary drilling rig.
Consequently, it is an object of this invention to provide an improved heavy-duty torque coupling, that includes the ability to make both a direct longitudinal drive coupling and an alternative lateral drive coupling.
SUMMARY OF THE INVENTION
Briefly, the invention concerns a heavy-duty dynamic high-torque-measuring coupling unit for transmitting a torque load. It comprises in combination a shaft for transmitting said torque load and having an output end and an input end. It also comprises means for making a direct longitudinal torque coupling at the input end of said shaft, and means for dynamically measuring the relative angular displacement between the input end of said shaft and a predetermined location spaced along said shaft between said input and said output ends thereof. It also comprises alternative means for making a lateral input torque coupling at said input end of said shaft.
Again briefly, the invention concerns a heavyduty dynamic high-torque-measuring coupling unit for transmitting torque load. It comprises in combination a shaft for transmitting said torque load and having an output end and an input end. It also comprises flange means integrally attached to said shaft at said input end for making a direct longitudinal torque coupling, and means for dynamically measuring the relative angular displacement between said input end of said shaft and a predetermined location spaced along said shaft between said input and said output end thereof. The dynamic measuring means comprises a dynamic torque meter having a pair of rotors and stators, and a plurality of spokes for attaching a first of said rotors to said shaft at said predetermined location. The coupling unit also comprises alternative means for making a lateral input torque coupling at said input end of said shaft. The alternative means comprises a coaxial sleeve surrounding said shaft, and a pair of chain sprockets securely attached to said sleeve. The alternative means also comprises welding means for securely attaching said sleeve to said shaft at said input end thereof. The said dynamic measuring means also comprises means for attaching a second of said rotors to said sleeve on the opposite side of said first rotor from said pair of chain sprockets, and unitary means for supporting said stators adjacent to one another, as well as a corresponding plurality of slots in said sleeve for permitting said spokes to pass therethrough with freedom for maximum relative angular displacement. The coupling unit also comprises a housing for protecting said chain sprockets and includes an opening for access to said sprockets for making said lateral alternative input torque coupling.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects and benefits of the invention will be more fully set forth below in connection with the best mode contemplated by the inventor of carrying out the invention, and in connection with which there are illustrations provided in the drawings, wherein:
FIG. 1 is a perspective, illustrating a torque unit according to the invention as mounted in place on the input drive of a rotary-well type of rotary unit, commonly known as a rotary table, and
FIG. 2 is an enlarged side elevation, partly broken away in cross-section, illustrating the details of a coupling unit according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As indicated above, this invention is concerned with a high-torque-measuring coupling unit and such a unit is particularly applicable to use in connection with rotary drilling for oil wells or the like. Consequently, FIG. 1 illustrates a unit 11 according to the invention, mounted in driving relationship on the input of an oil-well type rotary table 12. Such a rotary table may take various forms which are supplied by various oil-well equipment manufacturers. The table 12 is mounted (when in use) at the top of a bore hole (not shown) which is being drilled in the earth, either on a land based rig or over water.
The rotary table 12 supports a so-called rotary 15 which provides for accomodating clamping structures (not shown) that support a drill string (not shown) or other elements that are employed in drilling a rotary type well. Such a rotary 15 and rotary table 12 are part of a well known type of equipment that is employed during the drilling of a rotary type well (usually for oil or gas).
The rotary 15 is driven in rotation by a transmission arrangement (not shown) located within the table 12. Such transmission includes a gear train (not shown) to which a bevel gear 17 (FIG. 2) is coupled. Thus, the output of the coupling unit 11 is coupled with the transmission (not shown) of the rotary table 12 for driving the rotary 15 in rotation. It may be noted that the bevel gear 17 is mounted on the output end of a shaft 20 of the unit 11.
As indicated above, the unit 11 is a dynamic high-torque-measuring coupling unit. Its function is to make a torque measurement, in a dynamic manner while transmitting a torque load from an engine (not shown) to the transmission elements (not shown) of the rotary table 12. The shaft 20 is for transmitting this torque load. It has an output end 21 to which the bevel gear 17 is attached, and an input end 22. Fixed to end 22 by welding as indicated by reference numeral 24, or other appropriate means, there is a coaxial sleeve 25 that has a flange 26 securely fastened to it. Flange 26 is also welded as indicated by reference numeral 27, or otherwise firmly attached to the outer end of the sleeve 25. It will be understood that the flange 26 may have bolt holes (not shown), or some other conventional arrangement (not shown) for coupling the rotational driving force, i.e. input of torque, to the shaft 20 at the input end 22 from a direct longitudinally coupled source (not shown).
In a similar manner as with my earlier dynamic torque measuring units, there is provided the means for dynamically measuring the relative angular displacements between the input end 22 of the shaft 20, and a location 29 on the shaft 20. This location 29 is spaced a predetermined distance from the input end 22 of the shaft 20.
The dynamic torque meter has been fully described in my above noted three U.S. Patents and consequently, it will be sufficient to note here the structural locations of the rotor and stator elements, which locations are part of this invention. It will be understood that the torque meter measures the amount of twist between two locations along the shaft 20 in a dynamic manner as it transmits the load. There are a pair of rotors 32 and 33 which cooperate with a corresponding pair of stators 35 and 36 respectively. The rotor 32 is mounted on the shaft 20 at the location 29 by means of a plurality of spokes 40 that are securely fastened into the surface of the shaft 20. These spokes 40 support the rotor 32 so as to maintain angular correspondence with the shaft 20 at the location 29.
However, the spokes 40 extend through the sleeve 25, and it has a corresponding plurality of slots 41 therein. It will be appreciated that these slots 41 extend circumferentially far enough to permit adequate freedom of movement for maximum torque that will be applied to the shaft 20.
The rotor 33 is integrally attached to the sleeve 25 for rotation therewith at all times. This rotor 33 is located near the other rotor 32 so that a compact arrangement is provided. The stators 35 and 36 are located adjacent to one another and are supported by a unitary double bracket arrangement 44.
Attached at the inner end of the sleeve 25, there is a pair of sprockets 47 that are fastened onto a short flange 48 at the end of the sleeve 25. Such fastening may be done in any feasible manner such as by means of bolts 51, as indicated.
There is, of course, a bearing 52 that surrounds the shaft 20 and is for supporting the sleeve 25 at the inner end thereof. This permits free, low friction rotation of the shaft 20 relative to the sleeve 25.
It will be observed that the sprockets 47 are provided in order to act as an alternative means for coupling an input torque in a lateral manner to the unit 11. Such lateral drive may be applied via a chain or chains (not shown) which would be applied around the teeth of the sprockets 47.
There is a housing 55 that is for protecting the sprockets 47. It includes an opening 56 to provide access for the chain or chains (not shown) that would be applied around the sprockets 47 whenever the alternative driving input into the unit 11 is being used. It will be appreciated that the opening 56 may have a closure plate 58 if desired. This is indicated in FIG. 2 by dashed lines. It would be applied for keeping out foreign matter when the chain drive connection is not in use.
The housing 55 may be mounted for its support in any feasible manner. For example, there is a reduced diameter end or hub 62 that is adapted for fitting into a support (not shown) extending from the side of the rotary table 12. Attachment of the housing 55 is made by bolts (not shown) which pass through bolt holes 61 located around the edge of the housing 55 outside of the hub 62.
The hub 62 holds a pair of bearings 64 that support the drive shaft 20 near its output end 21. A band 63 around the hub 62, is illustrated. It merely acts to protect a lubrication passage 65 that is associated with the bearings 64.
The other end of the housing 55 holds a bearing 66 that supports the sleeve 25 and permits low friction rotation of the sleeve therein.
OPERATION
The principles of operation of this invention encompass those which relate to my above mentioned U.S. Pat. No. 3,823,607. However, that invention did not provide for or suggest the combination that comprises a longitudinal direct drive for the torque coupling along with an alternative coupling for a lateral drive.
In operation, the input drive (longitudinal torque coupling) may be attached to the flange 26. In such case the torque load is transmitted via the input end 22 of the shaft 20 and along the shaft 20 to the output end 21 that has the bevel gear 17 attached thereto. This is usually the primary mode for transmitting the load. In this mode the dynamic torque measurement is continually determined by the relative angular displacements caused by twisting of the shaft 20, between its input end 22 and the location 29 spaced along the shaft.
The rotor 32 of the torque meter rotates with the shaft 20, at the location 29, at all times. However, the other rotor 33 of the torque meter rotates with the input end 22, since the sleeve 25 has no torque load applied to it. Consequently, the phase difference of the two AC generator signals is in accordance with the twist in the shaft 20 measured between the end 22 and the location 29.
When the alternative input drive is employed, there will be a chain (not shown) applied around the twin sprocket 47 and the torque drive will then be applied to the inner end of the sleeve 25. The drive coupling then goes from the sprocket 47 via the flange 48 and along the sleeve 25 to the input end 22 of the shaft 20. Then the driving torque is transmitted along the shaft 20 as before, to the output end 21 thereof. However, in this case, the relative angular displacement of the rotors 33 and 32 will be measuring the twist of the sleeve 25 between the location of the rotor 33 and the input end 22 of the shaft 20, in addition to the twist of the shaft 20 from input end 22 to the location 29. But, in order to avoid a substantial change in the response of the torque meter, the sleeve 25 will be constructed of a sufficiently heavy gauge material to minimize twisting action in the sleeve. Furthermore, since the deflection because of the torque applied to the sleeve 25 is proportional to a fraction of 1 divided by the diameter to the fourth power, the deflection may be made relatively small. It would be expected to be less than 10 percent additional deflection. Consequently, the difference between employing the alternative chain drive input, and the direct longitudinal drive input (via flange 26), may be made small enough so that it can be easily corrected for. Or, if desired it may be neglected.
While a particular embodiment of the invention has been described above in considerable detail, in accordance with the applicable statutes, this is not to be taken as in any way limiting the invention but merely as being descriptive thereof.
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A heavy-duty coupling unit that incorporates a sensitive torque-measuring device. It has a compact arrangement for making a direct longitudinal torque coupling in normal use. And, in addition it provides for alternative lateral chain drive coupling. It is especially adapted for use with a rotary drilling rig.
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BACKGROUND
This following generally relates to dynamic merchandising and, more particularly, relates to a system and method for providing product recommendations.
There are an increasing number of business to customer (“B2C”) websites that allow customers to purchase products online. In using these systems, and at various times during the purchasing process, the website may offer recommendations of other products that the customer may also be interested in purchasing. These recommendations can serve not only to increase sales, but also to drive awareness that the merchant carries a particular product or brand.
By way of example, U.S. Pat. No. 6,317,722 discloses a system for recommending products to customers based upon the collective interests of a community of customers. For providing recommendations, a similar product table is created, using an off-line process, that functions to map a known product to a set of products that are identified as being similar to the known product. In this regard, similarity is measured by a weighted score value that is indicative of the number of customers that have an interest in two products relative to the number of customers that have an interest in either product. The numbers utilized to establish similarity in this manner are typically derived by examining invoices to determine when the two products appear together and when one product appears exclusive of the other product. The weighting value may be indicative of user ratings provided to products and/or a time duration since a product pair was last purchased.
In addition, many of the B2C websites sell products that are demographically sensitive. That is, it is assumed that any given product may appeal to customers only if the customer falls within a certain demographic category. These demographic categories might include an age range, an income range, a particular sex or sexual orientation, a particular marital status, a particular political view, a particular health status, etc. Thus, certain websites attempt to deduce demographic categories for customers based upon prior purchase histories of that customer and/or expressed product preferences provided by that customer. One such website is described in U.S. Pat. No. 6,064,980 which provides product recommendations by correlating product ratings provided by a customer with product ratings provided by other customers within a purchasing community.
While these website product recommendation techniques may be useful in the B2C environment, what is needed is an improved system and method for providing product recommendations, especially in the business to business (“B2B”) environment where products may have less customer-demographic sensitivity and where products do not have fads, trends, and/or fashions.
SUMMARY
To address this need, the following describes a system and method for recommending products which utilizes product relationships that are considered independently of customer demographics. The system and method generally creates for each of a plurality of products in a plurality of purchase orders a list of purchased-with products, i.e., products that were purchased with each of the plurality of products in each of the plurality of purchase orders. At the same time that the purchased-with product lists are created, or in another step, the same plurality of purchase orders are examined and, using the concept of “self organizing lists,” the lists of purchased-with products are ordered in a meaningful manner. The ordering of the products in a purchased-with list may then be considered when recommending products. The subject system and method may also be used to help identify significant customer behaviors that warrant additional processing or attention.
A better understanding of the objects, advantages, features, properties and relationships of the system and method for providing product recommendations will be obtained from the following detailed description and accompanying drawing that set forth illustrative embodiments that are indicative of the various ways in which the principles expressed hereinafter may be employed.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the system and method for providing product recommendations, reference may be had to preferred embodiments shown in the following drawings in which:
FIG. 1 illustrates an exemplary first data structure used to store data representative of information contained within a collection of purchase orders;
FIGS. 2-5 illustrate an exemplary second data structure used to order the data stored in the first data structure of FIG. 1 ;
FIG. 6 illustrates a flow chart diagram of an exemplary method for populating the second data structure with data extracted from the first data structure; and
FIG. 7 illustrates a flow chart diagram of an exemplary method for populating and ordering the data within the second data structure.
DETAILED DESCRIPTION
With reference to the figures, a system and method for recommending products is hereinafter described. To this end, the system and method examines product relationships and utilizes a data structure in which information indicative of these product relationships is maintained. The product relationships reflected in the data structure may then be used to recommend products, either in a web-based system or, for example, to prepare product merchandizing literature.
To create a data structure useful in discerning product relationships, a collection of customer purchase orders is preferably assembled. This collection of purchase orders may be assembled from any source such as, but not limited to, purchase orders related to on-line purchases, phoned-in purchases, faxed-in purchases, and over-the-counter purchases. An assemblage of purchase order data stored in a first data structure is illustrated by way of example in FIG. 1 . From this assemblage of purchase order data, product relationships may be determined by examining two data fields. The first data field 10 includes data 11 representative of a unique number assigned to each purchase order. The data 11 representative of the unique purchase order number allows the subject system and method to identify what products are contained in each purchase order. The second data field 12 includes data 13 a representative of the reference numbers that have been assigned to products contained in each purchase order. The unique product reference numbers may be assigned by the vendor of the products, may be representative of a barcode label associated with the product, etc. Thus, in the example illustrated in FIG. 1 , it can be discerned that a customer purchased products “3U552,” “4RJ34,” “4L582,” and “4L581” in purchase order “3227811.” It may also be seen in the exemplary assemblage of data illustrated in FIG. 1 that each unique product that is on every purchase order has a corresponding record which includes the first data field 10 (containing data 11 representative of the purchase order number) and the second data field 12 (containing data 13 a representative of the product identifier for that product). It may be further seen that, when a product (“3U522”) is repeated in the second data field 12 , the data in the first data field 10 will be different, i.e., signifying that the same unique product was purchased in two different purchase orders. As further illustrated by the exemplary assemblage of data presented in FIG. 1 , the assemblage of data need not track the number of times a given product was purchased in a given purchase order.
To populate a purchased-with data structure that may then be used to discern product relationships, the assemblage of purchase order data is further processed. In this regard, the assemblage of purchase order data is processed to populate two data fields in the purchased-with data structure. While not required, processing of the assemblage of purchase order data may be facilitated by sorting the assemblage of purchase order data by the purchase order number data field 10 .
More particularly, as illustrated by way of example in FIGS. 2-4 , the first data field 14 of the purchased-with data structure will include data 13 b representative of a product reference number. The second data field 16 will include data 13 c representative of products purchased-with the product referenced in the first data field 14 —considering all of the purchase orders. The data 13 c may be stored as a purchased-with string. When creating the purchased-with data structure, it will be appreciated that the second data field 16 should be large enough to hold data representative of all of the unique product references that could be purchased from the vendor with the product indicated in the first data field 14 . It will also be appreciated that the purchased-with data structure should have enough records for each uniquely identifiable product. Thus, if a vendor sells 10,000 unique products, the purchased-with data structure will require no more than 10,000 records.
As particularly illustrated in FIG. 6 , the purchased-with data structure may be populated by examining the assemblage of purchase order data to first discern the list of unique product references that occur within the purchase order collection. The unique product references that occur within the purchase order collection are then used to populate the first data field 14 of the purchased-with data structure. For this purpose, the data 13 a representative of a product reference number in each record in the assemblage of purchase order data is examined to see whether that product reference number is reflected in the data 13 b that already exists in a first data field 14 of the purchased-with data structure. If the product reference number 13 b is already reflected in a first data field 14 of the purchased-with data structure, the record currently being examined may be skipped, i.e., a first data field 14 of the purchased-with data structure need not be populated with data representative of that product reference number. If, however, that product reference number is not reflected in a first data field 14 of the purchased-with data structure, a new record is added to the purchased-with data structure and the first data field 14 of that new record is populated with data 13 b representative of that product reference number. This process may continue until all the records in the assemblage of purchase order data are examined in this way. In this manner, when this processing terminates, the purchased-with data structure will contain a single record for each unique product reference number that appears in the purchase order data assemblage as seen by way of example in FIG. 3 . (Note that only one record appears that includes data 13 b representative of product “3U552”).
To then populate and order the data 13 c in the second data field 16 of the purchased-with data structure, all the records in the assemblage of purchase order history data are again examined this time examining product groupings that correspond to a purchase order number. As illustrated in FIG. 7 , the process may start with the first record in the purchase order history data assemblage and, using the purchase order number reflected by the data 11 in the record currently being examined, all the unique product reference numbers as reflected in the second data field 12 for a record having data 11 representative of that current purchase order number are collected. Then, for each product reference number in this collection, a corresponding record in the purchased-with data structure is located, i.e., a record having data 13 b in the first data field 14 which corresponds to one of the product reference numbers in the collection. Once each record in the purchased-with data structure is located, the data 13 c in the second data field 16 of each record is examined to determine whether each of the remaining product reference numbers in the collected data (i.e., each product in the collected data but the product referenced by the first data field 14 of that record) is reflected within the data 13 c . If the data 13 c reflects a product reference number from the product reference numbers in the collected data currently being considered, then the data representative of that product reference number may be exchanged with adjacent data, if any, within the second data field 16 , e.g., the product reference number immediately to its left. If the product reference number currently being considered is not reflected by the data 13 c present in the second data field 16 , then data reflective of that product reference number may be added to the second data field 16 , e.g., to the end of the purchased-with string in the purchased-with data structure. Each collection of product reference numbers is processed in this way.
This manner of processing the data is illustrated in FIGS. 4 and 5 . In this illustrated example, it will be seen that, when purchase order “3298553” is processed, product “4RJ34”—which was purchased with product “3U552”—is exchanged in location with the adjacent product “6VR65” in the record having data 13 b in data field 14 that is representative of product “3U552.” Similarly, since product “3U552” has already been placed into data field 16 of the record having data representative of product “4RJ34”—signifying that an earlier purchase order included these two products—and since product “3U552” is already at the front of the list, the data indicative of product “3U552” is left unchanged in location. As further illustrated in FIG. 5 , in some instances it may be desirable to insert a “null” product place holder in the location immediately behind product “3U552” in this case where the purchased-with product under consideration is already located in the predetermined location in the list, e.g., the front of the list. The use of a “null” product place holder, which may be blank characters when the data 13 c is stored in a string, assists in maintaining purchased-with products that have a high tendency of being purchased with the product indicated by the data 13 b in data field 14 in the vicinity of the predetermined location in cases when the purchased-with occurrences are not evenly distributed within the data set being consider. When place holder are utilized, they may be treated as product data during the process of exchanging locations within the second data field 16 .
It is to be understood that ordering the data in the second data field 16 in such a manner may be performed concurrently with the populating of the second data field 16 or at a later time. It is to be further understood that the steps of ordering the data in the second data field 16 may be performed over multiple iterations to further ensure that products that are purchased concurrently with the product represented in the first data field 14 of a record are moved towards a predetermined location within the second data field 16 . In this case, the number of iterations may be a number selected so as to generally assure that the ordering attains some degree of stability each time the process is repeated or the ordering itself can be examined after each pass to determine if the ordering has attained a desired level of stability after which time the repetitions of the process may be halted.
From the foregoing, it will be understood that, after all the purchase order product collections are processed in this manner, the purchased-with data structure will have ‘n’ records that correspond to ‘n’ unique items that are contained in the aggregation of purchase order data and each purchased-with field 16 in the purchased-with data structure will contain a list of unique products reference numbers that were purchased with the product reference number in the first field 14 of that record. If a product referenced in the first field 14 of the purchased-with data structure was not purchased with another product, the second data field 16 for the record for that product will be empty. It will also be understood that the method for ordering the data in the second data field 16 functions to move the products that are generally the most frequently purchased with each product referenced by the data in the first field 14 towards a predetermined location within the second data field 16 , e.g., towards the front of the purchased-with string. This general ordering of the data in the second data field 16 will be sufficient to allow a B2B (or B2C) vendor to merchandise numerous products a customer may be interested in purchasing without requiring the vendor to consider the exact ranking or frequency of each of the purchased-with events. It will also allow marketing of products without requiring customer product rankings.
In particular, for identifying those products that may be of interest to a customer, the system and method considers the location of the product data within the second data field 16 . For example, when a customer identifies a product as being of interest, the first data field 14 of the purchased-with data structure may be examined to find the record corresponding to that product. The second data field 16 of that record can then be examined to extract the data in the second data field 16 that is located within the predetermined location within the second data field 16 . The products recommended would preferably be the products represented by the data in the predetermined location, i.e., this data would be representative of the products likely to be most often purchased with the identified product. While not intended to be limiting, the predetermined location may be the front of the purchased-with data string or the first X data entries in the front of the purchased-with data string.
The recommended products can be displayed to the customer in writing or images or be verbally expressed to the customer. Product recommendations may also include other data associated with the products recommended such as descriptions, prices, images, etc. It is to be understood that product identification used in the recommendation process may be by the customer searching for products using a website search engine, by being placed into a shopping cart, by being mentioned by customers in a conversation over the phone or in person, etc. Still further, the purchased-with data structure may be examined to discern products that are likely to be purchased together for the purpose of associating those products within a catalog or other sales literature, for providing directed marketing mailings, etc. The purchased-with data structure utilized in the recommendation process may be made accessible by being located on one or more servers within a network, may be distributed by being placed onto a CD or DVD ROM, may be downloadable, etc. In this manner, the purchased-with data structure may be accessible by being directly readable by a hand-held device (such as a PDA) or, for example, by providing the hand-held device with network access, preferably wireless, whereby the PDA may access the network server(s) on which the purchased-with data structure is stored.
While specific embodiments of the invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangement disclosed is meant to be illustrative only and not limiting as to the scope of the invention which is to be given the full breadth of the appended claims and any equivalents thereof.
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A dynamic merchandising system for presenting product recommendations to customers. The system and method generally creates for each of a plurality of products in a plurality of purchase orders a list of purchased-with products, i.e., products that were purchased with each of the plurality of products in each of the plurality of purchase orders. At the same time that the purchased-with product lists are created, or in another step, the same plurality of purchase orders are examined and, using the concept of “self organizing lists,” the lists of purchased-with products are ordered in a meaningful manner. The ordering of the products in a purchased-with list may then be considered when recommending products.
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